Concrete

Making the right choice

Published

5 years ago

December 21, 2021

admin

The cement industry has realised the importance of modular grinding techniques and grinding aids to achieve a better quality of product and to obtain high energy efficiency. We see a trend where cement manufacturers are shifting towards more advancement in vertical mill or roll press systems.

Energy consumption continues to remain the key issue associated with every industry today. In the cement industry, the grinding process accounts for significant energy consumption. Various research papers suggest that the grinding process consumes 60-70 per cent of a cement plant’s electrical demand. Hence, limiting energy consumption at the grinding process level is a major industry focus today. Another key focus area is the end-product. Cement manufacturers are exploring new ways to expand the cement additives range and cement/clinker ratio to make the final product more durable, stronger, and cost-effective. The solutions available in the market today come with versatile technologies, with low-energy consumption, as well as are easily capable of adapting to a wide range of raw materials. In short, solutions that offer low energy consumption and high flexibility are in high demand.

Trends

The three key trends in the grinding process in the cement industry are– efficiency, reduction of power consumption, and system flexibility/simplicity. In terms of demand, vertical mills have increased their share as compared to ball mills. The use of separate grinding plants is observed to have picked up drastically. IT Vendors have also increased their focus towards offering more and more technologically advanced and energy-efficient solutions for the grinding process.

Avanish Karrahe, Global Product Manager Grinding Products, Cement Industry, FLSmidth, said, “Along with mill design, advancement in high-efficiency separator design has further improved energy efficiency by reducing the amount of over-grinding, unnecessarily returning product-size material to the grinding part of the machine, allowing for more stable operation and better overall product quality.”

He further explains that when combined with the latest mill designs an optimised separator offers potential for up to 10% better overall energy efficiency than mill systems with inferior separators.

Grinding process

Many factors influence the grindability of cement/clinker. For example, clinker with a high content of small pores will be easy to grind. Other factors such as crystal size, cooling velocity, age of clinker also influence the grindability. A part of the grinding is done in a pregrinding unit, with help of roller press, vertical shaft impact crusher, and vertical roller mill.

In another scenario, the tube mill is omitted, and entire grinding work is done in roller press with desagglomerator and rotor type separator or vertical roller mill with integrated rotor type separator.

Various technical and economic aspects are taken into consideration before selecting the best grinding mechanism. Furthermore, factors such as mill feed, composition, grindability of components, grain size, moisture content of additive, mill control, manual or automatic processes, grinding aid, etc.

Explains Dr. Bibekananda Mohapatra, Director General, National Council for Cement and Building Materials, “Comparing different grinding systems, high pressure grinding rolls are at par in energy efficiency as compared to VRMs for grinding purpose. In VRMs, recent development in slave rollers is also providing grinding force enabling high energy efficiency. Advancements in VRM main drive gearbox is leading to lower cooling requirement and reduction in energy loss.”

Ball Mills: Ball mill systems are not the preferred option for any new projects. However, a few companies prefer starting with ball mills with minimum investment, and later when they expand the business, they adopt roller press or vertical mill for pre-grinding of clinker.

Vertical roller mill systems (VRM): These are the most versatile equipment, which can handle all the types of raw materials, solid fuels, and additives used in the cement process.

Karrahe says that roller presses and vertical roller mills have much higher grinding efficiencies compared to traditional ball mills and can operate with almost half the electrical energy consumption compared to a traditional ball mill.

Roller press systems: Over the last few decades, with the developments of technology and material sciences, roller press technology has now evolved as one of the most energy-efficient grinding systems for raw meal and cement grinding, completely eliminating the ball mills in grinding circuits.

Modular grinding v/s conventional

Traditional method: Grinding of clinker from the kiln is the final manufacturing stage at a cement plant. The griding process includes 4-5 percent gypsum and grinding aids (additives), into the final product, cement.

The cement grinding process accounts for approximately 40-50 percent of the energy consumption. It is noteworthy that the quality of the final cement is extremely dependent on the operation/grinding mode. The cement quality and the consumption of electrical energy are dependent on the grinding procedure. Thus, the cement grinding plant must be adequately designed and operated.

Modular grinding: This system is a portable solution for companies that need of quick start of production or need to increase production capacity on short notice to meet the peak market demands. Today, many vendors offer modular grinding mechanisms that offer quick installation setup, enhanced product performance, and low energy consumption. They are designed in such a way that it suits a wide range of raw material types and finish products’ variety (recipe, fineness, etc).

