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Reduce use of mineral-based lubricants

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Gopalkrishna Murthy, Vice President, Zuari Cement, discusses the importance of lubricants in maintaining the heavy machinery at cement plants and ensuring its smooth operation and cost savings.

What is the role of lubricants in maintaining the machinery of cement plants?
The main role of lubricants used in the machinery of a cement plant rotating. A lubricant is bought to help in the cement manufacturing process. They lubricate the bearings, rollers, engines or whatever is used in operations is lubricated to ensure smooth functioning of the plant.

How often are quality checks and maintenance functions performed in a cement plant?
All manufacturers of the equipment of the cement plant give manuals along with it that have time intervals like 100 hours, 500 hours or 5000 hours depending on the equipment application for the replacement or for quality checking. There is a compliance guideline and a laboratory for checking, examination and replacement of lubricants. Viscosity, total base number, contamination and wear depreciation are all examined based on the compliance guidelines. Other frequently conducted tests like checking for water contamination, exhaustion of the life of the lubricant, requirement of filtering of the lubricant for reuse etc., are checked. Generally, the number of hours, be it 500 hours, 5000 hours or 10,000 hours, depends on the equipment.
The general maintenance of a cement plant is usually done once in six months when there is a shutdown for refractory maintenance, mill maintenance etc. It is then when the condition of the lubricants like oil for the kiln, grease for the bearings is also checked. In any cement plant they have open gear systems for the mills which are regularly checked for spray patterns and application of lubricants if it is going in as instructed or not.
In rare cases when there is excess stock or if the plant stops for any reason, even then the lubricants are checked.


What are the types of lubricants used in a cement plant? Tell us about their applications.
In a cement plant, right from the beginning at the mining site, where shovels, extractors etc. are used, we use engine oils for the engines, hydraulic oils for the hydraulic systems and transmission oils for the transmission process.
In the plant, where there are multiple gear boxes, oils are used as lubricants. In kilns and open gears or spur gears, grease is used with a grease spray. This grease is also used for bearings throughout the plant. There are multiple motors in the plant, even though they are lubricated across the plant. Some of the motors have lubrication oil circulating systems also depending on the size of the motors. Circulating oils, lubricating oil and greases are used in a cement plant.

Does the external environment impact the choice of lubricants made for the plant?
One of the major considerations while selecting lubricants for equipment is to look at its working conditions. We look at the temperature in the area of function, exposure to dust, if the lubricant will work with the seal etc. All these factors are monitored and then a lubricant is selected for the application. Hence, the external environment plays a major role in selecting the lubricant for the cement plant.

How do you select your provider for lubricants and plant maintenance?
Ready availability is one of the key parameters we consider while selecting the lubricant provider for the plants. Other parameters like cost and quality certifications are what we look into while selecting the provider.
If any lubricant by a provider is certified or showed confidence in by our machinery supplier or equipment supplier, we consider them. If other players in the industry are using the lubricant, it shows a trust in their quality, then we consider them. If a lubricant provider has special application and certifications from member companies, appreciation and experience of their product in the market is looked at while selecting them. Another consideration is their viscosity grade and national or international certification of quality by recognised bodies.
After sales service is also an important aspect we look into for this selection, such as collecting samples, taking materials for testing and feedback, maintaining a data bank of the organisation and then the lubricant providers update it and share it with the concerned department. These become important considerations while selecting our
lubricant provider.

What are the standards you look for in a product before shortlisting them for your brand?
Generally, all the lubricants used in the cement plants have an ISO certified viscosity grade. Greases used are certified by the National Lubricating Grease Institute (NLGI) grades; oils used are certified by American Petroleum grades and military oil grades. They also have quality certifications from the original manufacturers. Sometimes, when the manufacturer makes an oil especially for their equipment, we consider that quality as well.

