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Use of digital technology can improve energy efficiency by as much as 5%

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Modern plants utilise high pressure grinding in vertical roller mills and hydraulic roll presses to achieve 30-50 percent better energy consumption compared to ball mills, says Avanish Karrahe, Global Product Manager Grinding Products, Cement Industry, FLSmidth.

Modern plants utilise high pressure grinding in vertical roller mills and hydraulic roll presses to achieve 30-50 percent better energy consumption compared to ball mills, says Avanish Karrahe, Global Product Manager Grinding Products, Cement Industry, FLSmidth.

Today, the requirement for the cement industry is to reduce energy consumption, especially in the grinding process. Please share your views on how this can be achieved.

 Improved energy efficiency in the grinding processes in the cement industry largely depends upon the comminution principle of the grinding equipment installed. Modern plants utilise high pressure grinding in vertical roller mills and hydraulic roll presses to achieve 30-50 percent better energy consumption compared to ball mills. 

Next, advancements in the geometry of the mill components or grinding profile, where grinding enabled gains in the general benefits from the types of technology employed. A further benefit is achieved with the tuning of design considerations and actual operating parameters, for example, grinding force (KN/m2), peripheral speeds, velocity profile within various zones inside the grinding equipment, etc. 

Along with mill design, advances in high-efficiency separator design have 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. Separator efficiency depends upon the actual geometry of the classifying equipment in the mill system. An ideal geometry ensures optimum velocity profile and physical dimensions within the various separation zones. When combined with the latest mill designs an optimised separator offers potential for up to 10 per cent better overall energy efficiency than mill systems with inferior separators. After the mechanical design, there are several operating and maintenance practices that enhance energy efficiency.

The use of grinding aid is already a common practice in many markets. While there is the obvious added cost for the additive itself, this is typically more than compensated for by improvements to mill capacity and overall better operation. For example, grinding aid stabilises the grinding bed in a VRM, reducing the vibration level, which allows for more capacity at the same power use. Better stability also reduces the number of mills stops and starts, which decreases the total energy consumption for the system in a given operating period.

Regularly making necessary adjustments of mechanical and process parameters to take care of incoming variations from input materials helps to sustain high-efficiency levels.

Following a predictive maintenance program with timely and proper maintenance of the overall grinding system helps to ensure consistency in higher efficiencies being achieved and also helps to avoid unplanned stops that largely can deteriorate the efficiency levels.

Consistent control of the quality of the feed material and final product also helps to aid the efficiency of the overall grinding system.

A final aspect of optimising energy consumption is the application of digital technologies that enable advances in feed material and product quality control, as well as process operating control. Digital connectivity also enables remote or online support services or condition monitoring that can enable both process and mechanical benefits.

What are the latest energy-efficient grinding technologies/solutions that can benefits cement companies in terms of energy consumption, quality and cost?

The latest energy-efficient grinding technologies include Vertical Roller Mills and Roller Presses. As such it is important to choose the right grinding machine on a case-to-case basis for a given requirement. The selection of the right machine depends upon several parameters, for example, layout constraints, physical and chemical properties of the material to be ground, product quality targets, the skill level of the operational staff, etc.

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. 

Regarding quality, there have been several tests done to compare the quality of the product out of various grinding machines. In today’s well-established designs of Vertical Roller Mills and Roller Press systems supported by high-efficiency Dynamic Separators, one can get the same quality as can be expected out of any traditional Ball Mill system. In fact, due to the larger number of adjustable mechanical and operating parameters in these mills, it is often possible to achieve better product quality targets than in older ball mill systems.

There have been significant developments in recent years on wear materials which have been a painful area for a long within the cement industry. Today we do have well-established superior wear materials that can not only increase the wear life drastically but can also ensure more effective energy transfer to the materials to be ground. For example, TRIBOMAX™ wear surface helps to increase the friction coefficient of the roller surfaces and eventually achieves improved energy transfer to materials being ground. 

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. 

Multi-compartment ball mills and air separators are the main process equipment in clinker grinding circuits. How has been the evolution in terms of technical innovations in this area?

