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IT enables cost-effective clinkerisation at Samrat Cement plant

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The cement Industry in Nepal mainly depends on clinker received from Indian cement plants, which is then put into the grinding process in Nepal before sending into the market. One of the biggest challenges for Nepal-based cement companies is the ever-increasing cement manufacturing cost due to surges in the cost of clinker and other raw materials. Availability of resources is another big challenge. Hence, having a clinkerisation plant locally is becoming a need for them to survive in this sector.

Samrat Cement was facing the same challenge. The company came into the cement sector in 2013-14 with their grinding and packing unit at Lamahi-District Dang in Nepal with a vision to build a brand with enhanced quality cement. After establishing itself as a strong brand in Nepal, the company?? vision was to own a clinkerisation plant to cope with cement demand and to survive with manufacturing costs.

Conceptualisation of Project

To meet its vision, Samrat cement awarded a 4000 TPD Clinkerisation Plant to KHD Humboldt Wedag Indiain 2018. The first land excavation started in November 2018, and the entire project was completed in December 2020 with the first production of clinker in January 2021. As added by Basudev Pandeya, Managing Director of Samrat Cement, clinkerisation plant was conceptualised on the following basis.

  • The cost of clinkerisation has to be lower down about 20 to 25 per cent from purchased clinker.

  • The project must be conceptualised in such a manner that the co-generation to be capable to cater the power requirement of the total clinkerisation plant excluding Raw Material grinding.

  • During the selection of clinkerisation plant technology suppliers were called and the best technology was selected.

The main performance parameters are as under:

  • Clinkerisation plant capacity between 3500-4500 TPD to get an optimum range of Co-generation and heat-saving benefits.

  • Raw Material Grinding: KHD Roller Press capacity 345 tph with a specific power of 11.75 Kwh/t Raw meal.

  • KHD High-efficiency cyclone 5 stage Pre-heater (First installation) with a Pressure drop of 300 mmwg at PH fan Inlet and lowest heat consumption.

  • Total Specific power consumption from crusher to Clinkerisation as 43-45 kwh/t.

  • Selection of Roller Press in Raw material grinding enables low heat requirement hence more co-generation possible.

  • Waste Heat recovery plant with hot air

Fast track project with a Target time of completion of 18-24 months

IT Solution to meet the challenges

Based on the above consideration, KHD deployed an energy-efficient grinding machine, Roller Press (RP 16-170/180, Roller surface- CHF), in a closed circuit with V-separator (VS 96/20) dynamic separator (SKS ??LC 3500).

The advantage of this system is that higher capacity requirements are met with lower power consumption.

For Pyro-processing Line, new generation Preheater consists of newly developed High-Efficiency series HE cyclones (PH- 90HE72), Pyro top, Low NOx PYROJET Kiln Burner, 3 station rotary kiln (4.2 m dia x 65 m long), IKN cooler with 90M2/effective cooler area.

The implementation also included other equipment — Limestone crusher-stacker- Reclaimer (Make- Tenova Takraf, 650 TPH), Coal Crusher-Stacker ??eclaimer (Make- Lepton, 150 TPH) & coal mill (VRM-make Pfeiffer, 35 TPH).

Cost-analysis and decision-making

Pandeya said, ??xecuting a 1.5 million tonne per annum cement project at a hilly area like Nepal was never an easy task and required many resources and committed teamwork, further we faced a challenge when it falls during pandemic duration for about 8-9 months hence completing this project within two years is really a success story.??He added further that it would not be possible without the professional skills of the Samrat Team and the professional and enriched experience of KHD Humboldt Wedag India.

Talking about the plant location, the clinkerisation unit of Samrat Cement is located at Satbaria nearby Lamahi Town on verge of the National highway connecting Butwal-Nepalgunj, which is most favourable for a clinkerisation unit because the raw materials are available within a short distance and transportation of product and materials to their destination becomes very easy via national highway.

Plants in Nepal usually require a DG set to run clinkerisation or a UPS of 5-6MW capacity. It is noteworthy that plants, where it is required to have DG sets to run on a continuous basis, will be about three times costlier as compared to the cost of Grid power/co-generated power.

Samrat Cements wanted to go for a better solution, so they finalised on KHD five-stage pre-heater mainly to ensure the co-generation up to 30 to 35 Kwh/t clinker is met. This means there was no need to have any UPS or DG set to continue for the clinkerisation plant.

Pandeya further explains that one side it may look that this decision is costlier in terms of specific heat consumption which is about 20 Kcal/kg as compared with six stage pre-heater technology but on the other hand, the KHD high-efficiency pre-heater solution has its advantage with specific power saving of three units in PH fan and co-generation of additional three units at Pre-heater.

