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Concrete

Increasing Use of Supplementary Cementitious Materials

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Jens Mose and John Terembula, Product Line Management, FLSmidth A/S, explore how cement manufacturers can utilise VRMs to reduce the clinker factor and meet their environmental targets, in the final part of this three-part series. You can find parts one and two in the August and September issues of Indian Cement Review.

OPTIMISING PARTICLE SIZE DISTRIBUTION
Experience has shown that practically every type of cement around the world can be – and is already being – produced in an OK MillTM.
While the particle size distribution (PSD) of the product is normally steeper in a VRM cement mill compared to a traditional ball mill, this can, to some extent, be modified by working with various parameters such as grinding pressure and dam ring height. The air flow and the separator speed are also used to customise the PSD curve to customer specific requirements.
However, as interest in greater utilisation of SCMs increases, cement manufacturers are keen to grind to an even steeper PSD curve to allow for the possibility of mixing more SCMs into the finished product.

THE ADVANTAGES OF VRMS FOR SCMS
When the VRM is designed specifically for grinding cement and cementitious materials, cement manufacturers experience better:

  • Efficiency: Lowest power consumption compared to other vertical roller mills on the market.
  • Reliability: The run factor is very high, > 95 per cent
  • Versatility: Rapid change between different feed compositions and the ability to grind a wide range of materials to very high Blaine or the lowest residues

The OK MillTM was designed with these priorities in mind, and has retained its original shape with a dual lobed roller surface and central grooved and bowl-shaped table design. As the only VRM in the market specifically designed for cement grinding, all rollers are active with each performing material bed compaction and de-aeration, and high-pressure grinding.
Sustainability is also a priority, which is why the mill is designed to require minimal water injection on the mill table, using an average 50 per cent less water than competing mill designs.


Maintenance is also a sustainability issue. Better to repair a part than replace it; better to be proactive than reactive. Predictive maintenance services aim to enable a higher level of proactivity, preventing unexpected downtime and reducing the cost of maintenance.
Over the last 20 years, in-situ rewelding or hard facing has become the standard maintenance practice for VRM, particularly for OK MillsTM with segmented wear liners that can tolerate repeated welding. Roller liner segments can be rewelded as many as 10 times or more and table segments 15 times or more. In order to improve its service capability for VRMs, FLSmidth works with welding services providers across the globe. We have also developed ceramic wear segments in an OK MillTM, which not only perform better but can also be recycled.

DIGITAL TOOLS FOR GREATER FLEXIBILITY
Digitalisation makes it easier to use SCMs and will enable further reductions in the clinker factor. The following are just a snapshot of the tools currently available; more are in development all the time:

  • Process control solutions give operators greater control over their mill operating parameters to optimise performance and ensure maximum efficiency.
  • Sensors continually monitor mill operation, enabling you to see any drop in stability as it happens and react swiftly.
  • Automated laboratories enable optimum quality control throughout the process.
  • Condition monitoring services and remote service support give you 24/7 access to expert assistance.

CONCLUSION
As the cement industry works to reduce its carbon footprint, investments have to be made in future-proof technologies capable of adapting to changing cement mixes and regulatory requirements. In the grinding process, cement manufacturers need a flexible, efficient system that is operated and maintained in an optimal manner. With the latest VRM technologies, advanced digital offerings and condition monitoring services, FLSmidth believes the industry is ready to achieve more widespread use of SCMs and achieve its carbon reduction goals.

Concrete

ESL Steel Switches To PNG In Pact With IOCL

Bokaro Plant To Shift From LPG To Cleaner Natural Gas

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ESL Steel Ltd has entered into an agreement with Indian Oil Corporation Limited (IOCL) for the supply of Piped Natural Gas (PNG) to its steel plant in Bokaro, marking a significant move towards cleaner industrial energy. The agreement was formalised in the presence of senior leaders from both organisations, including IOCL Executive Director Manoj K. Sharma, General Manager Amiya Kumar Behera, ESL Steel Deputy CEO and WTD Ravish Sharma, and CFO Anand Dubey.

Welcoming the collaboration, Ravish Sharma said the transition from LPG to PNG represents a major step towards operational efficiency and sustainability. “By adopting PNG—a cleaner and more dependable fuel—we are strengthening our commitment to reliable operations and environmental stewardship,” he noted.