Multi-compartment Ball Mills are widely used in the cement industry today mainly because of the history of their use over several hundred years. Over time advances in liner design and material of manufacture along with system layout and ball charge have helped optimise ball mill energy consumption. 

Digital technologies that optimise feed and product quality control, and advanced expert operating control can be applied to ball mill systems as well. 

As grinding technology evolved, Vertical Roller Mills and Roller Presses are now the leading machines across the globe for grinding. This is mainly due to the better energy efficiency, flexibility of producing various types of products, ease of operation and maintenance, and higher production capacities. Of course, upgrades to existing ball mill systems with a roller press for pregrinding or semi-finish grinding offer some limited efficiency improvement.

When it comes to separators, there has been significant improvement in separator designs in the recent past and the latest dynamic separators are equally effective irrespective of the main grinding machine (VRM, HRP, Ball Mill). However, the fact remains that ball mills are always going to be less efficient than the other grinding machines.

What kind of grinding aids/ additives are in demand and what are the advantages?

The adoption of supplementary cementitious materials (SCMs) varies widely depending on where you are in the world. In some markets, it is common to use fly ash and slag to reduce the clinker factor to as little as 65 percent. Worldwide, the average clinker/cement ratio is about 0.81, with the balance comprising gypsum and additives such as blast furnace slag, fly ash, and natural pozzolana. UNEP suggests a reasonable worldwide average of 0.60 is achievable by 2050. 

The grinding operation is critical to the success of increasing SCM use, to achieve the necessary particle size distribution. Some materials can be ground together, so-called ‘intergrinding’, while others may benefit from a separate grinding operation. Likewise, water demand (to increase workability) can present another sustainability concern that requires additional process treatments – such as chemical admixtures – to address. In terms of mill type, both roll press and VRM offer energy-efficient options for cement grinding, however, VRMs are more commonly used for SCM grinding due to more flexibility for drying and a wider range of acceptable feed particle size. 

Grinding aids are typically used to produce high Blaine cement products. There is a wide range of grinding aid options available ranging from the old industry standard of diethylene glycol (DEG) to a range of newer amine-based additives, and the latest specialised additives designed for specific machines and cement products with different SCM contents. In the end, the most effective option often is based on the combination of feed materials, cement products, local availability, and of course cost. 

From a mill OEM perspective, the specific type of grinding aid is less important than having the correct amount and distribution in the mill in combination with the best mill design for cement grinding. Experience in markets that have traditionally used grinding aids shows that under the right conditions they are a viable option to maximise energy efficiency and mill performance in a cost-effective way.

Please share your roadmap in the grinding innovation/ digital technology to enhance grinding efficiency.

Grinding technology has reached a stable point in the lifecycle curve. Incremental improvements are most likely to account for advancements for the near future. 

These are in the areas of:

  • Wear materials and metallurgy that allow for longer lasting and smaller/lighter component weights. 
  • Integration of digital technology to push the limits of efficiency and performance higher, while implementing predictive maintenance to streamline costs for labour, and parts supply and inventory.
  • Continued optimisation of the production of blended and high Blaine cement and the introduction of new high-performance cement that uses a wide range of SCM to replace clinker. This includes the advancement of separator designs to achieve finer product residues at a higher capacity than are possible today.

More significant advancements will likely come over the long term, as advanced research into energy consumption and grinding mechanisms is developed into new applications.

Could you also share a case study, where companies have benefited from adopting your grinding techniques/solution?

The Guinness World Record certified largest cement VRM, the FLSmidth OK 81-6 cement mill at Shah cement in Bangladesh grinds a wide range of cement products with clinker factor as low as 45 percent as well as a slag as shown in the table below. This mill is the perfect example of the type of energy-efficient grinding installation of the future.

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Akhoya Gets New 2.2 Km Road Link Under SASCI

Two cement concrete roads opened at Rs 29.1 million (mn) cost

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Two cement concrete pavement roads covering a total stretch of 2.2 km in Akhoya village were inaugurated on 27th June 2026 by MLA Nuklutoshi Longkumer, who attended as the special guest. The project comprises the one km L Pangersowa Road and the one point two km Longchara Junction to RC Chiten Jamir Memorial Government High School road. A formal programme followed the inauguration at the school auditorium.

