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Handling Clinker Efficiently

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Justus Von Wedel, Managing Director, IKN Engineering, discusses clinker handling and clinker cooling systems that are avenues for innovation in terms of sustainability.

I KN Engineering have had a big impact on the cost and quality of the clinker that discharges from the kiln and is then being quenched in the coolers. They also have lower electric power consumption as they are operating with an activated stratified layer of clinker bed, a unique feature of their clinker cooler. The drive for the most part can be hydraulic but for the smaller units is electronic, so there they transfer electrical energy in forward motion most efficiently.
Their impact in the cement industry, in terms of sustainability, has been very large. From the company’s perspective, they continue to work on maximum efficiency and recuperation. The clinker cooler is the recuperator for the most and they cool the clinker in the most effective and sustainable manner making them more competitive in the market.
The kiln situation has an impact on the kiln operation and that has an impact on the cooler operation. So, the cooler can look very good if the kiln is producing a homogenous clinker and the cooler can look challenged if the kiln is producing a high fraction of boulders and fines from the kiln.
For the most part, granulised clinker is needed. When alternative fuels like petcoke with a higher sulphur content are used or there are raw materials used, which are not conducive to producing well granulised clinker. The fines are the most critical and challenging for any cooler manufacturer to deal with. However, because of the resistance and integrity of IKN Engineering, they are suitable to handle a larger proportion of fine clinkers than competition.

Fine clinker is the most challenging to handle for clinker coolers.

Overcoming and Adapting
The most challenging part of handling clinker is the one with the highest fraction of fines. Fine clinker is the biggest challenge as it is harder to handle, to distribute and to classify and it is more abrasive to corrosion. It is definitely more difficult to control a pile of sand than a well granulised clinker.
However, generalisation is not possible. We see that the fraction of fine clinker of cement is increasing globally because of the alternative fuel situation. Cement producers are also using raw materials that are cost effective and this is something that’s needed to look at on a cooler to cooler basis.
With regards to pyrolines adapting to green cement, IKN Engineering operates in a competitive environment, not just locally but globally, too. It pushes them to find a window of opportunity and the basis for anyone to compete in this playing field is to have a solid base of technology.
They strive for efficiency. They like complications. They make sure that what is produced in the kiln is a competitive and quality product. This requires their preheater, calciner, alternative fuel perspective meets technical expectations of no pressure drop, complete combustion, low emission and everything else. In this window, they have to adapt their technology and are constantly doing so. Project and product cycles in the cement industry are very long. Feedback loops take a long time; however, a solid technological basis and human factor allows them to be competitive in the market and deliver a quality product.

Technological Advancements
It is all about availability and optimisation.
The keyword is big data and providing the hardware and software environment to digest the enormous amount of data that one can collect and to superimpose the algorithm to sort through the data and project a trend, which is relevant for decision makers.
It is going to be another playing field that the company is going to put more resources in.
The technology is there for the most part it is meant to be. It is required that the company finds a cost-effective solution that will help them improve efficiency and availability. It can help their customers make better decisions.
We live in a globalised world and benefit from one another. India can teach the world to focus on efficiency and the will to succeed and produce and take millions out of poverty. Where India can perhaps benefit from other parts of the world is the alternative fuel. It is a huge gate they need to walk through because it would require infrastructure and policy changes. It has no quick fix and will be addressed case by case. The Indian cement industry will develop the sourcing of the alternative fuels in a manner that is applicable to technology providers as well, so that they can bring in their ideas and approach and handle a higher substitution rate. It will depend on how you define alternative fuels, but 100 per cent of alternative fuel substitution is within the reach. We have the technology and just need better focus on the infrastructure side to achieve this.

Concrete

Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict

Crisil Sees Margins Easing Despite Steady Demand

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Crisil said operating margins of Indian cement manufacturers are expected to decline by Rs 50-75 per tonne (t) this fiscal to Rs 925-950 per t due to higher input costs triggered by the West Asia conflict. The analysis covered 18 cement companies accounting for nearly 90 per cent of India’s domestic cement capacity and noted margins had improved sharply to around Rs 1,000 per t in fiscal 2026.

Crisil noted that the reduction would be driven mainly by higher power and fuel costs, which account for about 30 per cent of total costs, as petcoke and imported coal prices have surged amid geopolitical uncertainties. Freight costs, which account for about a quarter of total costs, are also expected to remain elevated because of higher diesel prices. The impact on profitability is likely to be more pronounced in the first half of the fiscal year before easing commodity prices moderate cost pressures later.

