Concrete
Dust can adversely affect living organisms
Published
2 years agoon
By
admin
Pankaj Kejriwal, Whole Time Director and COO, Star Cement, shares how dust pollution is a severe problem and the efforts that are required to keep dust emissions in check.
What are the key areas where dust emission is prominent in cement manufacturing?
In the cement industry, dust is emitted from mining, transportation and many processes such as crushing of limestone, clinker production and storage, cement grinding and packing and power utilities (the coal mill and the power generators).
What are the measures taken to control the dust emissions at the cement plant?
Cement industry is one of the few industries where the dust generated is a value-added raw material and hence all cement manufacturers try to arrest the dust as it has its own pay back.
Generation of dust is being reduced by modification of transfer points, installation of efficient separators, modern cyclones, etc. Dust generation during mining and transportation is being reduced by effective water / mist / fog spraying. Modern mining equipment is deployed with dedicated dust separation systems. Electric/hydraulic equipped mining machinery is also being used to minimise the dust.
The cement industry has been modernised by introducing specific dedusting equipment used in the production, transport and storage processes. The installation is equipped with specific filters (bag filters or electrostatic filters). This has reduced the flue gas emission and amount of dust released into the atmosphere. The main dedusting machine is the state-of-the-art bag filter, which is available and guarantees a maximum emission of 10 mg/Nm3.
Truck mounted road/area sweeping machines are also operated to clean the dusty area. High pressure water spray systems are used to clean the tyres of vehicles moving inside the plant to minimise the fugitive dust emission.
Tell us about the regulations and compliance issued by the government for emission of dust particles in a cement plant.
In India, regulatory bodies like the Ministry of Environment, Forest and Climate Change, the Central Pollution Control Board (CPCB) and the respective State Pollution Control Boards (SPCB) deal with environmental issues. SPCB regularly inspects the cement plants/limestone quarries to verify compliance with emission norms. CPCB also inspects the cement plants to check compliance with emission standards under environmental surveillance squad activities. Cement plants also have to comply with the charter on Corporate Responsibility for Environment Protection (CREP).
The Indian cement industry must comply with the various environmental acts and regulations notified by the Ministry of Environment and Forests (MoEF), etc., which covers different spheres of the environment, encompassing emissions of air pollutants, consumption of water, generation and discharge of trade effluents, utilisation and storage of hazardous waste, noise generation, utilisation of forest land and wildlife areas. For dust emissions, the following are applicable:
- Air (Prevention & Control of Pollution) Act, 1981
- Environment (Protection) Act, 1986 (EPA)
- The Factories Act, 1948
- The Mines Act, 1952. Mines Rule 1955 and the Metallic Ferrous Mines Regulation 1961
These Acts/Regulations, together with some of the stringent conditions that are relevant for environment protection from industrial pollution are imposed by the pollution control boards. The government has made norms stricter for the cement industry, capping the stack emissions of PM to not more than 30 milligrams per cubic metre from 200 milligrams per cubic metre earlier. The 24-hour safe limits for ambient PM 2.5 and PM 10 are 60 ug/m3 and 100 ug/m3 respectively.
Tell us about the role of dust collectors in cement production?
Dust collector systems (Bag Filters, Electrostatic Precipitator, etc.) control the dust and gases from various sources during process at various stages, which helps to provide the factory with cleaner air that can provide numerous benefits. A dust collection system works by sucking air in from a given application and processing it through a filtering system so that particulate matter can be deposited into a collection area. Then the cleaned air is either returned to the facility or exhausted to the environment.
Where is the collected dust discarded?
After dust-filled air has been captured by a dry dust collection system, dust must be separated, collected, and disposed of. The dust collector separates dust particles from the airstream and discharges cleaned air either into the atmosphere or back into the workplace. The collected dust goes back into the process system as it is a value added product to cement. Nearly 100 per cent collected dust is recycled.
What is the impact of dust emission on the environment in and around the cement plant?
Dust pollution is the introduction of chemicals, particulate matter or biological materials that cause harm or discomfort to humans or other living organisms or cause damage to the natural environment.
Dust can adversely affect living organisms. Increased concentration of cement dust pollutants causes invisible injuries like progressive decline in the physiological process such as photosynthetic ability and respiration rate.
Can dust emission be qualified as a health hazard at a cement plant?
The point source emissions from the cement industry include particulate matter and gaseous emissions. Since the cement industry deals with various size reduction operations from limestone crushing to clinker grinding, dust emissions are a major pollutant. Gaseous emissions such as sulphur dioxide (SO2), oxides of nitrogen (NOx), carbon monoxide (CO), carbon dioxide (CO2), etc., are generated during pyro processing. All of these are major health hazards at a cement plant, if not controlled and minimised.
How can automation and technology contribute towards reduction of dust emission?
It is necessarily required to put in place the latest technology, management systems and continuous online monitoring system that helps to routinely implement the activities that facilitate adherence to the emission norms prescribed under the pollution control legislation The real time data of online stack monitoring and Ambient Air Quality Management Systems (AAQMS) is published on the web for better monitoring and controlling.
Tell us about newer innovations that the cement industry is adapting to reduce the emission of dust and control the same.
Some of the sustainable new innovations for air pollution control methods followed by the Indian cement industry are:
- In bag filters, use of low air to cloth ratio and use of latest filter media/fabric in pleated/cartridge shaped filter bags. For bag filters, the use of membrane filter bags is a useful innovation.
- Installation of hybrid bag filter and electrostatic preceptors for more effective control of
dust emission. - Substituting clinker with fly ash/blast furnace slag/limestone, which is readily available and reduces dust emissions and fuel consumed for producing clinkers.
- Using alternative fuel resources.
- Co-processing, i.e., using waste materials as fuel by burning them in the high temperature of the kilns. This also effectively disposes of solid waste.
- Installation of Waste Heat Recovery System (WHRS), in clinker production units.
-Kanika Mathur
Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
4 days agoon
September 16, 2025By
admin
Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.
India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.
Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:
- September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
- December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
- August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
- April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
- Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
- Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
- Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
- Orient Cement: It would serve as a principal manufacturing facility following the merger.
Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:
- By FY 2026: Reach 118 MTPA
- By FY 2028: Target 140 MTPA
These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).
Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.
Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.
Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.
Challenges potentially include:
- Integration challenges across systems, corporate cultures, and plant operations
- Regulatory sanctions for pending mergers and new capacity additions
- Environmental clearances in environmentally sensitive areas and debt management with input price volatility
When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.
Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.
About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.
Concrete
Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series
Published
1 month agoon
August 16, 2025By
admin
PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.
Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.
Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.
Beyond energy efficiency, the retrofit significantly improved operational parameters:
- Lower thermal stress on equipment
- Extended lubricant drain intervals
- Reduction in CO2 emissions and operational costs
These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.
Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:
- Enhanced component protection
- Extended oil life under high loads
- Stable performance across fluctuating temperatures
By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.
Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.
A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape

CCU testbeds in Tamil Nadu

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape
