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Promoting a circular economy is the key

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Prakhar Shrivastava, Corporate Quality, JK Cement, sheds light on the use of automation and sustainability in processing gypsum.

Explain the role of gypsum in the cement manufacturing process?
Gypsum plays a crucial role in manufacturing cement. It is used to delay cement setting by slowing down the reaction of mixing cement with water to prevent rapid hardening of cement and increase its workability for construction. Gypsum enhances cement strength at all ages. If we grind the clinker without gypsum, then the cement will set immediately after mixing with water and the strength development will be lesser.

What are the proportions of gypsum that are added in various types of cements produced? Tell us in details of the composition and percentage.
Presently different types of gypsum are available and are being added to meet the SO3 in cement, like mineral gypsum, chemical, phospho, marine gypsum, anhydrite, FGD and synthetic gypsum. The composition and percentage depend on the chemistry of clinker and gypsum to adhere to the desired SO3 target in cement. Normally the percentage addition of gypsum is 5 to 8 in cement mix as per gypsum quality and its availability. Few gypsums, which have higher purity above 85 per cent like imported mineral, anhydrite and phospho gypsum usage are less, whereas, Indian mineral gypsum having purity <40 per cent required higher percentage usage to meet the SO3 requirement.

Tell us about the process of obtaining gypsum by your organisation. What are the key resources utilised?
The different sources of gypsum and vendors are identified by our central procurement team. After getting the test report and sample from the supplier, and its testing in our laboratories then clearance by the QC team about the desired quality of gypsum, the procurement of bulk quantity of gypsum gets initiated. The gypsum is transported by road and rail to the plant. The receipt quality and quantity of gypsum is continuously monitored and if any deviation is found, it is immediately informed to the procurement team as well as the vendor. After this, the gypsum is used to feed into the hopper by Raw material handling equipment (eg. JCB, Payloader etc.) and its usage control through a weight feeder from CCR (central control room) to get the desired SO3 level according to the product requirement during the cement manufacturing process.

Tell us about the key technical feasibility factors that make gypsum viable for mixing with cement.
The size, purity, P2O5, chloride and moisture content of gypsum are the key technical feasibility factors that make gypsum viable for its usages. High moisture content and powdery gypsum are a major concern during cement production whereas the dry and adequate size gypsum is easy to use.
Similarly, low purity gypsum required higher usage to meet the SO3 requirement in cement resulted in increased insoluble residue (IR), which affected the product quality and also the fly ash addition in PPC. To consume such a low purity gypsum requirement of high purity gypsums like imported mineral gypsum to meet the SO3 and IR requirement which is not a cost effective solution.
Phospho gypsum has higher P2O5, which causes delay in the setting of cement and lesser early days compressive strength. Hence, it is mandatory to use it in a very controlled manner by blending it with other available gypsums to meet the product quality requirement.

What is the preparation or processing required to make gypsum ready to mix with the clinker?
Presently, preparation or processing of the different types of gypsum is done by handling equipment manually (eg. loader, dozer and JCB, etc.) as per recommended target and quality. Mixed gypsum is then fed to a separate hopper and controlled by a weight feeder and a controlled quantity of gypsum is mixed with clinker in the cement grinding process.
A more suitable solution to prepare uniform gypsum is to mix it separately before feeding
by blending various types of gypsums through
multi hoppers and controlled dosage to get targeted gypsum quality.

How does automation help in obtaining this mineral and increasing productivity of the unit?
The automation gives a timely update about the whole process to track the status and progress of procured material which saves time and avoids delays in procurement. It also helps to increase efficiency by fast process, productivity, growth and profitability of the organisation.
In all our units, the LIMs System has been implemented. All the quality test equipment is linked with the LIMs software and test results are directly transferred in LIMs and SAP. The quality analysis results of each type of gypsum and vendor wise are available in the automation system which helps to identify the deviation and consistency in quality thereby reducing error and confusion.

