Concrete

Material grinding is the largest electrical energy consumer in cement

Published

5 years ago

December 21, 2021

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Indian cement plants are at par with global cement industry in adoption of latest energy efficient technologies such as VRM, roller press in semi-finish and finish mode, believes Dr Bibekananda Mohapatra, Director General- National Council for Cement and Building Materials (NCCBM).

Indian cement plants are at par with global cement industry in adoption of latest energy efficient technologies such as VRM, roller press in semi-finish and finish mode, believes Dr Bibekananda Mohapatra, Director General- National Council for Cement and Building Materials (NCCBM).

Today, the requirement for the cement industry is to reduce power consumption and make the grinding process more energy efficient. Please share your views on how this can be achieved.

Material grinding is the largest electrical energy consumer in cement manufacture. For raw material grinding, the most preferred energy efficient technologies are Vertical Roller Mill (VRM), roller press with ball mill and roller press in finish mode. For coal grinding, VRM is the most energy efficiency technology. VRM is most preferred for using different type of fuels like coal, petcoke etc.

The introduction of an external re-circulation system for material, adjustable louvre ring, latest generation classifier, vortex rectifier, thin liners for ball mill, use of Computational Fluid Dynamics (CFD) to improve classification efficiency, multi-drive systems, secondary classification in the grid cone, installation of high-efficiency fans, the use of slide gates instead of dampers for major fans with Variable Frequency Drives (VFD) and modification of mill body in VRM to improve the air and material trajectories are examples of such changes which increase throughput and improve energy efficiency.

What are the latest energy efficient grinding/technologies/solutions that could benefit Indian cement companies in achieving energy efficiencies?

There are several energy-efficient grinding technologies/solutions available in grinding. Some of them are ceramic grinding media for mono-chamber ball mills, thin liners for ball mills and online particle size distribution analyser for cement mills. In (VRM) grit cone water injection concept can reduce the water consumption by up to 50 per cent and stabilise the grinding bed with less vibrations. Moreover, feeding solutions like rotary feeder, sandwich sealing system for clinker/slag mills results in less wear rate. 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 support rollers is also providing grinding force enabling high energy efficiency. Advancements in VRM main drive gear box is leading to lower cooling requirement and reduction in energy loss. Reduction in mills pressure drop, optimisation of grinding media in ball mills, separator fan volume loading, 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.

How is the adoption level of the latest grinding techniques in India as compared to the global cement industry?

Indian cement plants are at par with global cement industry in adoption of latest energy efficient technologies such as VRM, roller press in semi-finish and finish mode. The specific power consumption of grinding section of a cement plant depends on various factors such as type of grinding technology adopted, type of cement produced, fineness requirement, clinker/additives characteristics etc. While it is not possible to trace reduction in specific energy consumption of grinding section over the decades, however, for the Indian cement industry as a whole, the average specific electrical energy consumption for complete plant was around 122 kWh/t of cement in 1960 and started decreasing in late 80’s due to technology change in large cement plants to present level of average of 82.5 kWh/t of cement. The best achieved specific energy consumption for integrated cement plant in India is 63 kWh/t of cement when compared to global best achieved specific energy consumption of 65 kWh/t of cement in Japan.

How have we evolved in terms of innovation in grinding mills at cement plants? What are the latest developments observed in this area?

Innovation is the need of the hour. Grinding technology suppliers are also working consistently in this direction. Some of the innovative grinding technologies are:

Beta-mill: This mill works on the pressure grinding principle. By having defined feeding velocity, material height and width, a defined layer of material is fed to the pressure transaction zone (grinding zone). Energy savings of up to 30 per cent for mill motor as compared to Roller Press and up to 70 per cent as compared to ball mills is possible.

Ultrasonic comminution: Latest development in comminution is based on the application of ultrasonic energy. Ultrasonic comminution efficiently transfers the energy needed for crushing to the raw material, by means of acoustic ultrasonic pulses that are generated by two counter-rotating disks with special aerodynamic surfaces. The small-pulse durations exert pressure waves that pulverize the particles.

Microwave comminution: Grinding is very energy intensive process. Typically, only 1 per cent of the energy input is used to create new surfaces, the rest is turned into noise and heat. Now, prior to mechanically grinding the material, microwaves can be used to selectively heat parts of the rock, causing them to fracture along grain boundaries. This significantly reduces grinding power when the microwave treated material enters into the mill.

Applying ultrasonic field in a roller -press mill: The required energy consumption for grinding is significantly reduced by careful application of an ultrasonic field in the grinding zone. It is also expected to prolong the life of mechanical components. A lower stress on the shafts and a reduction of the required torque can be observed. The lower mechanical stress should also cause less abrasive wear on the rolls. Experimental results obtained by using ultrasound to enhance the performance of a roller-press mill are very encouraging. An experiment was carried out for coal grinding in which the energy consumption was as low as 3 kWh/t of material when compared to 20 kWh/t of material in hammer mills.

Further investigations are required for possible implementation of the above technologies in the cement industry.

Concrete

Cement Prices to Stay Flat in Q2 FY27 as Costs Squeeze Margins

HDFC Securities warns monsoon slowdown and higher fuel costs

Published

18 minutes ago

July 17, 2026

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HDFC Securities has said the cement industry is unlikely to register a sequential increase in prices in Q2 FY27 as monsoon-related demand moderation coincides with rising fuel and packaging costs that will squeeze margins. The brokerage observed that price gains remained modest, with increases of two to three per cent quarter-on-quarter across regions, and noted subdued offtake in May with improvement in June as a delayed monsoon supported construction activity. The brokerage added that modest pricing gains so far have been insufficient to offset the input cost escalation.

