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Duztec offers efficient spray technology solution

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Past few years cement companies have been aggressively targeting at reducing energy consumption. How do you look at this trend? Please explain which cooling technique is energy efficient and why?
The resistivity of cement dust reduces with lower gas temperature. There is always a debate between air dilution and gas cooling with water. Dilution with air entails bigger size downstream equipment like a fan, motor, bag house size, etc. The efficiency of gas cooling with water is fifteen times more efficient than cooling with dilution air. Hence, air dilution is a drain on energy consumption and proper water spray technological solution is required and available, for reducing the gas temperature and thereby its volume.

Most industries today use gas filtration techniques to reduce dust from cement, lime, steel, and other plants. Kindly throw some light on the latest gas filtration techniques for the cement industry.
India has done quite well in addressing the process of dust emissions from the industries, as mandated by the legislature. However, the fugitive dust levels are alarmingly high. The PM2.5 and PM 10 levels are quite high compared to the legislative values, which are affecting human health and well-being. Our technology of producing the required droplet size to encapsulate the dust particle and making it heavy to settle down is our main know-how.

Gas conditioning towers (GCT) are being used in the cement plants to cool down hot gases from kilns. But due to less space in plants, do you see it as a challenge? I
n most modern plants, the GCT is getting phased out due to space constraints. However, the required gas cooling is being done in the Preheater downcomer duct or top cyclone. We have excellent water spray technology for PH downcomer and for TOP cyclone of cement plants.

What are the trends in the cement industry when it comes to selecting the best gas cooling product. Cost is one of the biggest factors. What are the other factors?
Gas cooling by an efficient water spray system is the most efficient cooling method by the laws of physics. Lesser the gas temperature, the gas volumes to be handled are lower, thereby lowering the size of downstream equipment, energy requirements, and the cost of production. Hence, wherever air dilution is taking place in a cement plant, we should look at installing efficient water spray systems. Nowadays, we have spray technology that can handle rejecting water/waste water from cement processes for gas cooling.

How was the demand in the year 2020? Was your business affected too? What were your strategies to survive and compete in the market?
Air Pollution has no holiday. So, our products were in demand and we did manage to grow a bit in 2020. The pandemic made it difficult to offer our services at the customer?? place, which has been our SOP.

Our strategy is to offer tailor-made solutions to our customers??requirements. We have a fluid mechanics laboratory in which the dust characteristics are studied, before the selection of our technology for the best and sustainable results.

How do you foresee business in the year 2021-22? Do you have any strategies for the third wave, if it may hit us soon?
It is the set direction of our sails, which determines the way we want to go. The wind direction does not determine our destination. The pandemic situation may come and go, but we believe in our long term strategy to innovate, focus on customer?? requirements, be agile, adapt to new business norms and be profitable. We have handled the last two waves successfully and are confident about the future business prospects.

Which of your products do you see will be the most popular selling products for the cement market? Why?
Our entire product line for gas cooling, fugitive dust control, odour control, cooling and humidification, mill injection systems. Our product lines are for specific applications which will improve the quality and productivity of our customers??processes.

Cement players are adopting the latest technologies to achieve plant efficiency and cost reduction. Kindly share your views.
Yes, the Indian cement industry is technologically superior compared to many other developed countries. Most of our plants are of capacities over 3000 TPD dry kiln process with 6 stage preheater towers. The latest plant capacities are in the region of 10,000 TPD with 7 stage preheater towers. The energy efficiency is comparable to the best in the business. The specific electrical consumption is also very low compared to the world average.

Kindly share your future roadmap/investments.
We are upbeat about our future plans. We will be expanding our product portfolio as soon as the pandemic is coming to an end. We are also looking to increase our production capacities mainly for export to European countries. We have a goal to double our sales by 2025.

Concrete

Shree Cement Expands Bangur Concrete Network with Patna Plant

New facility takes the company’s national RMC network to 36 plants

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Shree Cement has inaugurated a 60 m³/hour ready-mix concrete plant in Patna, Bihar, under its Bangur Concrete brand. The facility takes the company’s ready-mix concrete (RMC) network to 36 plants across India and strengthens its presence in eastern markets.

The plant was inaugurated by Neeraj Akhoury, managing director of Shree Cement, in the presence of senior company officials and other guests. It has been established to serve demand for ready-mix concrete in Patna and neighbouring areas, where infrastructure development, urban expansion and real estate activity are supporting construction growth.

