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

Meghalaya Cabinet Approves MCCL Closure, Writes Off Rs. 244.3 mn

Cabinet approves winding up of state-owned cement company

Published

2 days ago

October 19, 2026

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The Meghalaya Cabinet has approved the closure and winding up of Meghalaya Cherra Cement (MCCL), a state-owned cement company, with pending liabilities of approximately Rs. 244.3 mn to be written off as part of the process. The decision was announced by Chief Minister Conrad K Sangma on October 13, 2026.

The approved write-off comprises about Rs. 89 mn in sales tax dues and Rs. 155.3 mn in royalty dues. The Cabinet’s decision addresses the liabilities that remained after the company’s operations and enables the government to proceed with its formal closure.

Sangma said employee dues owed by MCCL had been settled in line with the state government’s commitment. The settlement of employee-related liabilities is a key part of the winding-up process and removes outstanding obligations to the company’s workforce.

The Chief Minister explained that MCCL is owned by the government, meaning the pending liabilities would otherwise involve transfers between the state government and its departments. Writing off the dues is intended to simplify the accounting and administrative steps required to complete the closure.

The decision is also intended to ensure that the winding-up does not create an additional financial burden for the state government. With employee payments settled and the sales tax and royalty liabilities addressed through the approved write-off, the Cabinet’s approval marks a further step towards completing the formal closure of MCCL.

The action follows the state government’s decision to discontinue the company and resolve its outstanding obligations through an orderly winding-up process. The approved measures cover the principal liabilities identified for settlement and allow the government to advance the remaining formal procedures associated with closing the state-owned enterprise.

Concrete

Fornnax Wins AIRIA’s Special Export Award for Rubber Machinery in 2025-26

Published

2 days ago

October 19, 2026

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Fornnax Technology Pvt. Ltd. has been honoured with the Special Export Award – Rubber Machinery for 2025–26 by the All-India Rubber Industries Association (AIRIA), in recognition of its highest exports of tyre recycling plants to the European region.

With more than a decade of experience in India’s tyre recycling industry, Fornnax has contributed to the development of advanced recycling technologies and infrastructure. The company currently holds a 90% market share in India’s domestic tyre recycling sector, while exports account for 30% of its business, spanning markets such as Europe, Australia and the GCC.

The award marks another milestone for Fornnax, whose tyre recycling lines and advanced shredding technologies are supporting the growth of the circular economy in India and international markets.

Commenting on the recognition, Mr. Jignesh Kundaria, Founder and Director of Fornnax, said:

“This honour from AIRIA is a reflection of an incredible journey we have undertaken over the years. When we started Fornnax, there was no established recycling industry in India to follow. We chose to build for the future instead. Today, when you see India’s tyre recycling sector, it has already transformed into a dynamic, high-growth industry and we are extremely proud to have played our part in building it.”

Unlike standalone equipment suppliers, Fornnax focuses on developing complete, high-capacity recycling infrastructure. Its integrated systems combine multiple stages of shredding and size reduction to enable efficient, continuous operations. This system-level engineering approach helps recycling operators improve throughput, equipment reliability and operational consistency.

The recognition reinforces Fornnax’s commitment to developing engineering technologies that contribute to a more efficient and circular recycling ecosystem.

Looking ahead, the company aims to expand its international presence while continuing to develop advanced shredding and recycling solutions to address the growing volumes and evolving requirements of the global recycling industry.

For more information, visit: www.fornnax.com

Concrete

Cement Prices Likely to Rise Rs. 10-15 per Bag from Mid-October

Input costs and steady demand may drive cement price increases

Published

7 days ago

October 14, 2026

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Cement manufacturers in India are likely to raise prices by Rs. 10-15 per bag from mid-October, as they seek to offset persistent increases in power and fuel costs. Emkay Research said its channel checks indicated a high probability of an increase from October 12, supported by the start of the busy construction season and favourable demand-supply conditions.

The sector had implemented similar rate adjustments of Rs. 10-15 per bag during the first quarter, but the increases were insufficient to cover higher operating costs. Prices also softened during July and August because of the monsoon, widening the gap between realisations and input expenses. Delayed plant expansion programmes have pushed clinker utilisation rates towards 79 per cent by FY28, helping to balance market fundamentals.

Emkay Research said steady volume offtake was supporting cement consumption, with non-trade demand driving activity across regional markets. Industry volumes are expected to grow by 7-8 per cent year on year during the first half of FY27, while demand momentum is projected to remain firm over the following 18 months. The outlook includes the busy construction season in the second half of FY27 and infrastructure activity linked to general elections in the first half of calendar year 2029.

The brokerage expects overall cement demand to record a compound annual growth rate of about 7 per cent between FY26 and FY28. However, elevated operating expenses are likely to continue weighing on profitability. Input costs have risen by Rs. 300-400 per t over the past six to seven months, with the full impact expected to become visible in second-quarter earnings and remain persistent through the second half of FY27.

Spot prices for petcoke and imported coal are approximately 20 per cent and 16 per cent above their second-quarter averages, at USD 175 per t and USD 150 per t, respectively. Packing costs have also increased, with polypropylene granule prices rising above Rs. 135 per kg. Emkay Research estimated that second-quarter earnings could decline by Rs. 200-250 per t sequentially because of higher fuel bills and negative operating leverage, and said the sector requires sustained price increases of about Rs. 10 per bag to offset cost inflation.