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Cooler Market Heats Up!

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Cement being a continuous industry, the pyro section that runs 24/7 is the process part which is a non-stop operation. Though the cooler appears to be fairly simple but the operational part is more difficult when the capacity of a plant goes up.

It is a common practice in the industry to enhance the capacity of the kiln after a certain period of time when the plant stabilises. The problem arises when the engineers try to augment the capacity of a cooler with that of enhanced capacity of a kiln. The job becomes even more difficult when the space is limited. However with the support from cooler suppliers and after the selection of a right consultant, the job can be done. Retrofitting of cooler is quite often undertaken at a number of plants. (Refer to the article by ERCOM Engineers in this feature) Few leading manufacturers of coolers are FLSmidth, IKN (Ingenieurbnro Knhlerbau Neustadt), CemProTec, Claudius Peters, KHD Humboldt Wedag, ThyssenKrupp Polysius AG and FONS Technology. Major differences lie in the manner in which material is conveyed over the grates, the mode of aeration and the solid-gas heat exchange, the type and presence of self-regulating valves for airflow and the hydraulic system for moving parts.

Jayant Saha, a consultant having a vast experience with coolers, says, "The clinker cooler becomes a major bottleneck to support capacity upgradation. Almost all capacity upgradation projects involve increment in the capacity of existing coolers. Even with some extent of compromise with clinker temperature increase at cooler outlet, extra grate area requirement comes out to approximately 50-60 per cent for upgradation in existing calciner kiln system. For upgradation of older SP plants, the cooler grate area increment goes to even 150 per cent. Grate area can be increased only if free area is available within the cooler itself or by extending cooler longitudinally or by both methods. In most of the cases, the existing layout limits the cooler expansion and thus limits the upgradation scope. It is always advisable to keep a provision in the layout for cooler expansion, by keeping a little longer horizontal length for clinker pan conveyor."

Saha further says that though there are many types of coolers for cooling the clinker, the state-of-the-art coolers are either grate coolers or cross bar coolers. As cooling is a heat-transmission process, cooling efficiency is greatly dependent on the temperature difference between the two media, i.e., air and clinker.

In the course of rapid development in coolers in recent years, new generations of grate coolers have come into the market. In fact, it is little difficult to keep a track of the current cooler generation. However, little improvements have been made with regards to cooler efficiency and the cooling principle. At the same time, the grate load has typically been increased from approximately 40 to 50 t/d clinker per m2, considering the same clinker temperature, though the widely accepted value is about 45.

However good choice you make to erect a good cooler, the way in which it is operated is equally important. Here a process engineer plays a very important role. Snow man, Red River and jamming are some of the problems faced in cooler operation. These are process-related issues for which a good process engineering knowledge is necessary. The raw meal design has its impact on cooler operation.

Cooler optimisation can be carried out by maintaining:
-Maximum possible clinker residence time in the cooler to achieve the best possible distribution of clinker and cooling air. The clinker retention time in the cooler is determined by the grate surface loading and clinker bed depth;
-Proper cooling air flow distribution;
-Proper tuned PID controller (grate speed vis-a-vis under grate pressure) plays an important role.

Suchismita of ERCOM says that the efficiency of the cooler depends on its ability to recover the heat from the clinker entering the cooler, and cooling the clinker. The cooler also fulfills the key role of transporting the clinker away from the kiln in a reliable manner.

Saha writes, the cooler also provides hot air to be used in waste heat recovery system (WHRS). The steam turbine-based waste heat recovery boilers (WHRB) are placed between the cooler and the de-dusting system. Depending on situations/requirements, various configurations are considered. If no modification is made to the cooler and the excess gas is ducted from the cooler exit to the WHRB, then the vent fan should have enough margins to take care of the pressure drop in the heat recovery boiler.

The upgradation of cooler is a purely an engineering job requiring correct inputs about the existing status and the expected results.

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

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Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.

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