Concrete

Increasing Use of Supplementary Cementitious Materials

Published

3 years ago

October 19, 2023

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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.

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Concrete

Cement Demand Strong As Prices Remain Stable

Volumes rise amid steady trade pricing and higher fuel costs

Published

2 days ago

September 11, 2026

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Channel checks show cement demand remained healthy with volume growth estimated at six to seven per cent in July and August 2026. Trade prices were broadly stable while non-trade prices were volatile in the East, and attempted hikes were rolled back amid higher competition. Average fuel costs rose in August by five to nine per cent, lifting spot petcoke and coal prices.

All-India trade price remained flat month on month in August as increased rake supplies and competition offset early increases. Monsoon related demand softness limited sustained hikes and dealers indicated further attempts would depend on demand trends. Combined July and August volumes were estimated at six to seven per cent, supported by infrastructure spending while retail housing remained weather sensitive.

In the South, a Rs20 a bag hike in August did not hold and prices stayed flat month on month, while dealers planned Rs25 to Rs30 a bag from fifth September 2026 but with uncertain sustainability. In the East, trade prices were unchanged and non-trade prices corrected by Rs15 to Rs20 a bag amid weak construction in West Bengal, Jharkhand and Odisha.

The West remained most resilient on pricing and demand despite attempted hikes of Rs10 to Rs15 a bag, and Gujarat saw relatively better volumes in August. North and Central markets kept prices range bound as players focused on ramping up utilisation of new capacity, with schemes of up to Rs2 to Rs3 a bag used to meet month-end targets. Overall construction activity improved as the monsoon eased, aiding a pickup in several states.

Fuel cost pressures persisted, with South African coal at USD114 a t and petcoke around USD146 to USD147 a t in August, while spot imported petcoke and coal were higher. Imported coal consumption cost stood at Rs2.07 per Kcal and petcoke at USD2.11 per Kcal. Analysts estimate the all-India trade spread to decline by Rs90 to Rs100 a t quarter on quarter, weighing on near-term profitability and they prefer UltraTech Cement (UTCEM), JK Cement (JKCE) and Grasim Industries (GRASIM).

Concrete

Aditya Birla Group Launches Ultravolt Wires And Cables Business

UltraTech extends building solutions into electrical wiring

Published

4 days ago

September 9, 2026

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Aditya Birla Group has entered the wires and cables market through Ultravolt, extending UltraTech’s move from building materials into building solutions. The shift builds on UltraTech Building Solutions, a multi-category platform that already addresses customers across different stages of construction and extends beyond cement into ready-mix concrete, waterproofing, tile-fixing solutions and mortars.

The company intends to enter with scale, seeking presence across 100,000 retailers in more than 500 districts and availability through 5,000 plus UltraTech Building Solutions (UBS) outlets. The portfolio spans house wires, light-duty cables, communication cables, solar cables and low-tension and industrial cables to meet changing electrical requirements driven by solar installations, communications infrastructure and industrial automation.

An upstream advantage begins in the Group’s metals ecosystem, with conductor quality central to product performance. Ultravolt wires will use TruePure Copper, defined as 99.97 per cent pure electrolytic-grade annealed copper sourced from Hindalco, providing greater control over raw material quality and provenance and supporting electrical performance, safety and durability.

The business also targets the electrician community as a decisive influence on product choice and installation quality. The Wires and Cables Business has launched a Skill India Electrician Training Programme in partnership with the Electronics Sector Skills Council of India that aims to train and certify more than 40,000 electricians across India over the next year, focusing on safe wiring practices, correct installation and advanced wire technologies and offering Skill India-aligned certification and identification credentials.

The move combines market opportunity, UltraTech’s construction ecosystem, manufacturing capability and Group-level resources. A large Gujarat facility, advanced machinery and in-house testing and research and development underpin the product strategy, which is designed for both traditional and emerging applications. The ambition is to build a scaled national brand and become one of the top two players within five years, making the Group an integral participant in modern building infrastructure.

Concrete

Ramco Cements Mine Restoration Gets Global Biodiversity Certification

Pandalgudi mine restoration receives Advanced Certification from TGBS

Published

4 days ago

September 9, 2026

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The ecological restoration of Ramco Cements’ limestone mine at Pandalgudi in Virudhunagar district, Tamil Nadu, has received international recognition with the site being awarded Advanced Certification by The Global Biodiversity Standard (TGBS). The recognition makes Pandalgudi the first site in Peninsular India to receive the certification and places it among globally recognised biodiversity restoration projects.

TGBS, recognised by the International Union for Conservation of Nature (IUCN) and the Convention on Biological Diversity (CBD), assesses biodiversity restoration projects based on scientific evaluation and their contribution to ecosystem recovery and local communities. The certification is supported by more than 250 scientists and academics worldwide.

Spread across over 500 acres of worked-out mine areas, the restoration project includes a certified 234-acre site. Initiated in 2018 with technical support from Auroville Botanical Gardens, the project began plantation activities in 2019 and is expected to be completed by 2027. More than 430,000 native trees and shrubs belonging to 150 ecologically significant species have been planted at the site.

The restored mine, which was once a barren landscape with limited biodiversity, has recorded over 72 bird species and 53 butterfly species. The project has also captured an estimated 10,000 tonnes of carbon dioxide over the past seven years, supporting broader sustainability and carbon reduction goals.

Opened officially in 2022, the site has attracted more than 13,000 visitors through educational programmes for schools, colleges and training institutions. The restoration initiative has also contributed to the development of the Rajapalayam Masterplan and supported Tamil Nadu’s carbon neutrality ambitions.

Commenting on the achievement, Mr P. R. Venketrama Raja, Chairman, Ramco Group, said the company aims for the Pandalgudi restoration project to serve as an inspiration and blueprint for the mining industry in India. Dr David Bartholomew, CEO, The Global Biodiversity Standard, highlighted the project’s long-term commitment to biodiversity recovery and independent assessment of ecological outcomes.

The certification reinforces Ramco Cements’ focus on sustainable mining practices and ecological restoration as part of its commitment towards a carbon-neutral future.