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Concrete

Customised Solutions for Alternative Solid Fuels

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Looking at the properties of secondary fuels and other parameters in a bid to understand the correct technical solutions required for handling ASF.

WALTER Materials Handling division of ATS Group-France, is a globally renowned brand in the field of design, manufacturing machines for Alternative Solid Fuels (ASF) handling systems since 1990s. In 2005, ATS Group established a state-of-art facility in India at Chakan MIDC of Pune, registered with the name, ATS Conveyors India Pvt Ltd and this facility serves as a global manufacturing hub for the products of WALTER Materials Handling Division.
Properties of secondary fuels, conditions of materials supply, requisite precision of processing, feed position in the kiln, automation requirements as well as the specific operating conditions at cement works all these have to be considered while working out a successful technical solution for handling ASF. It is well known that the properties of the secondary fuels are never constant and are heterogeneous in nature. This requires the use of equipment that is very flexible in operation. Walter Materials Handling division of ATS with its decades of experience in design, manufacturing of ASF handling systems for cement plants has therefore developed suitable equipment specifically for safe and reliable feeding of alternative fuels such as Municipal Waste, RDF, Shredded tires, impregnated saw dust, shredded plastics etc. As a rule the alternative fuels, which are just listed above as examples, all tend to bridge when stored in hoppers or silos and, as lightweight materials, often have bulk densities as low as 0.1 t/m3 or in some cases even less.
After the multiple successfully operating installations, of ATS designed Extractors and Double Flap Valves throughout the Globe in various Cement plants, we are delighted to announce the launch of our below listed new innovative products designed dedicated for addressing very specific customised site requirements evolved in the field of ASF handling based on feedback from different clients.
Major Indian customers of ATS in Cement industry include UltraTech, Dalmia, Birla Corporation, Ambuja, ACC, JK Lakshmi, JSW and many more.

TWIN DOSEAHORSE: This is a unique solution by ATS for Extraction cum Dosing system, used for controlled Dosing of Alternate Solid Fuels in two different feeding points. Additional advantage of this system is that it can be installed in the preheater tower of a cement kiln, very close to the inlet point for excellent dosing response, which is one of the key factors required for the substitution of fossil fuel. Using this system avoids the need of Flow Diverter and Weigh Belt Feeders for dosing in two different feeding point. Side Walls Conveyor: Transfer solution to the Pre-Heater building with a Side Walls conveyor for ASF conveying in a customised route. This can be used to convey AFR material on a high inclination and even for vertical conveying. Air Floating Conveyor: Air Floating Conveyor of ATS is very useful to convey ASF material with zero spillage up to long distances using the minimum investment of time and cost for project installation as well as operation maintenance.

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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Concrete

Cement Prices to Stay Flat in Q2 FY27 as Costs Squeeze Margins

HDFC Securities warns monsoon slowdown and higher fuel costs

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HDFC Securities has said the cement industry is unlikely to register a sequential increase in prices in Q2 FY27 as monsoon-related demand moderation coincides with rising fuel and packaging costs that will squeeze margins. The brokerage observed that price gains remained modest, with increases of two to three per cent quarter-on-quarter across regions, and noted subdued offtake in May with improvement in June as a delayed monsoon supported construction activity. The brokerage added that modest pricing gains so far have been insufficient to offset the input cost escalation.

The report stated that input cost pressures intensified in Q1 FY27 owing to the West Asia conflict, which pushed up coal and pet coke prices and is expected to keep fuel costs elevated, with a likely peak in Q2 FY27. It assessed that total variable costs, including packing, could rise by around Rs 150 per t quarter-on-quarter and that lower offtake and seasonal operating deleverage could further raise operating expenditure by about Rs 50 per t quarter-on-quarter.

Overall, cement prices were estimated to remain flat in Q2 FY27 as monsoon-led demand weakness offsets limited upside in realisation, and rising fuel costs alongside seasonal deleverage were expected to compress industry margins by over Rs 100 per t quarter-on-quarter to below Rs 880 per t. The brokerage indicated that the combined impact of energy inflation and higher packing expenditure would be the principal drivers of margin contraction in the near term. HDFC Securities projected a recovery in margins in H2 FY27 should the West Asia turmoil subside and energy and packing costs cool off.

The brokerage expressed optimism on long-term demand fundamentals and said improving realisation together with an anticipated cost cool-off should support a margin rebound from H2 FY27 onward, underpinning favourable industry prospects over the medium term. Its outlook rests on monsoon normalisation and a decline in imported fuel prices in the second half of the fiscal year.

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Concrete

Dalmia Bharat Begins Rs 31 Bn Green Cement Unit in Kadapa

New Andhra Pradesh plant to add 9.6 MTPA cement capacity by FY28

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Dalmia Bharat Limited recently laid the foundation stone for its second manufacturing unit at Kadapa in Andhra Pradesh. The company will invest Rs 31 billion in developing the next-generation integrated cement manufacturing facility.
The foundation-laying ceremony was attended by Nara Lokesh, Andhra Pradesh Minister for Information Technology, Electronics and Communications, Real-Time Governance and Human Resources Development, along with Puneet Dalmia, Managing Director and Chief Executive Officer, Dalmia Bharat, senior government officials and company representatives.
Scheduled to be commissioned by the third quarter of FY28, the Kadapa unit will become Dalmia Bharat’s largest integrated manufacturing facility in southern India. It will have a clinker production capacity of 6.1 million tonnes per annum and a cement manufacturing capacity of 9.6 million tonnes per annum.
The facility is designed to produce what the company describes as one of the world’s greenest cements. It is also expected to generate approximately 1,000 direct and indirect employment opportunities while supporting local MSMEs, transporters, contractors and service providers.
Lokesh said the investment reflected Dalmia Bharat’s confidence in Andhra Pradesh and aligned with the state’s objective of promoting sustainable industrialisation, job creation and technology-led economic growth.
Puneet Dalmia said the project represented the company’s long-term vision of developing low-carbon cement manufacturing assets. He added that the facility would establish new benchmarks in operational efficiency and sustainability while supporting India’s infrastructure and environmental goals.
Dalmia Bharat will also expand its regional community development programmes in education, healthcare, skill development and welfare through its DIKSHa and Gram Parivartan initiatives.
The company currently has an installed cement manufacturing capacity of 54.7 million tonnes across 19 manufacturing units in 12 states. It is also the first cement company globally to commit to the RE100, EP100 and EV100 initiatives.

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