A technical report was presented by Er Waloniba of the Urban Engineering Wing-III, Kohima, which stated the project was sanctioned in March 2026 under the Special Assistance to States for Capital Investment scheme for 2025-26 at a sanctioned cost of Rs 29.1 million (mn). The work order was issued to M/s Ensign Construction on thirtieth April 2026 with a stipulated completion period of 12 months. Work commenced on fourth May 2026 and was completed on sixth June 2026, with the contractor and team finishing the tasks in around two months. The project included a single-lane cement concrete pavement with side drains, two slab culverts and breast walls at required locations.

Longkumer acknowledged the Chief Minister, the advisor for urban development, contractors and other stakeholders for the allocation and support, and he commended the contractor for early completion. He noted that cooperation from landowners and the community had been important in resolving land related issues that can otherwise delay developmental works. He emphasised that planned developmental activities carried out with collective effort would enable more projects to be implemented successfully.

The headmaster of RC Chiten Jamir Memorial Government High School, I Chubasenba Longkumer, outlined the school background, noting it was established in 1962, was earlier known as Government High School Changtongya and was renamed in 2014. Local representatives said the improved approach roads would ease access for students, staff, patients and the general public and fulfil a long standing aspiration of residents. A dedicatory prayer was offered by the pastor and the programme concluded with a ribbon cutting attended by village council and town council representatives.

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Green Construction Through Cement Innovation

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Indian Cement Review (ICR) and Fuller Technologies brought industry, policy and technology leaders together to discuss how cement innovation can drive green construction at scale, writes Rakesh Rao.

India is building at a pace few countries can match. Highways, airports, housing, logistics parks, industrial corridors and urban infrastructure are reshaping the country’s economic geography. But beneath this growth story lies a difficult question: can India continue to build at scale without locking itself into a high-carbon future?

That question formed the core of an online panel discussion titled “Driving Green Construction Through Cement Innovation”, organised by Indian Cement Review (ICR) in association with Fuller Technologies as the Presenting Partner on June 25, 2026. The webinar brought together experts from cement technology, R&D, global industry platforms, building performance policy and international development cooperation to examine how low-carbon cement and material innovation can accelerate India’s green construction transition.

The discussion came at a crucial time. India has committed to achieving net-zero emissions by 2070 and reducing the carbon intensity of its economy by 45 per cent by 2030. At the same time, the country’s construction sector is expanding rapidly, driven by urbanisation, infrastructure development, housing demand and industrial growth. Cement, as one of the most widely used construction materials, sits at the heart of this transition. It is indispensable to development, but also central to the challenge of reducing embodied carbon in buildings and infrastructure.

Moderated by Nitika Krishan, Senior Urban Infrastructure and Sustainable Policy Consultant, the panel featured:

  • Kiranmai Sanagavarapu, Director, Low Carbon Solutions, Fuller Technologies;
  • Dr Hemantkumar Aiyer, VP and Head R&D, Nuvoco Vistas Corp Ltd;
  • Devika Wattal, Innovation Lead, Global Cement and Concrete Association (GCCA);
  • Dr Sunita Purushottam, MD, GBPN India (Global Buildings Performance Network); and
  • Vaibhav Rathi, Senior Technical Advisor, GIZ (the German Agency for International Cooperation)

Setting the tone for the discussion, Nitika Krishan underlined the scale of the challenge before the sector. “The question before us is no longer whether we build, but how we build sustainably,” she said. She pointed out that construction accounts for nearly 40 per cent of global energy-related carbon emissions when both operational and embodied carbon are considered. Cement production, she added, remains one of the hardest industrial processes to decarbonise.

For India, this is not merely an environmental issue. It is a development issue, a competitiveness issue and increasingly, a market issue. As one of the world’s largest cement producers and among the fastest-growing construction markets, India’s material choices will influence the carbon trajectory of its built environment for decades. As Krishan observed, sustainability solutions in economies such as India must not remain limited to laboratory success. They must be scalable, commercially viable and practical at national level.