Does using lubricants for the plant have an impact on the environment? Can it be made more eco-friendly?
We ensure that whichever lubricant we use does not contaminate the environment. The lubricants should be made in such a manner that they can be re-filtered, recycled and reused. The plants usually push for longer drain intervals so that it reduces the impact on the environment when discarded. The lubricants should also be made in such a manner that they can be used as a source of energy or can be burned in the kilns without causing pollution to the environment. We consider these factors when we choose them for our plant.
Bio lubricants are now coming up in a big way and the industry is slowly reducing the use of mineral-based lubricants. Now there are multiple synthetic lubricants being formulated that are environment friendly. Their drain intervals are longer and hence, they can be used for a longer time, which means they are discarded at much longer intervals than other oils reducing the contamination of the environment and stay longer in the plants.

What innovative products do you suggest should be in the market for efficient cement plant lubrication?
There are two major requirements of the cement industry at this given time. Synthetic lubricants should be made for all kinds of applications and the cost should be in moderation that will allow more manufacturers to make the switch.
The cement industry consumes multiple lubricants and in large quantities. A scientific innovation should be made in the formulation to allow longer drainage intervals. Today the available synthetic lubricants are much costlier as compared to other type of lubricants and their drain intervals are also shorter.
The lubricants should also be energy efficient. If an organisation decides to invest in a higher costing lubricant, it should provide energy efficiency that will help them reduce their costs in other arenas. This would in turn make these lubricants environment friendly.

How do you foresee the collaboration of the lubricant industry and cement industry in the future?
Lubricant banks are developed by multiple oil industries, which they place in cement industries. This facility is not for all but cement plants do buy lubrication from the oil industry. However, this causes lack of availability. If all the lubricant manufacturers develop a banking type of structure in the plant campus itself, that will help in better interaction between the plant personnel and the lubricant makers and easy availability of the lubricants.
It will also help us recognise the many varieties of lubricants available in any category of lubricants which will help us make better informed choices and thus, improve the plant efficiency. The lubricant manufacturers will also have the opportunity to sell their best products and having these lubricants readily available on the plant campus will reduce lead time as well.
This development will make a better collaboration and interaction between the lubricant industry and cement industry.

-Kanika Mathur

Concrete

India Sets Up First Carbon Capture Testbeds for Cement Industry

Five CCU testbeds launched to decarbonise cement production

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The Department of Science and Technology (DST) recently unveiled a pioneering national initiative: five Carbon Capture and Utilisation (CCU) testbeds in the cement sector, forming a first-of-its-kind research and innovation cluster to combat industrial carbon emissions.
This is a significant step towards India’s Climate Action for fostering National Determined Contributions (NDCs) targets and to achieve net zero decarbonisation pathways for Industry Transition., towards the Government’s goal to achieve a carbon-neutral economy by 2070.
Carbon Capture Utilisation (CCU) holds significant importance in hard-to-abate sectors like Cement, Steel, Power, Oil &Natural Gas, Chemicals & Fertilizers in reducing emissions by capturing carbon dioxide from industrial processes and converting it to value add products such as synthetic fuels, Urea, Soda, Ash, chemicals, food grade CO2 or concrete aggregates. CCU provides a feasible pathway for these tough to decarbonise industries to lower their carbon footprint and move towards achieving Net Zero Goals while continuing their operations efficiently. DST has taken major strides in fostering R&D in the CCUS domain.
Concrete is vital for India’s economy and the Cement industry being one of the main hard-to-abate sectors, is committed to align with the national decarbonisation commitments. New technologies to decarbonise emission intensity of the cement sector would play a key role in achieving of national net zero targets.
Recognizing the critical need for decarbonising the Cement sector, the Energy and Sustainable Technology (CEST) Division of Department launched a unique call for mobilising Academia-Industry Consortia proposals for deployment of Carbon Capture Utilisation (CCU) in Cement Sector. This Special call envisaged to develop and deploy innovative CCU Test bed in Cement Sector with thrust on Developing CO2 capture + CO2 Utilisation integrated unit in an Industrial set up through an innovative Public Private Partnership (PPP) funding model.
As a unique initiative and one of its first kind in India, DST has approved setting up of five CCU testbeds for translational R&D, to be set up in Academia-Industry collaboration under this significant initiative of DST in PPP mode, engaging with premier research laboratories as knowledge partners and top Cement companies as the industry partner.
On the occasion of National Technology Day celebrations, on May 11, 2025 the 5 CCU Cement Test beds were announced and grants had been handed over to the Test bed teams by the Chief Guest, Union Minister of State (Independent Charge) for Science and Technology; Earth Sciences and Minister of State for PMO, Department of Atomic Energy, Department of Space, Personnel, Public Grievances and Pensions, Dr Jitendra Singh in the presence of Secretary DST Prof. Abhay Karandikar.
The five testbeds are not just academic experiments — they are collaborative industrial pilot projects bringing together India’s top research institutions and leading cement manufacturers under a unique Public-Private Partnership (PPP) model. Each testbed addresses a different facet of CCU, from cutting-edge catalysis to vacuum-based gas separation.
The outcomes of this innovative initiative will not only showcase the pathways of decarbonisation towards Net zero goals through CCU route in cement sector, but should also be a critical confidence building measure for potential stakeholders to uptake the deployed CCU technology for further scale up and commercialisation.
It is envisioned that through continuous research and innovation under these test beds in developing innovative catalysts, materials, electrolyser technology, reactors, and electronics, the cost of Green Cement via the deployed CCU technology in Cement Sector may considerably be made more sustainable.
Secretary DBT Dr Rajesh Gokhale, Dr Ajai Choudhary, Co-Founder HCL, Dr. Rajesh Pathak, Secretary, TDB, Dr Anita Gupta Head CEST, DST and Dr Neelima Alam, Associate Head, DST were also present at the programme organized at Dr Ambedkar International Centre, New Delhi.