Specific power consumption has about one-third of the cost than that generated by DG sets. (Grid Power costs about 8 to 10 NPR/unit whereas DG generated power costs about 24-27 NPR/unit) so a total of six units saving gives a clear-cut monetary term advantage of about double as it lost in extra heat in five-stage pre-heaters in comparison to 6 stage pre-heater. [Consideration 27 NPR/kwh cost of power with DG set, 15,000 NPR/T landed cost of South African coal, 710 kcal/kg.cl heat consumption, 5500 kcal/kg heat value]

Benefits of a 5 stage Pre-heater

Samrat Cements believed that having a five-stage pre-heater was a wise decision as many plant sites including Nepal do not have strong soil, which may not be suitable for a pre-heater height of more than 125 m. Hence, for higher capacity kiln lines, it may require going for twin string of preheater tower, which has an impact of 20 per cent in civil cost. Below are the advantages.

Planning and execution

Clinkerisation plant was sequenced to start with Limestone crusher along with stacker reclaimer unit and this dc was achieved one month before the kiln light-up. A raw mill that is equipped with roller press was started 15 days before kiln light-up as the roller press circuit does not require hot gas during start-up as compared to VRMs where it is mandatory. This is how the company saved on the cost of Hot air generator.

Around 5000 tonnes of raw meal were grounded with roller press operated in finish mode and kept ready in raw meal silo. Coal mill was started along with kiln light-up and clinker was achieved very fast within 72 hours from kiln start-up.

As per plant operating personnel, the roller press operation in raw material grinding is found to be very simple and trouble-free. Moreover, it is energy efficient.

So far, the total clinkerisation power best achieved is 42.4 kwh/t (Table1). However, the plant started just a few months ago and the company sees great potential to further optimise below 40kwh/t.

Roadmap

Samrat Cement, Nepal is towards a mission of achieving manufacturing cement with the lowest energy consumption and at an economic cost. Producing green cement, minimising carbon emission, energy efficiency, using alternative fuels, and saving water are some of the targets set by the company in near future. Below is a detailed roadmap.

  • Producing green cement with a minimum carbon footprint and saving water. Hence waste heat recovery and roller press technology were given priority.

  • Commissioning of waste heat recovery system, which will cover almost all power consumption of pyro-section excluding some intermediate departments.

  • Expected pay-back period is 2.5 to 3 years for WHRS when compared with DG power.

  • Waste heat recovery system is expected to get commissioned by October 2021.

  • Clinker grinding system where ball mill of 3.4 m x 10 m is getting upgraded with KHD roller press, which will increase the capacity of clinker grinding up to 225tph and specific power shall be 23-25 kwh in finish mode.

  • Samrat cement team added further that total specific power consumption after cement mill upgradation is anticipated as 63 Kwh/t of PPC (From crusher to cement grinding), which will be a benchmark to the cement industry.

  • Usage of alternative fuels in pyro process to consume solid waste produced by the community.

Conclusion

The company is optimistic about achieving specific power consumption for Clinkerisation below 40 kwh/t and total cement production below 60-62 Kwh/t with 700 kcal/kgcl heat consumption. After a successful implementation of this project, the company is hopeful to achieve milestones in near future too.

  1. Waste Heat recovery system (WHRS) with 6 stage Pre-heater have a potential of cogeneration about 28 units/T clinker which needs a UPS to absorb power fluctuation/ switching from grid to DG sets. Hence an additional cost of UPS rating 6-7 MW is huge along with a cumbersome job to maintain UPS batteries. Whereas 5 stage preheaters have the potential for above as 32-35 kwh/t clinker. Hence total clinkerisation plant excluding either Raw Mill can be operated with its own generated power by WHRS.

  2. Pre-heater exit Pressure is lowest among all the plants nearby countries as it found only 250 mmwg at fan inlet while operating without WHRS, which means after WHRS operation it may reach to 300-320 mmwg.

  3. Pre-heater exit pressure is directly linked with Pre-heater fan power which is in the range of 3.5-3.9 Kwh/t.

4. Raw Mix Burnability is found to be easy burning and the combination of Limestone and Clay enriched with Silica and Alumina reacts well and lowers the Pre-heater temperature to 280-290 Deg.C in 5 Stage Pre-heater.

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Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.

India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.

Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:

  • September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
  • December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
  • August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
  • April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
  • Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
  • Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
  • Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
  • Orient Cement: It would serve as a principal manufacturing facility following the merger.

Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:

  • By FY 2026: Reach 118 MTPA
  • By FY 2028: Target 140 MTPA

These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).

Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.

Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.

Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.

Challenges potentially include:

  • Integration challenges across systems, corporate cultures, and plant operations
  • Regulatory sanctions for pending mergers and new capacity additions
  • Environmental clearances in environmentally sensitive areas and debt management with input price volatility

When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.

Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.

About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.

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Concrete

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

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PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.

Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

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Concrete

Driving Measurable Gains

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Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.

Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.

Beyond energy efficiency, the retrofit significantly improved operational parameters:

  • Lower thermal stress on equipment
  • Extended lubricant drain intervals
  • Reduction in CO2 emissions and operational costs

These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.

Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:

  • Enhanced component protection
  • Extended oil life under high loads
  • Stable performance across fluctuating temperatures

By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.

Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.

A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

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