Concrete

Handling Clinker Efficiently

Published

3 years ago

April 10, 2023

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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.

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Shree Cement Posts Strong Q4 as Volumes Rise

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Published

5 hours ago

May 11, 2026

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Shree Cement reported results for the quarter and year ended 31 March 2026, with consolidated net revenue of Rs61,010 million (mn) and consolidated EBITDA of Rs13,840 mn. Standalone net revenue was Rs56,430 mn and profit after tax stood at Rs5,320 mn, improving from the prior year. Cash profit and operating metrics strengthened quarter on quarter. The board recommended a final dividend of Rs70 per share, taking total payout for the year to Rs150 per share.

Total domestic cement sales rose 11 per cent year on year from nine point five two mn tonnes (t) to 10.56 mn t, with quarter on quarter gains of about 24.5 per cent. Sales of premium products increased to 22 per cent of trade volume from 16 per cent in the prior quarter, supporting margin expansion.

The ready mixed concrete operations totalled 26 plants at year end and 10 new commercial plants inaugurated in March are under commissioning, which will raise the count to 36. The company commissioned an integrated project of three point six five mn t clinker and three point five mn t cement capacity in Karnataka, taking installed cement production capacity in India to 69.3 mn t.

Sustainability metrics included 61 per cent green electricity share in the quarter and green power generation capacity of 666.5 megawatt (MW). Manufacturing sites maintained zero liquid discharge and a water positivity index greater than eight times. Management said energy efficiency and digitalisation measures were helping to mitigate cost pressures from the West Asia conflict.

Management expressed confidence in medium term demand backed by infrastructure spending and Union Budget measures, while noting short term risks from geopolitics and monsoon forecasts. The company has incorporated a wholly owned subsidiary for overseas operations and is pursuing multiple expansion opportunities to accelerate capacity build up.

Concrete

Shree Digvijay Cement Reports Annual And Quarterly Results

Annual revenue rises as EBITDA expands sequentially

Published

6 days ago

May 5, 2026

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Shree Digvijay Cement Company Limited reported consolidated financial results for the quarter and year ended 31 March 2026, showing higher revenues and improved profitability. Revenue from operations for the quarter was Rs 2,084.7 mn, up from Rs 1,833.4 mn in the prior quarter, while revenue for the year was Rs 7,491.0 mn versus Rs 7,251.5 mn a year earlier. EBITDA for the quarter rose to Rs 251.0 mn from Rs 38.4 mn in the preceding quarter and reached Rs 746.1 mn for the year. Profit after tax for the year was Rs 250.0 mn.

Sales volume for the company s grinding and cement operations was zero point three six four mn t in the quarter and one point four zero three mn t for the year, while traded volumes were zero point zero three mn t in the quarter. EBITDA per tonne improved to Rs637 in the quarter and averaged Rs521 for the year. Under a brand usage, supply and distributorship agreement the company sold 29,928 t of Hi Bond cement, which generated Rs153.6 mn in revenue and Rs20.0 mn in EBITDA during the period.

The company said that it had commenced purchase and distribution of Hi Bond cement effective 19 March 2026 pursuant to the long term distributorship agreement, and that it had paid a refundable security deposit of Rs four bn under the same arrangement. Management indicated that the strategic integration with the Hi Bond network would support future growth and strengthen distribution capabilities. The board cited seasonally higher demand and improved pricing as factors behind the sequential improvement in realisations.

The board recommended a final dividend of Rs one per equity share subject to shareholder approval at the ensuing annual general meeting. The company reiterated focus on sustaining the positive momentum in revenue and margin metrics while integrating the new distributorship, and will continue to monitor market conditions and pricing trends to support further improvement in outcomes.

Concrete

Cement Production Up Eight Point Six Per Cent To 491.4 mn t In FY26

Icra Sees Seven To Eight Per Cent Growth In FY27

Published

1 week ago

May 4, 2026

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Icra reported that cement production volumes rose by eight point six per cent in the financial year 2026 to 491.4 million (mn) metric tonne (t). March output was 48.4 mn t, up four per cent year on year on a high base.

The agency projected that volumes are expected to grow by seven to eight per cent in the current financial year, supported by sustained demand from the housing and infrastructure sectors. Average cement prices were reported to have remained flat in March at Rs 340 per bag on a month on month basis, while prices for FY26 increased by two per cent to Rs 345 per bag year on year.

Among inputs, coal prices declined by 17 per cent year on year to USD 102 per t in April 2026 while petcoke prices rose sharply by 19 per cent month on month and 22 per cent year on year to around Rs 15,800 per t in April. Petcoke was higher by about five per cent year on year in FY26 and diesel prices were reported to have remained steady. Icra noted that coal, petcoke and diesel are expected to trend higher in FY27 and remain exposed to risks from the ongoing West Asia conflict.

The report emphasised that operating margins for Icra’s sample set of companies are estimated to moderate by 200 to 400 basis points (bps) in FY27 on account of a likely increase in input costs, with further downside risks should crude prices rise owing to geopolitical tensions. However, debt protection metrics are projected to remain comfortable and Icra maintained a stable outlook on the Indian cement sector.