The rating agency said steady domestic demand and strong balance sheets should keep credit profiles stable despite the moderation in margins. Green energy currently accounts for 35-40 per cent of the sector’s total electricity consumption and is expected to partly cushion higher energy costs. Operating cash flows are likely to remain resilient, supported by projected 6-7 per cent growth in cement demand this fiscal.

Crisil highlighted that demand growth will be driven primarily by infrastructure spending, which meets about one-third of sector consumption, and by a nearly 18 per cent higher budgetary allocation for core ministries that should support project execution. Weaker rural housing demand amid pressure on agricultural incomes from a possible below-average monsoon may be offset by improved urban housing demand supported by favourable home-loan rates and a strong pipeline of Pradhan Mantri Awas Yojana-Urban projects. Ongoing capacity additions will keep capital expenditure elevated and may lift net debt to EBITDA to between 1.2 and 1.4 times from around 1.0 time last fiscal, though ratios are expected to remain healthy.

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Concrete

UltraTech Board Approves Rs 50 bn Fundraise Via NCDs

Company to issue half a million debentures for expansion plan

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UltraTech Cement’s board of directors has approved raising Rs 5,000 crore (Rs 50 bn) through non?convertible debentures issued in rupees.

The finance committee cleared a proposal to issue up to 500,000 fully paid, unsecured, listed, rated, redeemable, rupee?denominated, non?convertible, non?cumulative debentures of Rs 1 lakh each (Rs 0.1 mn each), aggregating to the Rs 5,000 crore programme.

As of June 2026 the firm reported net debt of Rs 15,875 crore (Rs 158.75 bn) and said its capacity expansion projects under execution are backed by capital expenditure of about Rs 17,000 crore (Rs 170 bn) over the next two to two?and?a?half years.

UltraTech spent Rs 9,500 crore (Rs 95 bn) on capital expenditure in financial year 2026 and in April the group crossed 200.1 mn tonnes per annum of domestic grey cement capacity and 205.5 mn tonnes per annum of global capacity.

The chief financial officer indicated the company would take consolidated capacity beyond 242 mn tonnes per annum, with grey cement capacity reaching 212.7 mn tonnes per annum by the end of financial year 2027. He noted the net debt?to?earnings before interest, taxes, depreciation and amortisation ratio stood at 0.87 times as of June 2026 and the company was confident of ending financial year 2027 with the ratio below one time.

In the first quarter of financial year 2026?27 UltraTech’s net profit attributable to owners rose 16.8 per cent year?on?year to Rs 2,599.3 crore (Rs 25.993 bn) and revenue from operations increased 15.9 per cent to Rs 24,648.20 crore (Rs 246.482 bn). The board approval is expected to complement internal cash flows as the company advances its expansion programme.

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Concrete

Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa

Line-2 expansion to make Kadapa a major cement hub

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Andhra Pradesh Education and IT Minister Nara Lokesh on Wednesday laid the foundation stone for the Line-2 expansion of Dalmia Bharat Cement at Chinnakomerla village in Mylavaram Mandal in Kadapa district. The project carries an investment of Rs 31 billion (bn) and is slated for completion by the third quarter of the financial year 2028. The expansion is intended to boost industrial growth and employment generation across the Rayalaseema region.

Once commissioned, the Kadapa facility will become Dalmia Bharat’s largest integrated cement manufacturing ecosystem in southern India, creating over 1,000 direct and indirect jobs and opening new business avenues for regional micro, small and medium enterprises and transport operators. Lokesh said the expansion signalled growing corporate confidence in the state and reflected the practical ease of doing business that secured repeat investment.

He placed the project within the government’s wider economic targets and recalled the Yuvagalam padayatra commitment to generate two million (mn) jobs within five years, noting that the state would cultivate talent while industry created opportunities. Lokesh highlighted Andhra Pradesh’s competitive pursuit of major manufacturing accounts, mentioning past successes and a personal initiative to engage global investors when persuading them to anchor expansion in the state.

The plant will leverage Kadapa’s abundant limestone reserves to scale production and sustainability. Clinker capacity is planned to rise from two point five million tonnes per annum (mn tpa) to six point one mn tpa, while overall cement output will increase from three point six mn tpa to nine point six mn tpa. The unit is designed to operate on over eighty per cent renewable energy and deploy waste heat recovery, zero liquid discharge, water recycling and advanced AI systems to optimise efficiency. Industries Minister TG Bharat, BC Welfare Minister S. Savitha and Jammalamadugu MLA C. Adinarayana Reddy attended the ceremony.

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