Connect with us

Concrete

Towards Sustainability: Slag Grinding Circuits

Published

on

Shares

A detailed explanation of the joint approach of JSW Cement and the KHD Group helps in a better understanding on the acceptance of roller press in slag grinding and finish grinding.

JSW Cement has a strong commitment towards innovation in sustainability and technology to offer environment-friendly construction and building solutions. It is one of India’s leading ‘Green Cement’ manufacturers, growing exponentially since its inception in 2009. Today, after reaching a production capacity of 14 MTPA with minimum industrial bye product over the past 13 years, the group has a vision to build a self-reliant India by boosting the colossal infrastructure and fast-growing economy through projects that set benchmarks. The group aims to increase its production capacity to 75 MTPA by 2030.
In 2009, JSW ordered a 6000 TPD pyroprocessing line along with 8 roller presses for JSW’s first cement production facility at Nandyal, Andhra Pradesh, for raw material grinding, clinker grinding and slag grinding applications. This whole plant was ordered with a belief in KHD Technology. Since then the long continued association between the two companies has been a success story.
In 2015, JSW decided to increase capacity and ordered 16 roller presses for slag and clinker grinding (each unit comprising 2 RP @ 1.2 MTPA). Given the success of the Nandyal project and the market uptake in the use of roller press technology, JSW contracted KHD-HWI to execute the project, at the centre of which was the supply of KHD’s new-generation, energy-efficient roller press circuit. JSW Cement installed new slag grinding circuit at Jajpur plant, Odisha, India, with a KHD Humboldt Wedag roller press system.

Going the high-tech way
With over 160 years of experience in the cement industry, KHD is considered a global leader in cement plant technology. The system offered by KHD Humboldt Wedag for slag grinding is the most energy efficient grinding machine. Special features of the circuit include includes Roller Press (RP 16-170/180), V-separator (VS 80/20) and the well-proven SKS dynamic separator (SKS-V3000).The advantage of this system is that higher capacity requirements are met with lower specific power consumption. The offered system had a lot of innovative design features like, latest generation SKS dynamic separator at lower level to reduce the overall building height, reduced recirculation load on bucket elevator and reduced dust nuisance with the orientation of RP above V-separator. The fresh feed is put to RP first and the roller press discharge material enters the V-Separator. The material is then separated in SKS Separator, The very coarse fraction is discharged at the bottom end of the SKS separator, entering the feed bin of the roller press for further grinding.
The finished product is separated by SKS Rotor and collected in the baghouse. A reduced recirculation load on the bucket elevator, reduced dust nuisance with the orientation of the roller press above the V-separator, and less dedusting equipment due to the system’s self-venting mechanism in the riser of the separator. Figure 1 gives the configuration of the system offered and remains the key highlights of the system.
The focus to use roller press in finish grinding to get maximum energy advantage as compared to any other grinding technology is taking an edge day by day. Apart from electrical energy focus the offered roller press stud surface has minimum wear and offers trouble and maintenance free operation. The stud technology is a boon for slag grinding wherein Tungsten Carbide Studs are fixed on the roller surface by pressing in pre-drilled rollers, which offers autogenous grinding and minimum wear. The life expected out of these roller surfaces varies from 25000 to 40000 hours of operations without any surface maintenance. Figure 2 gives a picture of a stud surface roller.

Operational performance
The operating results of the slag grinding system with the roller press in finish mode are summarised in Figure 3. As can be seen, the very purpose of opting for roller press technology for slag finish grinding was significant savings in electrical energy consumption compared to other technologies and were successfully achieved. Furthermore, after stabilisation within months’ time the production figures recorded were higher than the original guaranteed parameters.

Conclusion
JSW Cement uses superior quality slag produced at its steel manufacturing plant, conforming to IS: 12089 standards for producing PSC. It is created with a combination of upto 45- 50 per cent slag, 45 per cent – 50 per cent clinker, and 3-5 per cent gypsum. PSC has been voted as the most suitable cement for mass construction because of its low heat of hydration. At present, carbon footprints of JSW are the lowest per tonne of cementitious products produced by the company.


During the year 2020-21, JSW Cement’s overall average net scope-1 CO2 emissions is 200 kg CO2/tonne of cementitious material, which is best in the industry. The steps to this achievement definitely goes to the meticulous approach of methodologies and technologies adopted to produce the desired quality of cementitious materials. Today, slag
grinding acceptance of roller press in finish grinding is well recognised throughout the cement industry. In the case of slag grinding, acceptance of roller press in finish grinding is well recognised. It offers a distinct advantage of saving of about 6-7 Kwh/t as compared to Vertical Roller Mill at 4200 Blaine. KHD has sold 27 Sag Grinding Circuits and maintains about 70 per cent market share in slag grinding in India. The advantage comes due to hardness of slag and pressure grinding in roller press instead of attrition and low pressure in Vertical Roller Press. The moisture issue is also tackled with the problem of coating by incorporating a V-separator below the roller press.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

on

By

Shares

World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

Continue Reading

Concrete

Building a Greener Future Together

Published

on

By

Shares

Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

Continue Reading

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

on

By

Shares



The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

Continue Reading

Video Thumbnail

    SIGN-UP FOR OUR GENERAL NEWSLETTER


    Trending News

    SUBSCRIBE TO THE NEWSLETTER

     

    Don't miss out on valuable insights and opportunities to connect with like minded professionals.

     


      This will close in 0 seconds