Concrete

Making gains with OKâ„¢ cement mill

Published

5 years ago

October 19, 2021

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Since 1982, the OK??vertical roller mill (VRM) has provided the cement industry an energy-efficient, flexible ??both in terms of size and the ability to handle variable feed materials ??and reliable solution for cement grinding. These benefits are ever more relevant today, as cement producers focus on reducing both operating costs and their environmental footprint through the increased use of supplementary cementitious materials added to the mill?? feedstock.

Nowhere are the benefits of the OK mill more appreciated than in the Indian subcontinent, where cement plant requirements vary widely in terms of grinding plant size and capacity to produce multiple cement types in each unit. In 2018 and 2019, a total of 15 VRMs were sold by FLSmidth in the region for raw, coal and cement applications.

The same trend applies to the neighboring countries, Nepal and Bangladesh; one such notable example is the OK 81-6 cement mill at Shah Cement in Bangladesh, which has been certified by Guinness World Records as the world?? largest VRM. The mill is 25.6m tall, weighs in at 1,904 tonnes and features the latest MAAG MAX Drive technology providing 11.6 MW of power. Successfully operating for two years since August 2018, the mill recently exceeded its performance guarantee testing.

??e are proud to have the world?? largest vertical roller mill as part of our operations,??said Hafiz Sikander, Director of Operations, Cement Division of Shah Cement Industries. ??e selected the FLSmidth OK 81-6 mill for its exceptional efficiency and reduced power consumption ??and it is living up to its promise. As the largest single-unit grinding mill in the industry, we expect it to meet our production requirements for many years.??/p>

Variable feed ??but invariably high product quality

Product quality is a function of cement particle size distribution (PSD) and the dehydration of the gypsum within the cement. In the OK mill, parameters such as mill air flow, separator speed and grinding pressure, can be easily adjusted during operation to control or alter the PSD curve to a (steeper or flatter) profile that achieves the desired quality standards. When needed, the PSD curve can match that of an existing ball mill.

The instant adjustability of operating parameters, as well as a short retention time, also means that switching between different types of products can be performed with almost immediate effect. The OK mill has also proven to be effective for grinding blended cements with one or more wet components, not only because of its highly-effective drying performance, but also due to its ability to maintain a stable grinding material bed. As a result, OK mills have been used to grind a wide range of materials from 100 per cent slag with feed containing more than 20 per cent moisture to limestone, pozzolan and fly ash.

Moreover, the OK Mill with ROKSH separator regularly grinds products with fineness above 5500 Blaine, further proving its versatility, as well as its capability for consistent, stable operation throughout a range of cement, blended cement, and slag cement products.

Figure 1: The composition of cement products produced using the OK??cement mill

Lower OPEX and maintenance with the FLSmidth OK??mill

Compared with other VRMs, the OK mill consistently operates with lower airflow and the lowest power consumption. As a result of the patented cement grinding profile and integral ROKSH separator with industry-leading high efficiency, the mill consistently uses 15 to 20 per cent (3 to 5 kWh/MT) less power than other cement VRMs.

The latest mill design adopts mechanical improvements based on actual operating and maintenance practices and the most recent metallurgical developments. A simple layout and fewer number of machines in the mill circuit ensure high run-factor, reduced civil construction costs and low long-term maintenance costs.

Modular design across applications and sizes allows for common spares, including roller assembly, lube systems, hydraulic systems and cylinders, and gear units. It also incorporates design elements in the roller and table profile that improve operating stability and reliability, regularly giving availability of 95 per cent of scheduled operating time. The OK mill can be operated with half of its rollers out of service and still achieve 60 to 70 per cent of the nominal output, minimising risk of lost production due to unplanned stoppages and guaranteeing long-term availability.

The ROKSH separator design has also been improved, allowing producers to achieve better product quality and ease of maintenance. Additionally, internal components have been adapted to improve airflow and mill velocity profile, reducing wear from jet abrasion. New features have also been added to provide easier maintenance access to the static guide vanes and rotor.

A mill to meet the needs of today?? cement producer

??s cement producers continually seek reduced energy consumption and lower maintenance costs, two emerging trends are changing the face of cement production: the increased use of grinding stations that support variable feed materials and more widespread use of vertical roller mills,??said John Terembula, FLSmidth Global Product Line Manager ??VRM. ??ement producers in India, Nepal and Bangladesh have achieved much success relying on the OK mill to meet these needs.??/p>

– Communication by the management of the company

Concrete

Dalmia Acquires Five Point Two MnTPA Cement Assets in Central Region

Acquisition adds capacity, power and rail access

Published

21 hours ago

May 26, 2026

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Dalmia Cement (Bharat) Limited (DCBL) executed a business transfer agreement on 21 May 2026 to acquire a cement undertaking from Jaiprakash Associates Limited (JAL) and Adani Infra (India) Limited. The assets include plants at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh with five point two million tonnes per annum (mn tpa) cement capacity and three point three mn tpa clinker capacity, plus 99 megawatt (MW) thermal power and railway sidings. The transaction carries an enterprise value of Rs 28.5 billion (bn).