The innovation gap: From technology to market

Experts believe that there is a need to bridge the innovation gaps for making decarbonisation in cement and concrete scalable. Devika Wattal of GCCA, explained, “The starting point must be the core cement manufacturing process itself. The first and foremost is the heart of our process, the heart of cement manufacturing. How do we reduce clinker? That is always a topic where industry is working very intrinsically.”

Clinker reduction remains one of the most important pathways for lowering emissions in cement. Since clinker production is energy-intensive and chemically emits carbon dioxide, reducing the clinker factor through supplementary cementitious materials (SCMs), blended cements and new chemistries can have a significant impact. Wattal also noted that carbon capture, utilisation and storage (CCUS) will have a role, though it may not be the first lever for all markets.

However, she stressed that innovation cannot stop at technology development. A solution that works in the lab must also be adaptable to industry, scalable in production and acceptable in construction practice. “It is important for that innovation to be adaptable, to be scalable, and so that it can be executed in real time,” she said.

Wattal also called for stronger enabling systems around innovation. These include performance-based standards, product-level embodied carbon databases and clearer frameworks for evaluating green materials. Without these, low-carbon cement products may struggle to compete with conventional materials in procurement and design.

R&D must balance carbon, cost and performance

Bringing in the R&D perspective into the discussion, Dr Hemantkumar Aiyer of Nuvoco Vistas emphasised that low-carbon cement development cannot be treated as a single-variable exercise. Cement must perform in real construction conditions. It must deliver strength, durability, consistency and cost competitiveness, while also reducing carbon.

“The root of understanding and balancing all these aspects lies in materials, and knowing the materials,” he said.

According to Dr Aiyer, R&D teams must understand the variability of raw materials such as fly ash, slag and clinker. Different sources produce different material behaviours. This makes mix optimisation, material characterisation and processing-property relationships critical. When performance is affected, cement manufacturers must understand how strength enhancers, admixtures and other performance chemicals interact with the material system.

He also linked material science with process efficiency. Clinkerisation takes place at extremely high temperatures, around 1,400 to 1,450 degrees Celsius. Any improvement in raw mix design, process control or energy optimisation can, therefore, help reduce emissions and cost. Dr Aiyer pointed to artificial intelligence-based optimisation, Cement 4.0 tools and advanced software as important enablers for real-time process and material control.

“The more you understand the materials, the more you can control it,” he said.

LC3: The promise is proven, the sequencing is not

Limestone calcined clay cement, commonly referred to as LC3, has attracted global attention because it can reduce clinker content significantly by using calcined clay and limestone while maintaining performance in many applications. Kiranmai Sanagavarapu of Fuller Technologies said the technology itself has already moved beyond proof of concept. Fuller Technologies has worked with calcined clay technology for nearly two decades and has seen plants running in France and Ghana. These plants, she said, are meeting local and national specifications, while the economics are beginning to make sense.

“The calciner is performing, the economics is stacking up, it is making business sense to produce,” she said.

But if the technology is viable, why has adoption not scaled faster? For Sanagavarapu, the answer lies in project sequencing. Too often, clay characterisation happens after equipment is specified. This, she warned, is a backward approach because calciner design depends on clay mineralogy, kaolinite content, iron levels, reactivity, moisture and other variables.

“If you don’t know what your deposit looks like before you commit for the equipment, you are, in a way, going blind into designing,” she said.

She also identified permitting and plant integration as major bottlenecks. Environmental clearances, mining permissions and local regulatory approvals must begin early. Similarly, calcined clay must be integrated into existing grinding, blending and logistics systems from the design stage, not treated as an afterthought during commissioning.

India already has IS 18189:2023 standard for LC3, but Sanagavarapu pointed out that the standard is not yet visible enough in procurement documents. “The gap between what is technically being permitted and what the procurement is asking is the single biggest bottleneck,” she said.

In her view, successful scale-up depends on getting the sequence right: clay characterisation first, permitting in parallel, standards aligned with construction, and integration built into plant design.