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Concrete

JK Lakshmi Adopts EVs to Cut Emissions in Logistics

Electric vehicles deployed between JK Puram and Kalol units

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JK Lakshmi Cement, a key player in the Indian cement industry, has announced the deployment of electric vehicles (EVs) in its logistics operations. This move, made in partnership with SwitchLabs Automobiles, will see EVs transporting goods between the JK Puram Plant in Sirohi, Rajasthan, and the Kalol Grinding Unit in Gujarat.
The announcement follows a successful pilot project that showcased measurable reductions in carbon emissions while maintaining efficiency. Building on this, the company is scaling up EV integration to enhance sustainability across its supply chain.
“Sustainability is integral to our vision at JK Lakshmi Cement. Our collaboration with SwitchLabs Automobiles reflects our continued focus on driving innovation in our logistics operations while taking responsibility for our environmental footprint. This initiative positions us as a leader in transforming the cement sector’s logistics landscape,” said Arun Shukla, President & Director, JK Lakshmi Cement.
This deployment marks a significant step in aligning with India’s push for greener transport infrastructure. By embracing clean mobility, JK Lakshmi Cement is setting an example for the industry, demonstrating that environmental responsibility can go hand in hand with operational efficiency.
The company continues to embed sustainability into its operations as part of a broader goal to reduce its carbon footprint. This initiative adds to its vision of building a more sustainable and eco-friendly future.
JK Lakshmi Cement, part of the 135-year-old JK Organisation, began operations in 1982 and has grown to become a recognised name in Indian cement. With a presence across Northern, Western, and Eastern India, the company has a cement capacity of 16.5 MTPA, with a target to reach 30 MT by 2030. Its product range includes ready-mix concrete, gypsum plaster, wall putty, and autoclaved aerated fly ash blocks.

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Concrete

Holcim UK drives sustainable construction

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Holcim UK has released a report titled ‘Making Sustainable Construction a Reality,’ outlining its five-fold commitment to a greener future. The company aims to focus on decarbonisation, circular economy principles, smarter building methods, community engagement, and integrating nature. Based on a survey of 2,000 people, only 41 per cent felt urban spaces in the UK are sustainably built. A significant majority (82 per cent) advocated for more green spaces, 69 per cent called for government leadership in sustainability, and 54 per cent saw businesses as key players. Additionally, 80 per cent of respondents stressed the need for greater transparency from companies regarding their environmental practices.

Image source:holcim

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