Under the agreement, PNG will replace LPG in selected operational processes at the Bokaro plant, providing a cleaner, safer and more reliable energy source. The partnership also reinforces broader cooperation between IOCL and ESL Steel on sustainable fuel solutions.

The initiative forms part of ESL Steel’s wider strategy to improve energy security, reduce emissions and enhance overall operational performance.

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Concrete

EU Carbon Tax Set To Hit India’s Steel Exports

Mills Shift Focus To Middle East And Africa As EU Costs Rise

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India’s steel exports to Europe are expected to decline once the European Union’s carbon tax comes into force next month, prompting domestic producers to look for alternative buyers in Africa and the Middle East, according to industry executives and analysts. From 1 January, steel imported into the European Economic Area will be subject to a levy under the EU’s Carbon Border Adjustment Mechanism (CBAM), which also covers cement, electricity, fertilisers and other emissions-intensive products.

India, the world’s second-largest crude steel producer after China, currently directs around two-thirds of its steel exports to Europe. Experts say the new regime will force Indian mills to accelerate emissions reduction. Former steel secretary Aruna Sharma said companies recognise the need for environmentally responsible production but are simultaneously scouting for new export markets.

Most Indian steel is produced using blast furnaces, which generate significantly higher emissions than electric arc furnaces. The Ministry of Steel’s top civil servant, Sandeep Poundrik, noted earlier that further blast furnace expansion is a concern. Global Energy Monitor estimates that upcoming capacity additions could increase sectoral emissions by roughly 680 million metric tonnes of carbon-dioxide equivalent.

Steady domestic demand—backed by infrastructure spending—has spurred Indian steelmakers to expand capacity. However, the new EU levy is expected to weigh on export volumes in the near term. “Most companies are still figuring out how to deal with CBAM,” said Ravi Sodah, analyst at Elara Capital. “It is expected to slow down India’s exports to the EU.”

Two senior executives at major steel firms said they had little clarity on how the tax would be calculated. One noted that with about 60 per cent of their exports heading to Europe, clarity on whether the tax would be uniform or company-specific was crucial.

According to CreditSights’ Lakshmanan R, the levy will increase the cost of Indian steel exports to Europe—particularly those produced via blast furnaces—compressing margins and eroding market share unless emissions fall. In response, producers are seeking to diversify their customer base, with mills targeting the Middle East through quick delivery commitments and flexible payment terms, said CRU Group principal analyst Shankhadeep Mukherjee.

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Concrete

JFE To Invest Rs 157.5bn In JV With JSW Steel

Deal Includes Transfer Of BPSL Steel Unit In Odisha

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JFE Steel Corporation of Japan will invest Rs 157.5 billion to form a joint venture with JSW Steel, according to a regulatory filing. The partnership will include the integrated steel plant of Bhushan Power & Steel Ltd (BPSL), a JSW Steel subsidiary, located in Odisha.

In its BSE filing, JSW Steel confirmed it has entered into a strategic 50:50 joint venture with JFE Steel. The steel business undertaking of BPSL will be transferred to the joint venture through a slump sale, with a cash consideration of Rs 244.83 billion. JFE will invest Rs 157.5 billion in two phases to acquire its half stake.

JSW Steel acquired BPSL in 2021 under the Insolvency and Bankruptcy Code process, transforming it from a distressed 2.75 million tonnes per annum unit into a profitable 4.5 million tonnes per annum operation. The plant currently employs around 25,000 people.

The transaction will enable JSW to monetise part of its holding in BPSL, supporting its broader growth strategy. The company said the partnership will combine JFE’s advanced technological capabilities with JSW Steel’s execution strength, enhancing value creation within the joint venture.

Jayant Acharya, Joint Managing Director and CEO of JSW Steel Ltd, said the collaboration brings together JSW’s expertise in India and JFE’s technological strengths, enabling the venture to scale and produce a wider range of value-added steels. JFE Steel’s President and CEO, Masayuki Hirose, added that the joint operation of an integrated steel plant in India will contribute to the growth of both companies and support the development of India’s steel industry.

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