India’s LC3 journey: Progress, but demand remains thin

Providing details of India’s LC3 commercialisation experience, Vaibhav Rathi of GIZ noted that JK Cement carried out the first commercial production of LC3 at its Rajasthan plant, followed by JK Lakshmi Cement three months later. These initiatives were supported by the International Climate Initiative of the Government of Germany, with IIT Delhi contributing deep institutional knowledge on LC3 research and BIS certification.

Rathi said India’s early experience has produced clear lessons. One of the biggest was the need to build capacity among regulators. While BIS certification existed, State Pollution Control Boards were unfamiliar with the technology and unsure about the approval pathway.

“The capacity building is not just needed amongst the producer and the users of the cement, but also the regulators who are working with this technology for the first time,” he said.

He also highlighted the need for better information on China clay deposits. Since China clay is currently classified as a minor mineral, centralised data on availability, quality and location is limited. If cement manufacturers are to adopt LC3 at scale, stronger mineral intelligence will be important.

The third issue is demand. LC3 has already been used in projects such as Palava City in Mumbai and Noida International Airport, but these remain limited examples. “It is in a chicken and egg situation,” Rathi said. “Cement companies are saying we need more demand, and users are saying there is not enough cement available.”

Public procurement, he suggested, could help break this cycle. If agencies such as CPWD and other public bodies begin testing, accepting and specifying LC3, it could create the market confidence needed for cement companies to invest in production and storage.

Building codes must catch up with innovation

Dr Sunita Purushottam of GBPN India argued that material choices will determine built environment emissions over the long term, but India’s current policy signals remain fragmented. Although LC3 has received BIS recognition, she pointed out that building codes, municipal bylaws, schedules of rates and sustainability codes do not yet provide uniform guidance on low-carbon cement.

“The current cement regulations are largely prescriptive and favouring traditional materials,” she said. This limits the ability of alternative materials to compete on performance, durability and emissions.

Dr Purushottam also raised the issue of taxation. Cement, including LC3, currently falls under the same GST bracket as conventional cement. A differentiated tax structure, she argued, could help accelerate market adoption. “In order for the market to demand LC3, that differentiation in the GST could go a long way,” she said.

She noted that green building certifications such as IGBC and GRIHA are already creating demand for low-carbon materials by assigning points for embodied carbon and sustainable material use. However, she said large-scale adoption will require regulatory mandates, particularly through building codes and state-level notifications.

She also cautioned that low-carbon cement alone does not solve the entire building performance problem. A material may reduce embodied carbon, but the operational carbon of a building depends on thermal performance, design, insulation and energy use. “The energy part has two elements,” she said. “One is the embodied carbon of the material itself, and the other is the operational carbon.”

Collaboration is the bridge between invention and impact

Wattal said GCCA sees innovation as a strategic priority and works through platforms that connect industry with academia and start-ups. “There is no way we will decarbonise our sector without innovation,” she said.

However, she stressed that research must be connected to actual industry challenges. Innovations developed in isolation may fail when they encounter real-world barriers such as raw material variability, plant integration, cost, standards and finance. Start-ups, too, need industry mentorship and scale-up pathways.

Wattal also flagged the importance of finance. Even strong technologies may struggle to attract investment if there is no common understanding of bankability. “We have always put projects into, is this a bankable project? But the definition of a bankable project has never been defined,” she said.

For India, she saw strong potential in its academic and start-up ecosystem, but said the challenge lies in alignment and prioritisation. The country has the research base, industrial capacity and market size. What it now needs is a coordinated route from innovation to deployment.

There is a practical concern for cement manufacturers: how can existing plants be adapted for lower emissions without compromising reliability or commercial viability?

Kiranmai Sanagavarapu addressed, “The reliability risk in calcined clay retrofit is definitely real, but it is almost always self-inflicted. The risk arises when a new process is added to an existing circuit without properly redesigning grinding and blending configurations.”

Existing cement plants, she explained, can take two broad routes. The first is external sourcing of calcined clay combined with mill optimisation. This requires lower capital investment and can potentially move in 12 to 18 months if other conditions are in place. It may reduce emissions by around 20 to 30 per cent. The second route is integrated calcination on site, which requires higher capital expenditure and longer lead times, but provides greater control over quality, supply and emissions reduction potential.