The advantages of the modular design are:

Proven technology of major equipment
Low cost of transportation of equipment to site
Low delivery times of equipment
Low investment risk and fast market entry
Low construction and Installation periods
Compact design with minimum land usage

Automation in grinding process

Today, a lot of many equipment companies have come up with automation solutions allowing the grinding process to be fully automated. They offer dynamic systems, which are more accurate to control than a conventional ball mill. Fully automated systems allow easy management of raw material quality variations and are very smooth and safe to operate. Moreover, automation in grinding also eliminates the high responsibility of daily operations, thus allowing resources to focus on more valuable tasks.

During the pandemic, remote services have picked up fast, offering daily operations, predictive maintenance, and troubleshooting services. This kind of development has shown its relevance during the pandemic.

In the past decade, the cement industry has realised the importance of process control in grinding circuits to achieve a better quality of product, and to obtain high energy efficiency. The PLC-based automation system is so common even in mill systems of capacities as low as 30 tph.

Karrahe said “The use of digital technology such as advanced process control can further improve energy efficiency by as much as 5 percent. References of combining separator upgrades to modern high-efficiency design or upsizing to accommodate new feed materials and/or product types with advanced process control have yielded as much as 25 percent overall performance improvement.”

“Reduction in mills pressure drop, optimisation of grinding media in ball mills, separator fan volume loading, the addition of grinding aids are some of the optimisation measures adopted by cement plants as seen in recent PAT cycles. Some high-energy efficient plants have already achieved overall specific electrical energy consumption of 63-65 kWh/t cement. It is anticipated that with the improvements in motor efficiencies, fan efficiencies, implementation of above-mentioned technologies and innovations, there is a scope for further electrical energy savings in grinding section,” explains Dr. Mohapatra.

Grinding aids

Cement clinker is difficult to grind, and the fine grinding of this material is one of the major problems of the cement industry. Cement clinker is difficult to grind, and the fine grinding of this material is one of the major problems of the cement industry. One method is to use special breakage machines, but it is usually more expensive as it requires more energy and reduces capacity. The most economic and the best alternative is to use a grinding aid or additives to obtain the best product.

Grinding aid or grinding additives are substances which when mixed into the grinding mill contents lead to an increase in the rate of size reduction and flowability. These additives are added into the material in a certain ratio based on the weight and the grinding machine for a definite time at the same condition. Different types of grinding additives are suitable for clinker grinding, which results in an improvement in the grindability by decreasing agglomeration and increasing breakage.

The use of grinding aid is a common practice in cement manufacturing for bringing improvements in mill capacity and overall better operations. For example, grinding aid stabilises the grinding bed in a VRM. This reduces the vibration level, for more capacity at the same power use. Since grinding aids offer better stability, it reduces the requirement of stopping and starting the mills, which further decreases the total energy consumption.

Conclusion

Globally, cement producers are fighting climate change challenges and the focus is more toward attaining sustainability in each step of cement manufacturing. Suppliers are well aware of this challenge and are coming up with innovative ideas to develop flexible solutions with high levels of energy efficiency, emission control, and product quality. Such kind of evolution will help the cement industry reduce the use of natural resources, make use of recycled materials and preserve energy consumption.

In terms of choosing the grinding system, though ball mill systems are still preferred due to less CAPEX, we see a shift in the industry towards vertical mill or roll press systems.

Concrete

ACC To Expand Cement Capacity Amid Strong Infrastructure Demand

Chairman signals calibrated growth and sustainability focus

Published

1 hour ago

June 26, 2026

admin

ACC will continue to expand its cement capacity in a calibrated manner, deepen its ready-mix concrete (RMC) footprint and accelerate the adoption of low-carbon technologies, the company chairman conveyed in the latest annual report. The note emphasised a balanced and disciplined approach as the business pursues growth while maintaining environmental safeguards.

He argued that the long-term growth outlook for the Indian economy remains strong but that demand conditions in the near term were likely to stay moderate, necessitating cautious expansion. He pointed to India’s relatively low per capita cement consumption compared with global averages as an indicator of significant long-term potential and highlighted the rise in public capital expenditure to Rs 12 trillion (Rs 12 tn), which he said accounted for about four point four per cent of the GDP.

