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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Nuvoco Vistas, CleanMax Partner for Wind-Solar Hybrid Project in Rajasthan

Published

4 hours ago

September 29, 2026

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The project – comprising 20 MW of wind and 26.4 MWdc of solar capacity – will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy.

Mumbai, September 29, 2026

Nuvoco Vistas Corp Ltd, part of Nirma Group and one of India’s leading cement companies, has partnered with Clean Max Enviro Energy Solutions Limited (CleanMax), a renewable energy solutions provider for the commercial and industrial (C&I) sector, to develop a 46.4 MW wind-solar hybrid renewable energy project in Rajasthan.

The project will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy. It is expected to increase the share of renewable energy in Nuvoco’s power mix, reducing fossil fuel consumption and associated emissions.

Developed by CleanMax, an Independent Power Producer (IPP), at Bhikamkhore, Rajasthan, the project will comprise 20 MW of wind capacity and 26.4 MWdc of solar capacity, along with a 2-MWh Battery Energy Storage System (BESS). Power generated from the facility will be supplied to Nuvoco through the State Transmission Utility (STU) Open Access network.

The hybrid project is expected to generate approximately 100 million units (MU) of renewable electricity annually and help avoid around 1,25,485 tonnes of CO₂ emissions every year across Scope 1 and Scope 2 emissions.

The initiative supports Nuvoco’s ongoing efforts to reduce the carbon intensity of its manufacturing operations through renewable energy adoption, Waste Heat Recovery Systems (WHRS), energy-efficiency measures and increased use of alternative fuels. It also aligns with the company’s DIRE (Digitalisation, Innovation and Renewables) agenda, which focuses on climate action, renewable energy transition, water stewardship, circularity and biodiversity conservation across its manufacturing ecosystem.

Commenting on the initiative, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said, “This marks an important step in advancing Nuvoco’s journey towards more sustainable and resilient operations. Our collaboration with CleanMax will increase the share of renewable energy across our Rajasthan operations, strengthening our energy mix while improving long-term cost efficiency and reducing our dependence on conventional power sources. Initiatives such as these reinforce our commitment to operational excellence and responsible growth, while supporting our vision of Building a Safer, Smarter and Sustainable World.”

Kuldeep Jain, Founder and Managing Director, CleanMax, said, “Cement plants run continuously, so the power behind them has to be dependable for decades, not years. We’re seeing manufacturing industries view clean energy as an integral part of their core operations and long-term strategy. Our partnership with Nuvoco reflects that shift, and we’re pleased to support its decarbonisation journey. This wind-solar hybrid project is designed to deliver long-term cost certainty while supporting the Company’s transition to cleaner power.”

Nuvoco has been advancing its sustainability initiatives through renewable energy, operational efficiency and technology-driven solutions. The company operates across Cement, Ready-Mix Concrete (RMX) and Modern Building Materials (MBM) segments, with a presence across East, North and West India.

The company began operations in 2014 with a greenfield cement plant in Nimbol, Rajasthan, and later acquired Lafarge India Limited, which entered India in 1999, along with Emami Cement Ltd in 2020 and Vadraj Cement Limited in April 2025. With planned expansion initiatives, including a new grinding mill at the Arasmeta Cement Plant and multiple debottlenecking projects, Nuvoco aims to achieve a cement capacity of 35 MMTPA.

The company reported total income of Rs 113.62 billion in FY 2025-26, reflecting its continued growth trajectory. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem brands, while its RMX business offers products under Concreto, Artiste, InstaMix, X-Con and Ecodure brands. Nuvoco also provides construction solutions under its Zero M range of modern building materials.

Concrete

UltraTech Unit Runs Entirely on Green Energy

Kukurdih Cement Works meets its full electricity needs through green energy.

Published

5 hours ago

September 29, 2026

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UltraTech Cement has achieved a decarbonisation milestone, with its integrated Kukurdih Cement Works in Chhattisgarh meeting 100 per cent of its electricity requirement through green energy every month since April 2026.

Commissioned in 2024, the plant has an installed grey cement capacity of 3.3 million tonnes per annum. It meets its entire electricity requirement through a combination of renewable power sourcing and Waste Heat Recovery Systems (WHRS), while maintaining operational reliability.

Since April 2026, nearly a third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements. Five units, including Kukurdih Cement Works, have exceeded 95 per cent green energy utilisation.

UltraTech is also progressively deploying Battery Energy Storage Systems (BESS) across its manufacturing network to enable deeper integration of renewable energy. The company has not invested in new captive thermal power capacity for greenfield projects or brownfield expansions at its integrated units for more than a decade.

As of Q1FY27, UltraTech’s captive green energy capacity stood at 1,897 MW, comprising 1,463 MW of renewable capacity across solar, wind and hybrid sources, and 434 MW of WHRS capacity.

Under its RE100 commitment, UltraTech aims to increase green power’s share in its total power mix to 85 per cent by 2030 and 100 per cent by 2050.

Concrete

UltraTech Cement achieves 100% green energy milestone at Chhattisgarh plant

Published

5 hours ago

September 29, 2026

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UltraTech Cement’s Kukurdih Works becomes its first integrated unit to meet 100 per cent electricity needs through green energy every month.

Raipur (Chhattisgarh)

UltraTech Cement Limited, the world’s largest cement company outside China, has achieved a significant decarbonisation milestone, with its Kukurdih Cement Works integrated unit in Chhattisgarh meeting 100 per cent of its electricity requirement through green energy every month since April 2026.

Commissioned in 2024, Kukurdih Cement Works has an installed grey cement capacity of 3.3 million tonnes per annum. The unit achieved this milestone through a combination of renewable power sourcing and Waste Heat Recovery Systems (WHRS), which now collectively meet its entire electricity demand while ensuring operational reliability.

Since April 2026, nearly one-third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements. Five units, including Kukurdih, have exceeded 95 per cent green energy utilisation. The company is also progressively deploying Battery Energy Storage Systems (BESS) across its network to enable deeper renewable energy integration.

As part of its decarbonisation strategy, UltraTech has not invested in additional captive thermal power capacity for greenfield projects or brownfield expansions at its integrated units for over a decade.

As of Q1FY27, the company’s captive green energy capacity stood at 1,897 MW, comprising 1,463 MW of renewable energy capacity from solar, wind and hybrid sources, along with 434 MW of WHRS capacity. Under its RE100 commitment, UltraTech aims to increase the share of green power in its total energy mix to 85 per cent by 2030 and achieve 100 per cent by 2050.

UltraTech Cement Ltd, the cement flagship company of the Aditya Birla Group, is a $10-billion building solutions company and the largest cement producer globally by sales volume outside China. The company has a total grey cement capacity of 210.1 MTPA and white cement/putty capacity of 3.5 MTPA. It is a signatory to the GCCA Climate Ambition 2050 and has committed to the Net Zero Concrete roadmap announced by GCCA.