DCBL, a wholly owned subsidiary of Dalmia Bharat Limited (DBL), will see cement capacity rise to 54.7 mn tpa on completion. Ongoing expansions at Belgaum, Pune and Kadapa are expected to raise capacity to 66.7 mn tpa by the second to third quarter of fiscal 2028. The company said the transaction would be consummated within two weeks.

The deal follows a framework signed in December 2022 to settle long running disputes with JAL, including a long term clinker supply arrangement. Completion was delayed when JAL entered insolvency and the earlier sale did not finalise. Following approval of a resolution plan under the Insolvency and Bankruptcy Code, DCBL executed a fresh business transfer agreement to resolve pending legal and arbitral matters.

Company statements described the acquisition as strategic, accelerating access to central markets compared with a greenfield route and offering scope for expansion through debottlenecking and brownfield investment. Proximity to the company’s captive mines and established vendor relationships should support faster ramp up. The assets should augment EBITDA delivery and enhance returns by enabling entry into newer markets with relatively better prices.

Senior executives said the addition aligned with a long term plan to build a pan India presence and would provide a head start in central markets. They noted that familiarity with the plants under earlier tolling arrangements offers operational insight and strengthens channel relationships, supporting quicker market entry. Management expressed confidence that the assets’ expansion potential would generate value for stakeholders.

Concrete

Ramco Cements Reports FY26 Revenue Growth And Higher Profit

Net debt reduced as exceptional items boost FY26 earnings

Published

21 hours ago

May 26, 2026

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Ramco Cements reported standalone audited results for FY26 with net revenue of Rs 90,560 million (mn) and profit after tax of Rs 6,940 mn. EBIDTA rose to Rs 14,820 mn and blended EBIDTA per tonne was Rs 788 on a two per cent volume rise to 18.81 million (mn) tonne (t). Cement revenue increased by five per cent and construction chemicals revenue rose by 66 per cent.

Raw material cost per tonne rose to Rs 1,023 from Rs 956 mainly due to a mineral bearing land tax of Rs 160 per t in Tamil Nadu, adding about Rs 86 per t. Power and fuel cost per tonne fell to Rs 1,098 from Rs 1,123 with petcoke mix down to 47 per cent and green power up to 40 per cent.

Profit before tax after exceptional items was Rs 8,790 mn. Net exceptional items were Rs 5,530 mn, including Rs 5,740 mn from sale of surplus land and Rs 200 mn of past service cost. The company monetised Rs 10,980 mn from non core asset sales over the past two years and recorded capex of Rs 9,970 mn, with guidance of Rs 8,000 mn for FY27.

Net debt fell by Rs 8,170 mn to Rs 36,640 mn at 31 March 2026 and cost of debt eased to 7.29 per cent, reducing net debt to EBIDTA to 2.47 times. Management indicated the full impact of higher fuel costs is expected from Q2 FY27, while packing and diesel cost increases will be visible in Q1 FY27. The board has proposed a dividend of Rs two point five zero per equity share and the company flagged risks from elevated fuel and logistics costs, commodity volatility and competitive pricing.

Concrete

Dalmia Cement to Acquire 5.2 MnTPA Capacity

Deal covers cement assets in Madhya Pradesh and Uttar Pradesh

Published

21 hours ago

May 26, 2026

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Dalmia Cement (Bharat), a wholly owned subsidiary of Dalmia Bharat, has executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra (India) to acquire cement assets with 5.2 MnTPA capacity in the Central region.

The acquisition covers cement plants located at Rewa in Madhya Pradesh, and Churk, Chunar and Sadwa in Uttar Pradesh. The assets include 5.2 MnTPA cement capacity, 3.3 MnTPA clinker capacity, 99 MW thermal power capacity, railway sidings at Rewa and Chunar, and a common railway siding at Churk. The enterprise value of the transaction is Rs 28.5 billion.

Following completion of the transaction, Dalmia Bharat’s cement capacity will increase to 54.7 MnTPA. Its ongoing expansion projects at Belgaum, Pune and Kadapa are expected to further raise capacity to 66.7 MnTPA by the second or third quarter of FY28. The transaction is expected to be completed within two weeks.

Dalmia Cement had entered into a framework agreement with Jaiprakash Associates in December 2022 for the sale of business assets and related agreements, including a business transfer agreement and cement sale purchase agreement. The agreements were intended to settle disputes between the parties, including those under the long-term clinker supply agreement. However, the transaction could not be completed after Jaiprakash Associates was admitted to insolvency.

Following approval of the Adani Group’s resolution plan for Jaiprakash Associates under the Insolvency and Bankruptcy Code, Dalmia Cement requested that the earlier agreement be considered to settle pending disputes. The company has now executed a fresh Business Transfer Agreement with Jaiprakash Associates and Adani Infra (India) for the cement undertaking.

The acquisition supports Dalmia Bharat’s strategy to become a pan-India cement player and provides faster access to Central markets compared to a greenfield project. The assets also offer expansion potential through debottlenecking and brownfield development.

Puneet Dalmia, Managing Director and CEO, Dalmia Bharat, said the assets are a strong strategic fit and will help the company serve high-potential markets in the Central region. He added that the expansion potential of the assets and their proximity to Dalmia’s captive mines could help create a future capacity hub.