Against this backdrop, ACC and the wider Adani Cement business are positioning themselves as integrated building materials solution providers rather than traditional commodity suppliers, prioritising capability creation over consolidation. The chairman framed cement as the ingredient and concrete as the performance and said that infrastructure and real estate development increasingly demand engineered solutions delivered at site.

He described how deeper integration across energy, logistics and digital systems is intended to improve responsiveness and efficiency across manufacturing, transport and market operations. The company intends to strengthen technical engagement, mix optimisation and application support to improve project timelines, reduce wastage and enhance structural durability while embedding data analytics and predictive systems.

On sustainability, ACC affirmed its commitment to reducing its environmental footprint through greater use of blended cement, renewable energy, alternative fuels and improved thermal efficiency, presenting industrial growth and environmental responsibility as parallel objectives. The message positioned the group to supply engineered concrete solutions at the point of application as it scales capacity and service offerings.

Concrete

Ambuja Sees Cement Demand Easing To Around Five Per Cent In FY27

Company Cites Housing, Infrastructure And Government Capex

Published

4 days ago

June 22, 2026

admin

Ambuja Cements has said in its latest annual report that cement demand in India is likely to moderate to around five per cent in fiscal year twenty seven, marking a slowdown from the estimated six point five to seven point five per cent growth anticipated for fiscal year twenty six. The company described this as a transition to a more measured pace of expansion after several years of strong momentum in the sector.

It said that underlying demand drivers such as housing, infrastructure development, urbanisation and government capital expenditure remain intact and are expected to sustain cement consumption across regions. The report noted that global geopolitical uncertainties and weather risks, including forecasts of a below normal monsoon, could influence near term demand, while emphasising that the longer term infrastructure story for India continues to provide a solid foundation for the sector.

Industry observers have said that the sector may move towards mid single digit growth rates in fiscal year twenty seven after stronger performances in recent years. The company outlined a calibrated expansion strategy with capacity additions phased to match project pipelines, regional demand patterns and market absorption, seeking to avoid oversupply and pressure on pricing.

Ambuja has crossed the 100 million tonnes per annum capacity milestone (100 mn t per annum) following acquisitions and organic expansion, strengthening its position in the competitive market. The outlook in the report broadly aligns with other market assessments that placed demand at around five per cent in fiscal year twenty five, a recovery to six point five to seven point five per cent in fiscal year twenty six and an easing in fiscal year twenty seven as capacity increases. Executives remain focused on long term demand fundamentals driven by infrastructure and housing.

Concrete

Powering Cement Through Intelligent Motion

Published

1 week ago

June 17, 2026

admin

Gears, drives, and motors have evolved from essential mechanical components into strategic enablers of reliability, efficiency, and sustainability in modern cement plants. ICR explores how advanced motion technologies, predictive maintenance, digitalisation, and intelligent drive systems are helping cement manufacturers reduce downtime, optimise energy use, and build future-ready operations.

As the Indian cement industry prepares for another phase of capacity expansion, the focus is shifting from merely increasing production volumes to improving operational efficiency, reliability, and sustainability. According to industry estimates, India is expected to add nearly 160–170 million tonnes of cement capacity between FY26 and FY28, driven by infrastructure investments, urbanisation, and housing demand. In this environment, gears, drives, and motors have emerged as critical enablers of productivity, forming the backbone of every major process from raw material extraction and grinding to clinker production and cement dispatch.
Motors alone account for nearly 60 per cent to 70 per cent of industrial electricity consumption globally, according to the International Energy Agency (IEA), while rotating equipment failures remain among the leading causes of unplanned downtime across heavy industries. In cement plants, where equipment operates under high loads, extreme dust conditions, elevated temperatures, and continuous-duty cycles, the performance of gears, drives, and motors directly influences energy consumption, maintenance costs, plant availability, and overall profitability. As digitalisation and Industry
4.0 technologies gain momentum, these systems are evolving from passive mechanical components into intelligent assets capable of delivering real-time operational insights.