What are the sustainability measures taken by your organisation in obtaining and processing the desired quality of gypsum?
As part of our sustainability goals we have taken significant measures to replace natural or mineral gypsum with industrial waste. All our manufacturing units are utilising available industrial waste such as chemical gypsum, anhydrite gypsum, FGD, synthetic gypsum etc.
Blending of mineral gypsum with industrial waste as an economical and sustainable solution to replace natural minerals. Promoting a circular economy is our key pillar of the sustainability journey to reduce the environmental impact of our product by replacing natural resource consumption with industrial wastes which in turn has reduced our dependency on natural resources and is economical as well. It benefits our business, society and the environment by eliminating waste and decoupling our growth from the consumption of natural resources.

What are the major challenges faced in handling and obtaining gypsum for the manufacturing process?
The major challenges in handling and obtaining gypsum are moisture, SO3 and purity, which are the key parameters in deciding the quality of gypsum. Some minor elements also affect the quality of gypsum like phosphorus pentoxide and chloride percentage.
The deviation in SO3 content increases or decreases the quantity of gypsum in cement. Also, typically, a decrease in the SO3 content increases the insoluble residues, especially in Indian mineral gypsum, which causes higher IR in cement and lowers the performance/durability of cement.
In chemical gypsum, the main concern is the moisture of material and colour, which directly affects the operation with reference to jamming, choking and product quality.

-Kanika Mathur

Concrete

ICRA Sees Steady Cement Demand Growth Ahead

Volumes seen rising 6–7 per cent in FY27 on infra push

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India’s cement industry is expected to record steady growth over the coming years, with cement volumes projected to expand by 6–7 per cent in FY27, supported by sustained demand from the housing and infrastructure sectors, according to a report by rating agency ICRA.

The agency said the sector is likely to maintain healthy momentum after registering growth of 6.5–7.5 per cent in FY26, despite a higher base in the second half of FY25. Cement demand remained strong in the current financial year, with volumes increasing by 8.5 per cent during the first eight months of FY26, driven by robust construction activity across regions.

ICRA expects demand to strengthen further in the second half of FY26 as construction activity accelerates after the monsoon. Continued government focus on infrastructure spending and the possibility of a reduction in goods and services tax on cement are also expected to support demand through FY26 and FY27.

Against this favourable demand backdrop, cement manufacturers are continuing to expand capacity through both organic and inorganic routes to strengthen their market positions. The industry is estimated to add 85–90 million tonnes per annum of capacity during FY26–FY27, including around 43–45 million tonnes per annum in FY26 and a further 42–44 million tonnes per annum in FY27.

Commenting on the outlook, Anupama Reddy, Vice President and Co-Group Head, Corporate Ratings at ICRA, said sector profitability is expected to improve significantly in FY26, supported by better pricing and higher volumes. Operating profit before interest, depreciation, tax and amortisation per tonne is projected to rise to around Rs 900–950 per tonne in FY26, compared with Rs 810 per tonne in FY25.

However, ICRA expects some moderation in earnings in FY27 due to rising input costs. Operating profit per tonne is estimated at Rs 880–930 in FY27, as costs related to pet coke and freight are likely to increase and remain influenced by global crude oil prices and geopolitical developments.

On a regional basis, North and Central India are expected to report capacity utilisation levels above the national average, while the southern region may continue to see relatively moderate utilisation due to existing capacity overhang. ICRA noted that recent merger and acquisition activity in the southern market has helped large players strengthen their regional and pan-India presence.

Overall capacity utilisation for the cement industry is projected to remain stable at around 70–71 per cent in FY27, broadly in line with FY26 levels, albeit on an expanded capacity base.

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GCCA India–NCB Carbon Uptake Report Released at NCB Foundation Day

New report highlights CO? absorption by concrete in Indian conditions

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The Global Cement and Concrete Association (GCCA) India–NCB Carbon Uptake Report was recently released during the 63rd Foundation Day celebrations of the National Council for Cement and Building Materials (NCB). On the occasion, a Gypsum Board Testing Laboratory and a Micro-Characterisation Laboratory were also inaugurated, strengthening India’s research and quality infrastructure for construction materials.

