Concrete

Increasing Use of Supplementary Cementitious Materials to Achieve Carbon Reduction Targets

Published

3 years ago

October 19, 2023

admin

Jens Mose and John Terembula, Product Line Management, FLSmidth A/S, discuss why Vertical Roller Mills (VRM) are the best grinding solution for SCMs, in this second part of a three-part series looking at how Supplementary Cementitious Materials (SCM) can help cement manufacturers reduce carbon emissions.

Current examples of SCM adoption
India is a successful adopter of SCMs, with an average clinker factor of 0.71 in 2017. This is largely thanks to the introduction of standards for composite cements in 2015, as well as the widespread availability of fly ash from thermal power plants. Portland Pozzolanic Cement (PPC) had approximately 65 per cent market share in 2017, and the clinker factor of PPC was also improved from 0.68 in 2010 to 0.65 in 2017. Portland Slag Cement (PSC) makes up about 10 per cent of the market and also reduced clinker content in that time from 0.55 to 0.40. Meanwhile, ACC has achieved a clinker factor as low as 44 per cent through the use of fly ash from power plants and slag from steel production.
In the sub-continental India region, FLSmidth has supplied grinding systems with all types of mills. The most common grinding systems installed over the last 10 years are VRM or HRP with ball mill in semi-finish arrangement. One example is the Guinness World Record holder, the largest VRM for cement grinding at Shah Cement in Bangladesh. That mill regularly produces both PPC and PSC Cements.
Throughout Asia, a wide range of blended cements are made encompassing many different additive materials including trass, which is very hard-to-grind overburden from the quarry. Stable/reliable operation has been proven in the OK Mill even with this difficult material.
In other parts of the world, the uptake of SCMs varies. For example, in Brazil the nationwide average clinker-to-cement ratio is below 70 per cent , with blast furnace slag from steel mills the most widely used SCM . The country is targeting reductions in clinker content to 59 per cent in 2030 and 52 per cent in 2050 and will need to increase the use of limestone filler and calcined clays to meet these targets.
In Brazil, the VRM has been the standard for new cement grinding for the last 10+ years, with OK Mills accounting for 28 per cent of the country’s total cement production in 2015.
Meanwhile, in the US, the use of SCMs by cement manufacturers is on the rise , as more cement plants adopt ASTM C595 Standard (American Society for Testing and Materials), which allows up to 15 per cent limestone within Type 1L or Portland Limestone Cement (PLC). PLC is currently seeing a dramatic upward trend, thanks to widespread acceptance by end users like the Department of Transportation and the Federal Aviation Administration.

Which mills are best for SCMs?
The grinding operation is critical to the success of SCMs, to achieve the necessary particle size distribution. Some materials can be ground together with the rest of your cement mix (so-called ‘intergrinding’), while others may benefit from a separate grinding operation. Likewise, water demand (to increase workability) can present another sustainability concern.
In terms of the best mill type, the answer is almost always VRM. Over the last few decades, the industry has been gradually moving towards the use of VRM for both raw and cement grinding, due largely to the reduced energy consumption compared to ball mills: a saving of between 30 and 50 per cent. This transition will prove crucial as the adoption of SCMs increases, from a practical as well as economic and environmental perspective. VRM provides much greater flexibility to grind several different materials, to switch between different cement mixes, and to adjust to changing material characteristics – all while protecting quality.
For example, FLSmidth has a customer using the OK Mill to grind 100 per cent slag with raw feed containing more than 20 per cent moisture to produce moisture levels less than 1 per cent. This is only possible thanks to the drying capacity of the VRM. This level of flexibility is imperative to SCM adoption.
Ultimately, product quality is defined by cement strength development and setting times. To achieve the best result, you need optimal particle size distribution and dehydration of the gypsum within the cement. And for that, the precise operational controls of the VRM are a clear advantage over other mill types, enabling you to optimise the system’s temperature profile, mill airflow, separator speed and grinding pressure for optimum efficiency and productivity.

1- https://docs.wbcsd.org/2018/11/WBCSD_CSI_India_Review.pdf
2- Weston, J. ‘Brazil gives OK to VRM’, International Cement Review, 20 June 2016
3-https://www.mckinsey.com/~/media/mckinsey/dotcom/client_service/infrastructure/pdfs/pathways_low_carbon_economy_brazil.ashx
4- http://snic.org.br/assets/pdf/roadmap/roadmap-tecnologico-do-cimento-brasil.pdf
5- https://pubs.usgs.gov/of/2005/1152/2005-1152.pdf p.10

You can find part one in the August issue of Indian Cement Review and part 3 in the upcoming October issue.

(Communication by the management of the company)

Up Next

Enhancing Efficiency in the Cement Industry

Don't Miss

Gaztron : Transforming the Cement Industry’s Safety Standards with Unparalleled Innovation

Concrete

JSW Cement Commissions 1 MTPA Unit in Rajasthan

Rajasthan grinding capacity rises to 3.50 MTPA after commissioning

Published

2 days ago

October 9, 2026

admin

JSW Cement has commissioned an additional 1 MTPA cement grinding unit in Nagaur, Rajasthan, taking the company’s total cement grinding capacity to 25.1 MTPA. The commissioning was announced on Tuesday, October 6.