Why gears, drives, and motors are the backbone of cement plant operations
Every major process in a cement plant depends on the seamless operation of gears, drives, and motors. Raw mills, vertical roller mills, crushers, kiln drives, conveyor systems, fans, and clinker coolers all rely on rotating equipment to maintain continuous production. A failure in any one of these systems can disrupt entire process chains, highlighting their strategic importance.
Modern cement plants process thousands of tonnes of material daily, requiring equipment capable of transmitting enormous torque while maintaining precision and reliability. Kiln drives and grinding systems, in particular, operate under some of the highest mechanical loads found in industrial manufacturing. The ability of gears and motors to withstand these conditions directly impacts plant throughput and production stability.
Satish Maheshwari, Chief Manufacturing Officer, Shree Cement says, “Effective lubrication management remains one of the most critical factors in extending the lifespan of cement plant drive systems. Proper lubrication, supported by regular oil analysis, vibration diagnostics, and condition monitoring, helps minimise wear, prevent unexpected failures, and maintain the integrity of critical components such as gearboxes, motors, and drive assemblies. By identifying potential issues at an early stage, plants can move from reactive maintenance to a more proactive and reliability-focused approach.”
“Smart motors, intelligent drives, and next-generation gearboxes are set to redefine cement plant maintenance and performance. Equipped with embedded sensors, IoT connectivity, digital twins, and AI-driven diagnostics, these technologies enable real-time condition monitoring, predictive maintenance, and seamless digital integration. As the industry embraces Industry 4.0, smart drive systems will play a pivotal role in improving energy efficiency, reducing downtime, and optimising asset performance across the cement manufacturing value chain” he adds.
Industry studies suggest that rotating equipment accounts for a significant proportion of maintenance expenditure in process industries. Effective design, selection, and maintenance of gears, drives, and motors therefore have a direct influence on asset utilisation, operational efficiency, and total cost of ownership.

The cost of downtime: reliability challenges in rotating equipment
Unplanned downtime remains one of the most expensive challenges facing cement manufacturers. Industry estimates indicate that a major failure involving a critical gearbox, kiln drive, or grinding mill can result in production losses running into lakhs of rupees per hour, depending on plant capacity and operating conditions.
Sanjeev Arora, President – Motion Business & IEC LV Motors Division, ABB India says, “One of the most significant shifts taking place in industrial decision-making today is moving away from evaluating equipment based solely on upfront capital cost toward understanding total cost of ownership (TCO). In a typical motor system, the purchase price often represents only a small fraction of the total lifecycle cost however energy consumption, maintenance requirements, downtime and operating efficiency account for the vast majority of long-term operational expenses. For cement manufacturers operating in highly competitive markets, this distinction is critical.”
“A high efficiency motor paired with an appropriately configured variable speed drive may require a higher initial investment, but the long-term benefits are substantial. Reduced electricity consumption, lower maintenance needs, longer service intervals and improved process stability can deliver faster payback and stronger profitability over time” he adds.
Cement plants present a particularly challenging environment for rotating equipment. Dust ingress, thermal fluctuations, shock loads, vibration, shaft misalignment, and lubrication contamination contribute significantly to equipment degradation. Studies by SKF indicate that nearly 50 per cent of bearing failures are linked to lubrication issues and contamination, while improper alignment and vibration-related problems remain leading causes of gearbox and motor failures.

Energy-efficient motors and drives: unlocking operational savings
Energy is one of the largest operating expenses for cement manufacturers, often accounting for 25 per cent to 35 per cent of total production costs. Grinding operations alone can consume nearly 60 per cent to 70 per cent of a plant’s electrical energy, making energy-efficient motors and drives a strategic investment.
According to the International Energy Agency, high-efficiency motors combined with Variable Frequency Drives (VFDs) can reduce energy consumption by 20 per cent to 30 per cent in suitable applications. By matching motor speed and torque to actual process requirements, VFDs minimise unnecessary power consumption while reducing mechanical stress on equipment, improving both efficiency and reliability.