For Sanagavarapu, the principle is simple: low-carbon retrofits must be designed with intent. “Design it with an intent properly from the start. Start in the market conditions where the economics are already working,” she said.

Circularity: The overlooked advantage

According to Vaibhav Rathi, fly ash and slag are already well established in cement and construction (C&D), but construction and demolition waste remains underutilised. “C&D waste is a growing business opportunity which not many have taken up,” he said. India’s continuous construction and demolition activity creates huge volumes of waste, much of which contributes to air pollution, land degradation and material inefficiency. With the right processing and standards, this waste can be converted into useful construction products.

Rathi also pointed out that LC3 has a circular economy dimension that is often overlooked. It can use low-grade kaolin-rich clay left behind after high-grade clay is extracted for other applications. “LC3 is not only a low-carbon solution, but also a circular economy solution,” he said.

At the same time, he cautioned that LC3 in India is not yet cheap because it has not reached scale. Site-specific techno-commercial feasibility studies, supported jointly by development agencies and industry, could help companies assess whether LC3 production makes technical and financial sense at a given location.

Dr Purushottam added that India must address both low-carbon cement and construction waste together. “Both low-carbon cement and C&D waste go hand in hand. India does not have an option but to work on both,” she said.

Dr Aiyer called for policy shifts from both government and industry, including preferential purchasing of sustainable materials, minimum supplementary cementitious material requirements in public and public-private projects, and faster regulatory implementation. “If we can fast-track the regulatory standards and their implementation on the ground, that is the way to go,” he said.

From green ambition to green construction

Cement innovation is no longer only about chemistry. It is about systems. Low-carbon cement will scale only when technology, standards, procurement, finance, regulation, education and construction practice move together.

LC3 and other low-carbon technologies have shown promise. India has early commercial examples, strong research capability and growing market interest. But mainstream adoption will depend on whether demand can be created, regulators can be capacitated, standards can be embedded in procurement, and manufacturers can see a clear business case.

For a country building at India’s scale, the opportunity is enormous. Cement will continue to be central to infrastructure and urban development. The challenge now is to ensure that the cement used in India’s growth story carries a lower carbon burden.

  • Rakesh Rao

Participate in Cement Expo 2026 and discover how next-gen infrastructure can be built with innovations in cement.

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Concrete

JK Cement Declared Preferred Bidder For Gilund Limestone Block

Shares Edge Higher As Company Wins Rajasthan Block

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JK Cement gained after being declared preferred bidder for the Gilund Limestone Block in Chittorgarh, Rajasthan, a lease area of 370.96 hectares. The firm saw its shares trade at Rs. 5550.05, up by 28.45 points or 0.52 per cent from the previous close of Rs. 5521.60 on the BSE. The scrip opened at Rs. 5569.15 and touched a high of Rs. 5625.00 and a low of Rs. 5531.00.

The stock recorded turnover of 1742 shares on the counter and the BSE group A stock with face value Rs. 10 has a 52 week high of Rs. 7565.00 on 20-Aug-2025 and a 52 week low of Rs. 4670.05 on 12-Jun-2026. Last one week high and low stood at Rs. 5625.00 and Rs. 5329.00 respectively. The promoters holding in the company stood at 45.66 per cent, while institutions and non-institutions held 40.61 per cent and 13.73 per cent respectively.

The e-auction conducted by the Government of Rajasthan resulted in the company being declared preferred bidder for the mining lease, and the allocation will enable the company to plan phased development of the deposit, subject to regulatory approvals. The Gilund block spans 370.96 hectares and its allocation is intended to support raw material security for the company’s cement operations in the region. The designation follows the government auction process and will allow the company to plan development and integration of the deposit into its supply chain.

The current market capitalisation stands at Rs. 430.38 billion (bn), reflecting market response to the mining news and prevailing valuation levels for the sector. Investors and analysts will watch for formal allotment and related disclosures that can clarify timelines, capital expenditure and expected production profiles. The report is intended for informational purposes and does not constitute investment advice, and market participants are advised to consult advisers before making decisions.

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