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SPECTRAFLOW, now in India

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Cross belt analysers have been gaining popularity over years especially for the raw material analysis that goes for raw meal preparations. This leads to consistency of raw meal before clinkerisation takes place.

Ramco Cements, an independent Indian group, ordered a Crossbelt and Airslide analyzer from SpectraFlow analytics, for their new integrated plant at Kalvatala, to optimize the stability of their raw meal.

Ramco Cements Limited, founded in 1961, is a reputed cement manufacturer in India, headquartered in Chennai. Ramco Cements produces superior quality cement at their state-of-the art facilities including integrated cement plants and grinding units. The company is the fifth largest cement manufacturer in India and also produces Ready Mix Concrete and Dry Mortar products and operates one of the largest wind farms in the country.

About Ramco Cements Limited, Kalvatala plant:

Greenfield integrated cement plant is being setup at Kalvatala, Kolimigundla Mandal, Kurnool District. The foundation stone was laid in December 2018 and the plant shall be operational in first quarter of 2021. The project will include a Waste Heat Recovery System and a Thermal Power Plant.

FLS was chosen as the main equipment supplier and Ramco Project Team looked after specialized components themselves and choose SpectraFlow Analytics Crossbelt Analyzer for their stockpile and pre-blending management and SpectraFlow Airslide Analyzer for the raw meal optimization of their two raw mills.

SpectraFlow Installation for Quarry/Stockpile Optimization:

The SpectraFlow Crossbelt Analyzer is the online analyzer to be able to measure raw materials on belt conveyors. As raw materials from the quarry are processed through a crusher the raw material on the conveyor belt is statistically homogeneous and therefore the analytical results of the SpectraFlow Crossbelt Analyzer are accurate.

By using SpectraFlow Crossbelt analyzer and a site specific blending strategy at Kavalatala the high variation in the local raw materials shall be balanced out to increase consistency of the stockpile quality.

Summarized benefits are:

– No need of sampling. Sampling from conveyor belts is unrepresentative and slow for process optimization. Additionally, sampling is very work intensive regarding operation and maintenance.

– The analyzer together with a Pre-Blending control software from RAMCO SYSTEMS is fully automating the feed from the hoppers. The analyzer delivers the analytical results and according the setpoint the software is adjusting the feeders into the mixing stage

– The analyzer together with a Pre-Blending control software is informing the quarry/crusher operators of the current composition of the stockpile and accordingly the trucks can be coordinated to reach the setpoint of the stockpile.

– Stockpile quality will be homogeneous and on setpoint. That results in stable and low additive consumption at the raw mill.

– Stable feed from the stockpile leads to stable raw mill operation and fine raw meal/clinker quality.

SpectraFlow Installation for Raw Mill Optimization:

The SpectraFlow Airslide Analyzer is the online analyzer to be able to measure raw materials in airslides. As raw materials in airslides are very homogeneous and dry the analytical results of the SpectraFlow Airslide Analyzer are very accurate and based on these accurate results the raw mix control software can optimize the weight feeders before the raw mill in real time every minute. This results in very low LSF STDEV without the need of extensive sampling and laboratory efforts.

Kalvatala operates 2 Roller Press raw. The raw meal will feed to a joint airslide where the SpectraFlow Airslide analyzer will measure.

For the control of the weight feeders at the 2 raw mills Ramco will use control software from RAMCO SYSTEMS.

By using SpectraFlow an increase in the raw meal homogeneity will be achieved.

Summarized benefits are:

– Two raw mills can be controlled by one online analyzer.

– No need of intensive sampling. No automated sample transport system, no automated laboratory required.

– High cost reduction due to reduced laboratory usage (CAPEX, OPEX, man power,??

– The analyzer together with the control software is fully automating the raw material grinding. The analyzer delivers the analytical results and according the setpoint the software is adjusting the weight feeders of the additive bins.

– Adjustment of the weight feeders in real time every minute. No time delay due to sampling, sample preparation, ??/p>

– Lower LSF STDEV/better and more consistent raw mill quality


RAMCO SYSTEMS

SpectraFlow order

This SpectraFlow order is the 39th order for the Cement Industry and the 1st installation in India. This order raises the installed based in India to 2 analyzers (1 Crossbelt & 1 Airslide) and worldwide to 56 analyzers (31 Crossbelt & 25 Airslide).

SpectraFlow Analytics Ltd. Switzerland are the experts in providing online analysis for the cement and minerals industry without any radioactive sources nor neutron generators. The NIR technology used for the SpectraFlow Analyzers is not requiring any permits or licenses and there are no restrictions in buying, importing or maintaining the analyzers. This results in very low operating costs and high availability of the analyzers combined with highly accurate measurement results.