The facility is designed to supply construction projects across Patna and surrounding markets. Its installed capacity of 60 m³/hour will enable Bangur Concrete to serve customers across the region while improving distribution and supply capabilities in eastern India.

The expansion is intended to improve customer service, strengthen the company’s market presence and support development activity in Bihar. The plant incorporates modern batching technology, material handling systems and quality control processes aimed at maintaining consistency in production and improving operational efficiency.

With the addition of the Patna facility, Bangur Concrete now operates 36 RMC plants across India. The business is expanding its footprint in key construction markets to improve customer access to ready-mix concrete, which is increasingly used in infrastructure, commercial and residential projects because it supports controlled production, consistent quality and more efficient material management at construction sites.

The facility will also follow environmentally responsible operating practices, in line with Shree Cement’s focus on sustainable construction solutions. The latest addition adds capacity to the company’s RMC operations and supports its efforts to serve regional construction markets as development activity continues across Bihar.

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Concrete

Ambuja Plans 2.9 MTPA Godda Cement Unit

Proposed unit forms part of Ambuja Cements’ Rs. 145 bn expansion

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Ambuja Cements has proposed a 2.9 mn tonnes per annum (MTPA) cement grinding unit in Godda district, Jharkhand, as part of a Rs. 145 bn expansion programme. The plan is intended to lift the company’s overall cement capacity to 155 MTPA by financial year 2029-30 (FY30), from its current 113.5 MTPA.

The proposal forms part of the Adani Group company’s wider manufacturing expansion across eastern and northeastern India, according to a company statement issued on Monday. The Godda unit would add grinding capacity to Ambuja Cements’ network and is intended to help serve demand in Jharkhand and neighbouring states.

Locating production closer to these markets is expected to reduce transportation costs and delivery times, while the project could support employment in plant operations, maintenance, logistics and administration. The company also linked the facility to indirect activity in transportation, contract services, construction, warehousing and local supply chains.

The expansion plan includes a 2.9 MTPA grinding unit each in Assam and Bihar, as well as additional clinker capacity in Assam. Together, the projects are designed to distribute manufacturing capacity more widely and improve the connection between clinker production and grinding operations, Ambuja Cements’ cement-business chief executive Vinod Bahety said.

Clinker is the intermediate material produced before it is ground and blended to make cement, making the Godda proposal part of a broader materials and logistics network rather than an isolated facility. Ambuja Cements has not provided a commissioning timeline, a Godda-specific investment breakdown, land details or a detailed employment estimate in the supplied announcement.

The project’s impact will depend on implementation of the plant, associated transport links and local supply chains. The announcement sets out the capacity objective but does not specify the project’s construction schedule or operational start date.

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Concrete

Capacity with Conscience

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Ambuja Cements has locked in its next phase of growth. The Adani Group company has earmarked 14,500 crore, roughly 145 billion, for greenfield and brownfield projects that will add 30 MTPA and lift its total capacity to 155 MTPA by FY2030.
It is hardly alone. The industry added about 55 million tonnes in FY2025-26, taking installed grinding capacity to an estimated 720 to 730 MT by March 2026. UltraTech Cement, Adani Cement, Shree Cement, Dalmia Bharat and JK Cement are expected to drive another 115 to 125 MT by FY2027-28. Production itself reached close to 490 million tonnes in FY26. The appetite to build is not in doubt.
Costs are another matter. The conflict in West Asia continues to push up fuel and freight bills, and the pressure on profitability is real. More capacity arriving in a market that is absorbing higher input costs leaves little room for inefficiency.
Then there is carbon. Indian cement emits around 0.62 tonnes of CO2 per tonne of cement, and the decarbonisation roadmap points to 0.56 by 2030 and 0.51 by 2047. Output, meanwhile, is projected to climb towards 1,546 million tonnes by 2070, the year India has set for net zero. Intensity can fall steadily while total emissions still rise. That is the arithmetic the industry must solve.
So, how does the sector sustain its expansion momentum while honouring its net-zero commitments? That question anchors the discussions at the Indian Cement Review Conference & Awards and Cement Expo 2026. More than 60 industry leaders will weigh how rising demand, capacity growth and productivity gains can sit alongside decarbonisation across the value chain. They will also examine which technologies, investments and strategies will make that possible.
The Expo runs from 15 to 17 December at India Expo Mart, Greater Noida. Come and be part of the answer.

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