Concrete

Only cement has the ability to enhance the viscosity of concrete

Published

4 years ago

August 10, 2022

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ICR engages Anirudh Dani, Grinding Unit Head, JK Cement Works, Jharli, in a discussion about the grinding processes at the plant.

Explain the grinding process in cement manufacturing.
Cement is a core ingredient in construction and is also the most widely used construction material because only cement has the ability to enhance the viscosity of concrete, which in return provides a better locking result of sand and gravel together in a concrete mix.
Fresh feed along with the coarse material from the separator is fed back into the grinding system. Fines from separator i.e. the product passes from the bag house through a fan. The material collected at the bottom of the bag house is transported through a set of air slides and bucket elevator to the cement silo.

Tell us about the equipment used for grinding raw material and clinker.
A closed circuit Ball Mill, VRM, Roller Press or a combination of these are used for the grinding of raw materials and clinker. At JK Cement works, Jharli Roller press and ball mill combo are used for cement grinding, which has a capacity of 2.0 MTPA.
Mills are selected according to the type, which is most suitable in terms of variables like desired capacity, investment, space availability and grinding efficiencies based on relevant raw materials. In our organisation, we are using all three available combinations at various locations. All available technologies of cement grinding have their own benefits and drawbacks. Looking at the advancement of technology we prefer the Roller Press with Ball Mill and VRM. Several types of separators are also used in mill circuits and there are numerous variations of each type available in the market.

What are the key functionalities that are looked at while installing a cement grinding plant in your organisation?
In general, cement grinding plants are installed with the clinkerisation plant. But cement grinding is also installed at different locations on the basis of various strategic variables like nearby market locations and raw material sources. By installing cement grinding at different locations, the cement industry is effectively utilising the ‘Hub and Spoke Model’.
Major key technical functionalities are production capacity, cement grade, special energy consumption, maintenance cost, construction cost etc., for the installation of the grinding unit.
Further major key strategic deciding factors are land availability, market demand, logistics optimisation, geographical analysis and raw material availability for the finalisation of the cement grinding location.

What is the contribution of the grinding unit in making the cement grinding process efficient and productive?
Cement grinding is an integral part of the cement manufacturing process. The main function of cement clinker grinding is to provide a finished cement product with a certain particle composition. The dispersion of cement can be expressed by fineness and specific surface area. Cement grinding is required for inter grinding of various raw materials like clinker, gypsum, fly ash, slag and performance improvers. Efficient cement grinding contributes to enhancing the quality of the cement by better particle size distribution.

How do cement grinding /grinding units contribute to profitability of the cement making process?
Cement grinding cost is 40 to 45 per cent of the variable cost of cement production. By effective control measures and minuscule innovations, we can achieve a significant impact on profit maximisation with environmental sustainability.
Major KPIs of cement grinding units are clinker factor, specific power consumption, MTBF and maintenance cost to contribute for the profit maximisation.
Clinker factor has a pivotal role in profit maximisation with GHG reduction that is environmentally sustainable. For example, the clinker factor in PPC varies from 55 per cent to 65 per cent at various plants.
In general, as an industry, we are more concerned about the reduction in heat consumption during the clinkerisation process but concerted efforts to optimise the clinker factor will give more benefits in a shorter time. For example, 1 per cent reduction in clinker factor achieves higher environmentally sustainable gain, compared to 1.5 per cent reduction of specific heat consumption in clinker.
Specific energy consumption of grinding varies from 18.5 Kwh/MT to 30 Kwh/MT in the industry. Optimisation of grinding efficiency helps us in increasing the profitability of the cement-making process. Earlier we were on the higher side of energy consumption however by optimisation and innovations we have surpassed the industry benchmark and achieved higher profitability and environmental sustainability.
Further logistics costs also can be optimised by placing cement grinding on the basis of various strategic variables as already explained.

What are the materials and equipment that aid in the process of cement grinding?
Other than the standard raw materials, grinding aids and performance improvers play an important role in cement grinding. Grinding aids are effective chemicals that are utilised for various applications like increasing the flow ability of cement, higher early/later mortar strength and higher concrete strengths. Grinding aids for cement are like ‘Few drops can make a huge impact’.
Weigh feeders, VFD, screw conveyors, high efficiency separators, bag houses, compressors and hot air generators are the types of equipment used in the cement grinding process.
How do you ensure standards in the process? How often is the same monitored?
We ensure that our processes are BIS and ISO compliant. Further, we have also well-established internal norms by benchmarking the global data.
Chemical analysis of cement, product fineness, blaine surface and 45-micron residue, cement sulphur trioxide (SO3), percentage of grinding aid usage, moisture percentage, production rate, specific power consumption (SPC) and MTBF are also continuously monitored.
To ensure we meet quality standards, we leverage various digital platforms for taking real time action. We have an expert control system, world class laboratory, energy management system, lab automation and mobile applications that are well placed for continuous monitoring of the same.

What challenges do you face in the cement process of grinding?
Largely, availability of good quality raw materials, periodic variation in composition and size of materials, low availability of fly ash, power outage, optimum utilisation of alternative raw materials like wet fly ash, chemical gypsum, mould gypsum, and flue gas desulphurisation (FGD) gypsum are the major challenges in cement grinding. But as we have seen several times, challenges present opportunities whereby we can become more efficient in our operations. The cement industry is looking at alternatives and gearing up to handle these challenges through innovative solutions.