Advances in gearbox design and power transmission technologies
Modern gearbox technology has evolved significantly in response to the increasing demands of cement manufacturing. Advanced materials, case-hardened gears, optimised tooth profiles, improved surface finishing, and enhanced lubrication systems are helping reduce friction, wear, and thermal loading.
Girish Hanchate, Director – Industrial Market, India SKF India (Industrial) says, “Smart diagnostics are significantly improving the lifecycle of gears, motors, and other rotating equipment by enabling a shift from reactive maintenance to condition-based asset management. Hidden issues such as vibration anomalies, bearing defects, misalignment, and temperature fluctuations can quietly reduce plant throughput by 10 per cent to 20 per cent while increasing energy consumption long before a breakdown occurs. By leveraging advanced sensors, predictive analytics, machine learning, and real-time monitoring of vibration, temperature, and motor current, cement manufacturers can detect developing faults early, optimise maintenance schedules, and prevent costly secondary damage. This not only improves reliability but also supports energy efficiency and sustainability objectives.”
“The next major evolution in drive and bearing technology lies in the development of fully integrated smart mechanical ecosystems that combine high-performance bearings, advanced lubrication management, and digital intelligence. Sensor-enabled condition monitoring embedded directly within bearings and drive systems allows operators to capture critical operational data at the source, enabling predictive maintenance and real-time performance optimisation. Innovations such as SKF’s VA9A1 Spherical Roller Bearing series, engineered specifically for demanding cement applications such as crushers and kilns, demonstrate this trend. By increasing internal bearing space and optimising lubricant flow, these designs improve grease retention, reduce wear, minimise downtime, and create more resilient, energy-efficient rotating equipment systems for the future of cement manufacturing” he adds.
Manufacturers are increasingly focusing on compact, high-torque gearbox designs capable of delivering higher power density while maintaining service life. Innovations such as condition-monitored gear systems, improved sealing technologies, and modular gearbox architectures are simplifying maintenance while enhancing operational reliability.

Predictive maintenance, condition monitoring, and asset health management
The shift from reactive to predictive maintenance is transforming asset management across the cement industry. Technologies such as vibration monitoring, thermography, oil analysis, ultrasound testing, and motor current signature analysis are enabling operators to identify potential failures before they occur.
Research by Deloitte suggests that predictive maintenance can reduce breakdowns by up to 70 per cent and lower maintenance costs by 25 per cent. In cement plants, where shutdown windows are limited and equipment operates continuously, predictive maintenance offers a powerful tool for improving reliability and extending asset life.
Digitalisation, industry 4.0, and the rise of intelligent drive systems
Industry 4.0 technologies are redefining the role of gears, drives, and motors. Smart sensors embedded within motors, bearings, and gear systems can continuously monitor temperature, vibration, load, lubrication condition, and energy consumption.
Girish Hanchate says, “As the industry embraces automation, sustainability, and digital transformation, the importance of intelligent motion technologies will continue to grow. The convergence of advanced engineering, predictive maintenance, and Industry 4.0 solutions is creating a new generation of cement plants where reliability, efficiency, and sustainability work together to deliver long-term value. For cement manufacturers navigating increasing production demands and environmental expectations, investing in smarter gears, drives, and motors is no longer optional—it is a business imperative.”
Cloud-based monitoring platforms and Industrial Internet of Things (IIoT) architectures enable maintenance teams to access equipment health data remotely, improving visibility across geographically dispersed operations. Advanced analytics and
artificial intelligence are further enhancing fault detection capabilities, enabling more accurate maintenance planning.
The emergence of digital twins represents another significant development. By creating virtual replicas of physical assets, operators can simulate operating conditions, predict failures, optimise maintenance schedules, and improve lifecycle management decisions. These technologies are helping transform rotating equipment into intelligent assets that actively contribute to operational decision-making.

Building future-ready cement plants through smart motion technologies
The future of cement manufacturing will depend heavily on the ability to integrate mechanical reliability with digital intelligence. Smart motion technologies combine high-efficiency motors,
intelligent drives, condition monitoring systems, and automation platforms to create more responsive and efficient operations.
Sustainability goals are also accelerating investment in advanced motion technologies. Reduced energy consumption, improved equipment efficiency, and extended asset life contribute directly to lower carbon emissions and reduced resource consumption.
These benefits align closely with the industry’s decarbonisation objectives.
As capacity expansions continue across India, future-ready cement plants will increasingly prioritise reliability, flexibility, and data-driven decision-making. Organisations that successfully integrate smart motion technologies into their operations will be better positioned to reduce costs, improve productivity, and maintain a competitive advantage in a rapidly evolving market.

Conclusion
Gears, drives, and motors are no longer viewed solely as mechanical components; they have become strategic assets that influence every aspect of cement plant performance. Their reliability affects production continuity, their efficiency impacts operating costs, and their digital capabilities increasingly shape maintenance and operational strategies.