The laboratories were inaugurated by Urmila, Economic Advisor, Department for Promotion of Industry and Internal Trade (DPIIT), and Mohd. Kamal Ahmad, Special Director General, Central Public Works Department (CPWD), in the presence of L. P. Singh, Director General, NCB.

The newly established Gypsum Board Testing Laboratory will support quality assurance and standardisation requirements of the gypsum board industry, particularly in the context of the Gypsum-Based Building Materials (Quality Control) Order, 2024. The Micro-Characterisation Laboratory is equipped with advanced analytical tools for detailed investigation of cementitious and construction materials.

Addressing the gathering, Ms Urmila highlighted NCB’s sustained contributions to research, technology development, quality assurance and capacity building for the cement sector. Shri Mohd. Kamal Ahmad also commended NCB’s role in promoting sustainable construction practices through focused research and development.

The GCCA India–NCB report titled Carbon Uptake by Concrete assesses CO? uptake through carbonation in concrete under Indian conditions. Prepared in collaboration with the Global Cement and Concrete Association (GCCA) India, the study is based on the Tier-I methodology of IVL Swedish Environment Research Institute. It notes that while the cement industry contributes around seven per cent of global anthropogenic emissions, carbon uptake by concrete can partially offset process-related emissions.

The report outlines future actions to improve data robustness, refine estimation methodologies and support integration of carbon uptake into national sustainability and climate reporting frameworks. It will be submitted to the Ministry of Environment, Forest and Climate Change for consideration of inclusion as a carbon sink in India’s National Communications to the UNFCCC.

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Concrete

Shree Cement To Invest Rs 20 Billion In Maharashtra Plant

New 2 mtpa unit to strengthen capacity expansion plans

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Shree Cement Ltd has announced an investment of Rs 20 billion to set up a new cement plant in Maharashtra, the country’s third-largest cement maker said on Friday at the World Hindu Economic Forum (WHEF) 2025. The letter of intent for the proposed investment was signed in the presence of Maharashtra Chief Minister Devendra Fadnavis in Mumbai. Shree Cement chairman Hari Mohan Bangur said the company will establish a 2 million tonnes per annum plant in Chandrapur district, where land has already been acquired. He added that the project is awaiting environmental clearance and, once approved, is expected to be completed within two years. The expansion will be funded through internal cash reserves, with the company reporting a cash balance of Rs 65.41 billion at the end of FY25.

Shree Cement currently has an installed capacity of 62.8 million tonnes per annum. During the second quarter of FY26, the company commissioned a 3.65 mtpa clinker unit at Jaitaran in Rajasthan, while a 3 mtpa cement mill at the same location is expected to start operations shortly. A 3 mtpa integrated plant at Kodla in Karnataka is in the final stages of development and is scheduled to be commissioned within the third quarter of FY26. Following these ongoing expansions, the company’s total capacity is expected to rise to 68.8 mtpa, according to an ICICI Direct Research note dated 29 October.

Analysts estimate that Shree Cement’s capacity could reach between 72 and 75 mtpa by FY27E, with further potential to scale up to 80 mtpa by FY28E or FY29E, depending on demand trends. However, market observers have flagged medium-term risks, noting that industry-wide capacity additions may outpace demand growth through FY28-29, particularly in northern and western India where significant new capacity is expected. At the same time, cement prices declined sharply in the third quarter, especially in eastern and southern regions, though analysts expect some recovery from January, led by the South and East.

The announcement comes amid aggressive expansion plans by larger peers. UltraTech Cement recently raised its capacity target from 167 mtpa to 240 mtpa by FY28, while the Adani Group increased its cement capacity target by nearly 10 per cent to 155 mtpa by the same period. Shree Cement reported a 15 per cent year-on-year rise in revenue to Rs 43.03 billion in the September quarter, driven by higher volumes, premiumisation efforts and a value-over-volume strategy. The company’s chief financial officer Ashok Bhandari has guided for capital expenditure of around Rs 30 billion in FY26-27, with a similar level expected in FY27-28. Shares of Shree Cement ended 0.18 per cent lower on Friday, while the benchmark Sensex closed 0.53 per cent higher.

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