The report stated that input cost pressures intensified in Q1 FY27 owing to the West Asia conflict, which pushed up coal and pet coke prices and is expected to keep fuel costs elevated, with a likely peak in Q2 FY27. It assessed that total variable costs, including packing, could rise by around Rs 150 per t quarter-on-quarter and that lower offtake and seasonal operating deleverage could further raise operating expenditure by about Rs 50 per t quarter-on-quarter.

Overall, cement prices were estimated to remain flat in Q2 FY27 as monsoon-led demand weakness offsets limited upside in realisation, and rising fuel costs alongside seasonal deleverage were expected to compress industry margins by over Rs 100 per t quarter-on-quarter to below Rs 880 per t. The brokerage indicated that the combined impact of energy inflation and higher packing expenditure would be the principal drivers of margin contraction in the near term. HDFC Securities projected a recovery in margins in H2 FY27 should the West Asia turmoil subside and energy and packing costs cool off.

The brokerage expressed optimism on long-term demand fundamentals and said improving realisation together with an anticipated cost cool-off should support a margin rebound from H2 FY27 onward, underpinning favourable industry prospects over the medium term. Its outlook rests on monsoon normalisation and a decline in imported fuel prices in the second half of the fiscal year.

Concrete

Dalmia Bharat Begins Rs 31 Bn Green Cement Unit in Kadapa

New Andhra Pradesh plant to add 9.6 MTPA cement capacity by FY28

Published

1 day ago

July 16, 2026

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Dalmia Bharat Limited recently laid the foundation stone for its second manufacturing unit at Kadapa in Andhra Pradesh. The company will invest Rs 31 billion in developing the next-generation integrated cement manufacturing facility.

The foundation-laying ceremony was attended by Nara Lokesh, Andhra Pradesh Minister for Information Technology, Electronics and Communications, Real-Time Governance and Human Resources Development, along with Puneet Dalmia, Managing Director and Chief Executive Officer, Dalmia Bharat, senior government officials and company representatives.

Scheduled to be commissioned by the third quarter of FY28, the Kadapa unit will become Dalmia Bharat’s largest integrated manufacturing facility in southern India. It will have a clinker production capacity of 6.1 million tonnes per annum and a cement manufacturing capacity of 9.6 million tonnes per annum.

The facility is designed to produce what the company describes as one of the world’s greenest cements. It is also expected to generate approximately 1,000 direct and indirect employment opportunities while supporting local MSMEs, transporters, contractors and service providers.

Lokesh said the investment reflected Dalmia Bharat’s confidence in Andhra Pradesh and aligned with the state’s objective of promoting sustainable industrialisation, job creation and technology-led economic growth.

Puneet Dalmia said the project represented the company’s long-term vision of developing low-carbon cement manufacturing assets. He added that the facility would establish new benchmarks in operational efficiency and sustainability while supporting India’s infrastructure and environmental goals.

Dalmia Bharat will also expand its regional community development programmes in education, healthcare, skill development and welfare through its DIKSHa and Gram Parivartan initiatives.

The company currently has an installed cement manufacturing capacity of 54.7 million tonnes across 19 manufacturing units in 12 states. It is also the first cement company globally to commit to the RE100, EP100 and EV100 initiatives.

Concrete

Nuvoco Inaugurates Limla Cement Plant in Surat

Acquisition boosts Western India cement capacity

Published

2 days ago

July 15, 2026

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Nuvoco Vistas Corporation Limited inaugurated the Limla Cement Plant in Surat, Gujarat, marking a key milestone in its acquisition and revival of Vadraj Cement Limited.

The company completed the acquisition of Vadraj, which had been undergoing a corporate insolvency resolution process, by discharging a consideration of Rs 18 billion (bn) in June 2025. Vadraj’s asset base includes a clinker unit at Kutch and a grinding unit at Limla, along with high quality captive limestone reserves and a captive jetty at Kutch that enhance logistics efficiency.

Since taking over the assets, Nuvoco has undertaken revival, refurbishment and expansion across both sites, culminating in the opening of the Limla facility. The grinding unit at Limla achieved project completion ahead of schedule with the commissioning of two million tonnes per annum (mn t per annum) grinding capacity, further expanding the company’s scale and market reach.

Upon full operationalisation of the Vadraj assets, nearly 40 per cent of Nuvoco’s total cement capacity will be accounted for by plants in the North and West regions, supporting improved access to high growth markets. The plant is expected to support a phased volume ramp up in Gujarat and to serve adjoining markets in western Maharashtra while releasing northern capacities for other markets.

It will produce a complete portfolio of cement products including Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement, and will offer the Duraguard range including the premium Duraguard Microfibre. The transaction is set to create synergies with Nuvoco’s existing manufacturing facilities at Nimbol and Chittorgarh, strengthening logistics optimisation and market access across key regions.

Nuvoco reported total income of Rs 113.62 billion (bn) in FY 2025-26 and stated it is on track to consolidate total cement capacity to 35 million tonnes per annum (mn t per annum) by FY2028. The company operates across cement, ready-mix concrete and modern building materials segments and highlighted a pan-India ready-mix presence alongside contributions to major infrastructure projects. Corporate communications contact details were provided by the company.