The company said the new unit had increased the total cement grinding capacity at its Rajasthan plant to 3.50 MTPA. The expansion adds to JSW Cement’s production infrastructure as it continues to build capacity across its operating network.

The company’s total clinker manufacturing capacity, including capacity at its joint venture JSW Cement FZC, stands at 9.74 MTPA. Clinker is an intermediate material used in cement production, and its availability supports the company’s grinding operations.

JSW Cement is also pursuing a proposed merger of its listed subsidiary Shiva Cement with the company. The scheme, approved by the boards of the respective companies, involves issuing five fully paid-up JSW Cement equity shares for every 41 shares held by Shiva Cement shareholders other than JSW Cement.

The arrangement remains subject to shareholder and regulatory approvals. JSW Cement currently holds 66.23 per cent of Shiva Cement’s paid-up equity share capital, and the shares held by JSW Cement in the subsidiary will be cancelled under the proposal without any issue of JSW Cement shares against that holding.

The scheme has an appointed date of April 1, 2026, and the company has indicated that completion could take 12 to 14 months, depending on the receipt of approvals. These include clearances from stock exchanges, the Securities and Exchange Board of India, the National Company Law Tribunal and other applicable authorities, along with approvals from shareholders and creditors where required. JSW Cement shares closed at Rs. 113.15 on the BSE, up Rs. 2.05, or 1.85 per cent.

Concrete

Wonder Cement appoints Mahesh Singh as VP Corporate Brand Communication

Published

2 days ago

October 9, 2026

admin

Singh brings 20+ years of brand and marketing experience, and will lead integrated corporate brand communication initiatives at Wonder Cement

New Delhi

Wonder Cement, a leading cement manufacturer, has appointed Mahesh Singh as Vice President – Corporate Brand Communication. In his new role, he will oversee corporate brand strategy and communication, including digital and performance marketing, public relations, trade, events, exhibitions, sports and experiential marketing.

Singh brings over two decades of experience across marketing and communications, with roles spanning the automotive industry, agencies and entrepreneurship. He spent more than a decade with Honda Motorcycle & Scooter India, working across integrated communication, media, digital, retail and consumer engagement. His stint also included helping build the company’s digital marketing capabilities.

He moved to dentsu X India as Vice President – Strategy & Planning, working across categories such as automotive, auto components, electric vehicles, FMCG, consumer electronics, BFSI, apparel and brand consulting. His responsibilities included media and marketing strategy, product launches, content, performance marketing and consumer activations.

Singh subsequently took an entrepreneurial route with Radiant Brands before joining Shriram Ltd (SPR Autotech) as Head – Marketing & Communications. There, his remit included brand and corporate strategy, communications, PR and ORM, retail identity, loyalty programmes and events.

At Wonder Cement, Singh will be responsible for bringing together the company’s corporate brand communication initiatives across digital, performance marketing, PR, trade, sports and experiential platforms. The role will focus on creating an integrated approach to communication across consumers, trade partners and other key stakeholders.

The appointment brings to Wonder Cement a marketer whose career has spanned the brand, agency and entrepreneurial sides of the communications ecosystem.

Wonder Cement, part of the RK Group, is a cement manufacturer with roots in Rajasthan and a focus on quality, trust and transparency. The company has grown to six manufacturing plants, and a cement capacity of 21.5 MTPA. With more than 2,000 employees and a network of over 5,000 dealers, its operations span manufacturing, distribution and customer engagement, with a focus on consistent product quality and efficient execution.

Concrete

JSW Cement commissions additional 1 MTPA grinding unit in Rajasthan

The Nagaur expansion takes JSW Cement’s total grinding capacity to 25.10 MTPA.

Published

3 days ago

October 8, 2026

admin

JSW Cement has commissioned an additional 1 million tonne per annum (MTPA) cement grinding unit at its Nagaur Integrated Plant in Rajasthan. The commissioning takes the company’s total cement grinding capacity to 25.10 MTPA.

JSW Cement’s total clinker manufacturing capacity, including its joint venture JSW Cement FZC, now stands at 9.74 MTPA.

The company began operations in North India in March 2026 with the Nagaur Integrated Plant, comprising a 3.30 MTPA clinkerisation unit and a 2.50 MTPA cement grinding unit. With the latest expansion, the plant’s total grinding capacity has increased to 3.50 MTPA.

The additional capacity will cater to cement demand across Rajasthan, Haryana, Punjab and the National Capital Region (NCR). The expansion has been funded through a combination of equity and long-term debt.

During the quarter ended September 30, 2026, JSW Cement also commissioned an Alternate Fuel Handling System and a Waste Heat Recovery System (WHRS) at the Nagaur plant.

Nilesh Narwekar, CEO, JSW Cement, said the additional grinding capacity was a strategic priority for the company’s expansion in North India. He added that the Alternate Fuel Handling System and WHRS were expected to reduce production costs.