For further information, contact: Vijay Kumar Vemuri, Managing Partner, SPV Engineers, 2242, BHEL MIG,

Phase-I, Serilingampally, Hyderabad – 502032

M no. +91 8885744161, Email:vk.vemuri@spvengineers.com

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Concrete

30-Day Traffic Diversion In Place For CC Road Works In Madhapur

Diversions in place from May 16 for cement concrete road works

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The Cyberabad Traffic Police issued a traffic advisory as road works begin for the laying of a cement concrete (CC) road from Jaya Shankar Statue to RRR Restaurant at Parvathnagar in Madhapur limits. The advisory indicated that traffic diversions will be in place for 30 days from May 16 to ensure the smooth flow of vehicles and to minimise congestion on the affected stretch. The measure aims to balance uninterrupted construction activity with the movement needs of commuters.

Traffic moving from Toddy Compound towards Parvathnagar village will be diverted at Parvathnagar junction towards Sunnam Cheruvu and the 100 feet road. Local motorists and public transport operators have been advised to follow the diversionary route as directed by traffic personnel on duty. Alternate routes and signage have been planned to mitigate delays and to manage peak hour congestion.

Police officials said the diversion had been planned to facilitate uninterrupted road works while maintaining traffic movement in the area. Commuters were urged to plan their travel accordingly and to cooperate with traffic staff managing the stretch. Authorities indicated that enforcement of diversions would be active and that violations could attract penalties.

The 30 day schedule is intended to allow contractors to complete the laying and curing phases with minimal interruption to vehicular flow. Residents and businesses in adjacent localities have been advised to factor the diversion into deliveries and travel plans. The traffic police promised continuous monitoring of the works and the operational diversions and emphasised that temporary inconvenience was necessary for longer term improvement of the road network. Traffic personnel will be stationed at key junctions and additional signage and temporary markings will be displayed to guide motorists and pedestrians through the revised alignments while public transport services will follow the diversion where feasible and operators have been asked to adjust timetables to minimise disruption.

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Concrete

HeidelbergCement India Receives Consent For Khandwa Grinding Unit

Consent granted by Madhya Pradesh Pollution Control Board

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HeidelbergCement India (HeidelbergCement India) has received regulatory consent to establish a cement blending and grinding unit at Village Dongaliya, Tehsil Punasa, District Khandwa in Madhya Pradesh. The consent was granted by the Madhya Pradesh Pollution Control Board under the Water (Prevention & Control of Pollution) Act, 1974 and the Air (Prevention & Control of Pollution) Act, 1981 and is dated 17 May 2026. The company disclosed the development in a filing made under Regulation 30 of the SEBI (Listing Obligations and Disclosure Requirements) Regulations, 2015.

The project plan envisages procurement of long term availability of fly ash and the allotment of land on lease for setting up the unit. The proposed facility is described as a blending and grinding installation which will process cementitious materials sourced from nearby operations and suppliers. Company filings state the measures required to secure raw material logistics and statutory compliance before commencing construction.

The addition of a grinding unit in Khandwa is intended to strengthen regional supply and improve logistical efficiency by reducing haulage distances for finished product. The unit is expected to complement existing capacities in central India and to offer flexibility in product mix through blending operations. The reliance on fly ash as a supplementary cementitious material will necessitate long term supply agreements with thermal power producers and coordination with waste utilisation policies.

The disclosure to the regulator and to the stock exchanges follows standard corporate governance practice and aims to keep investors apprised of capital expenditure initiatives. The company indicated that subsequent permits and clearances would be sought in accordance with applicable environmental and land use rules. The project is presented as part of HeidelbergCement India’s broader strategy to optimise capacity distribution and to respond to regional demand dynamics.

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Concrete

PROMECON introduces infrared-based tertiary air measurement system for cement kilns

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The new solution promisescontinuous, real-time tertiary air flow measurement in cement plant operations.

PROMECON GmbH has launched the McON IR Compact, an infrared-based measuring system designed to deliver continuous, real-time tertiary air flow measurement in cement plant operations. The system addresses the longstanding process control challenge of accurate tertiary air monitoring under extreme kiln conditions. It uses patented infrared time-of-flight measurement technology that operates without calibration or maintenance intervention.

Precise tertiary air measurement is a critical requirement for stable rotary kiln operation. The McON IR Compact is engineered to function reliably at temperatures up to 1,200°C and in the presence of abrasive clinker dust. Its vector-based digital measurement architecture ensures that readings remain unaffected by swirl, dust deposits or drift. Due to these conditions conventional measurement systems in pyroprocess environments are often compromised.

The system is fully non-intrusive and requires no K-factors, recalibration or periodic readjustment, enabling years of uninterrupted operation. This design directly supports plant availability and reduces the maintenance overhead typically associated with process instrumentation in high-temperature zones.

PROMECON has deployed the McON IR Compact at multiple cement facilities, including Warta Cement in Poland. Plant operators report that the system has aided in identifying blockages, optimising purging cycles for gas burners, and supplying accurate flow data for AI-based process optimisation programmes. The practical outcomes include more stable kiln operation, improved process control, and earlier detection of process disturbances.

On the energy side, real-time tertiary air data enables reduction in induced draft fan load and helps flatten process oscillations across the pyroprocess. This translates to lower fuel and energy consumption, fewer unplanned shutdowns, and a measurable reduction in NOx peaks. This directly reflects on the downstream cost implications for plants operating SCR or SNCR systems for emissions compliance.

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