What are the innovations you would like to see in the technology of the grinding process and grinding aids?
Innovation is a continuous journey and grinding technology is continuously evolving and has modernised since its inception. We like to see innovations like low-weight grinding media/liners in ball mill, low maintenance-based rollers, high-efficiency separators of more than 95 per cent of efficiency, spares having less maintenance and higher life, brushless direct current motor based air conditioners, low clinker-based cement like limestone calcined clay cement, online real-time quality monitoring equipment etc.
Currently, various grinding aids are available in the market claiming high early/later strength, flowability of cement, higher concrete strength etc. We have seen continuous innovation happening in this area and there’s ongoing research on some materials like graphene to increase the impact on the cement strength by 15 per cent to 20 per cent. Further, we would also like to see the grinding aids, which will reduce the water demand drastically in the cement manufacturing process.

-Kanika Mathur

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Nuvoco commissions Surat grinding unit

Nuvoco posts 20 per cent rise in Q1 PAT

Published

18 hours ago

July 14, 2026

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Nuvoco Vistas Corp. has announced its financial results for the quarter ended June 30, 2026, reporting growth in volumes, earnings and profitability while advancing its expansion plans in western India.

The company inaugurated a 2-million-tonnes-per-annum (MTPA) grinding unit at its Limla Cement Plant in Surat on July 11, 2026, ahead of schedule. The facility, part of the Vadraj Cement assets, is expected to strengthen Nuvoco’s presence in western India while freeing up capacity at its Rajasthan plants to cater to demand in northern markets.

Progress at the Kutch project remains on track, with phased commissioning scheduled to begin in the third quarter of FY27. The company has also commenced work on a bulk cement terminal at Viramgam, Sachana, Gujarat, featuring a dedicated railway siding. The terminal is expected to become operational by the second quarter of FY28 and will support distribution across Gujarat. These projects form part of Nuvoco’s capacity expansion programme, which is expected to increase its total cement capacity to 35 MTPA by FY28.

During Q1 FY27, the company recorded cement sales volumes of 5.3 million tonnes, up 5 per cent year-on-year. Consolidated total income rose 9 per cent to Rs 31.29 billion, while EBITDA increased 7 per cent to Rs 5.72 billion, marking the company’s highest-ever first-quarter EBITDA. Profit after tax grew 20 per cent year-on-year to Rs 1.60 billion.

Commenting on the results, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp., said the company delivered improved business performance despite macroeconomic and geopolitical challenges. He attributed the results to disciplined execution, cost optimisation and operational efficiencies, while highlighting the early commissioning of the Surat grinding unit as a key milestone in the company’s expansion strategy.

He added that the company remains focused on prudent procurement, supply chain efficiency and cost discipline while monitoring geopolitical developments that could affect industry supply chains and input costs.

Concrete

Cement Sector Faces Sluggish Growth in First Half of FY27

April Price Hikes Unlikely To Offset Margin Decline

Published

2 days ago

July 13, 2026

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Nuvama Institutional Equities has warned that India’s cement industry is expected to record subdued volume growth in the first half of fiscal year 2026-27 before a recovery in the second half. The brokerage assessed that price increases implemented in April 2026 will be insufficient to offset an overall decline in sector profitability. It attributed the outlook to weak demand and fresh capacity additions scheduled during fiscal years 2026-27 and 2027-28 that are likely to keep prices under pressure.

The report noted that demand was sluggish in April and May 2026 owing to global uncertainty, labour shortages, heatwaves, constraints in raw materials and unseasonal rainfall. Producers raised prices across regions in April to mitigate rising petcoke costs and higher packaging expenses, but the increases proved short lived. Nuvama reported that standard petcoke prices rose to USD153/t, around USD41/t higher than in the third quarter of fiscal year 2025-26.

Price correction followed weaker demand, limiting the net increase to about Rs 10-12 per bag by the end of the quarter. Imported petcoke prices have since fallen to USD132/t from a recent peak of USD168/t, although they remained roughly USD20/t higher quarter on quarter. The brokerage expected the higher input cost impact to begin reflecting from late quarter one of FY27 and to continue into early quarter two.

Nuvama also estimated that crude linked increases were likely to raise packaging costs by about Rs 120-150/t and to exert upward pressure on freight. It warned that soft demand combined with significant new supply coming on stream in FY27-28 would keep pricing under strain and constrain near term margin recovery. The report concluded that volume growth was likely to be sluggish in the first half of FY27 before recovering in the second half.

Concrete

Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint

Published

2 days ago

July 13, 2026

admin

Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.

Surat (Gujarat)

Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.

Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.

Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.

The Limla Cement Plant is expected to support a phased increase in sales volumes across Gujarat. It will also help Nuvoco supply neighbouring markets in Western Maharashtra and release cement capacity from its northern plants, which can consequently be redirected towards markets in North India. The plant will manufacture a full portfolio comprising Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. It will additionally produce the complete Nuvoco Duraguard range, including the premium Nuvoco Duraguard Microfibre product. The acquisition is also expected to generate operational synergies with Nuvoco’s existing plants at Nimbol and Chittorgarh in Rajasthan, improving logistics optimisation and market reach across important regional markets.

The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.

Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”

He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”

Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.

Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.