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Strategic Capacity Enhancement

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Amarkant Pandey, Deputy General Manager (Process), Prism Johnson (Cement Division), Satna, presents a case study on capacity enhancement of clinker production in an existing kiln.

This case study outlines the strategic initiatives taken to enhance production capacity of Prism Johnson (Unit-2) from 8000 TPD to 9100 TPD. This would help the company to expand its market share, develop new products and fortify our position in the cement industry.
With a consistent increase in regional demand and a positive market outlook, it was imperative for Prism Johnson’s Unit-2 to augment its production capacity from 8000 TPD to 9100 TPD in FY 2020-21. This enhancement aligned with our commitment to provide high-quality cement products while maintaining operational efficiency.

Cement capacity and production
The production capacity of Prism Johnson’s Unit-2 in FY-21 was at 8000 TPD. The plant was operating close to full capacity, with production data indicating steady growth trajectory, and it was evident that the current capacity was reaching its limits, thereby necessitating the need for expansion.
New capacity: The project entailed increasing the production capacity from 8000 TPD to 9100 TPD, thereby accommodating the rising market demand.
Timeline: The project was anticipated to span across 60 days.
Technology and process improvements: To optimise efficiency, the capacity enhancement project incorporates state-of-the-art technologies and process improvements. These advancements aim to reduce energy consumption, enhance product quality and ensure sustainable production practices.
The following technical upgradations has been implemented in order to support the upgraded production:

  1. 1. Kiln feed transport bucket elevators 352.BE250 and BE340 were upgraded (to 723 tph) to increase kiln tonnage.
  2. 2. Preheater ID Fans (2) were retrofitted to suit 9100 TPD.
  3. 3. Kiln feed rotary valves, ID Fan motors and VFDs have been changed.
  4. 4. Cooler was upgraded from SF 5×6 to SF-CB 5×7 (177 to 206 m2 grate area).
  5. 5. Clinker crusher was changed from hammer to heavy duty roller breaker HRB MF-418.
  6. 6. Expansion of kiln riser duct and connection of TAD to calciner.
  7. The areas where major upgradations took place are highlighted in these figures:
    Risk assessment: Potential risks, including construction delays, regulatory approvals and associated delays, and market fluctuations, have been identified. A comprehensive risk mitigation strategy is in place to address and minimise these challenges.
    Performance evaluation: Kiln started operating in January 2023 following the upgrade. We encountered several problems with M/s FLS’s cooler hydraulics. In January and February of 2023, a new hydraulic system was installed to replace the entire one. Kiln has produced 9100 TPD of clinker since April 2023. The plant performance before and after upgrading is tabulated below.
    The chart indicates that an increase in clinker production resulted in a specific heat consumption reduction of around 5 Kcal/kg of clinker.
    Presently, kiln volumetric loading is about 7.0, which is significantly higher than what is specified in the design. Additionally, with enhanced clinker production, we are meeting all quality targets (C3S, litre weight, free lime, etc.) for the clinker.

Challenges
• Crushed limestone size: Limestone size was in the higher side (+100mm to 5 per cent) and the gap between blow bar tip and lower grinding path was adjusted at 50mm previous the same was 70mm
• Pile homogeneity: The homogeneity of the pile was the biggest challenge due to huge variation in the mine’s limestone quality (6 different sources of mines). We increased the stacker speed from 11m/s to 13m/s to get better homogeneity. Also, CBA was installed to control variation in input materials from mines and standard deviation of pile was reduced from 80 to 20.
• Raw mills output: To fulfil raw meal requirements with increased kiln production, various modifications were done in the raw mill like replacement of old nozzle rings with new design nozzles etc.
• Kiln burner replacement: Old duo flex burner replaced with Pyrojet burner to reduce frequent snowman formation, increase utilisation of high sulphur petcoke and enhance flame quality.

Conclusion
The capacity enhancement by modification from 8000 TPD to 9100 TPD is a strategic move for Prism Johnson. It positions the company to meet market demands efficiently, contribute to regional development, and ensure the long-term sustainability and competitiveness of our operations.

ABOUT THE AUTHOR
Amarkant Pandey, Deputy General Manager (Process), Prism Johnson (Cement Division),
Satna, holds an engineering degree in mechanical with specialisation in heat and power from Institution of Engineers (India). He has an in-depth understanding of cement manufacturing processes, including raw material preparation, clinker production and cement grinding. His responsibilities include process optimisation, quality control, production planning, etc.


Concrete

Dalmia Acquires Five Point Two MnTPA Cement Assets in Central Region

Acquisition adds capacity, power and rail access

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Dalmia Cement (Bharat) Limited (DCBL) executed a business transfer agreement on 21 May 2026 to acquire a cement undertaking from Jaiprakash Associates Limited (JAL) and Adani Infra (India) Limited. The assets include plants at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh with five point two million tonnes per annum (mn tpa) cement capacity and three point three mn tpa clinker capacity, plus 99 megawatt (MW) thermal power and railway sidings. The transaction carries an enterprise value of Rs 28.5 billion (bn).

DCBL, a wholly owned subsidiary of Dalmia Bharat Limited (DBL), will see cement capacity rise to 54.7 mn tpa on completion. Ongoing expansions at Belgaum, Pune and Kadapa are expected to raise capacity to 66.7 mn tpa by the second to third quarter of fiscal 2028. The company said the transaction would be consummated within two weeks.

The deal follows a framework signed in December 2022 to settle long running disputes with JAL, including a long term clinker supply arrangement. Completion was delayed when JAL entered insolvency and the earlier sale did not finalise. Following approval of a resolution plan under the Insolvency and Bankruptcy Code, DCBL executed a fresh business transfer agreement to resolve pending legal and arbitral matters.

Company statements described the acquisition as strategic, accelerating access to central markets compared with a greenfield route and offering scope for expansion through debottlenecking and brownfield investment. Proximity to the company’s captive mines and established vendor relationships should support faster ramp up. The assets should augment EBITDA delivery and enhance returns by enabling entry into newer markets with relatively better prices.

Senior executives said the addition aligned with a long term plan to build a pan India presence and would provide a head start in central markets. They noted that familiarity with the plants under earlier tolling arrangements offers operational insight and strengthens channel relationships, supporting quicker market entry. Management expressed confidence that the assets’ expansion potential would generate value for stakeholders.

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Concrete

Ramco Cements Reports FY26 Revenue Growth And Higher Profit

Net debt reduced as exceptional items boost FY26 earnings

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Ramco Cements reported standalone audited results for FY26 with net revenue of Rs 90,560 million (mn) and profit after tax of Rs 6,940 mn. EBIDTA rose to Rs 14,820 mn and blended EBIDTA per tonne was Rs 788 on a two per cent volume rise to 18.81 million (mn) tonne (t). Cement revenue increased by five per cent and construction chemicals revenue rose by 66 per cent.

Raw material cost per tonne rose to Rs 1,023 from Rs 956 mainly due to a mineral bearing land tax of Rs 160 per t in Tamil Nadu, adding about Rs 86 per t. Power and fuel cost per tonne fell to Rs 1,098 from Rs 1,123 with petcoke mix down to 47 per cent and green power up to 40 per cent.

Profit before tax after exceptional items was Rs 8,790 mn. Net exceptional items were Rs 5,530 mn, including Rs 5,740 mn from sale of surplus land and Rs 200 mn of past service cost. The company monetised Rs 10,980 mn from non core asset sales over the past two years and recorded capex of Rs 9,970 mn, with guidance of Rs 8,000 mn for FY27.

Net debt fell by Rs 8,170 mn to Rs 36,640 mn at 31 March 2026 and cost of debt eased to 7.29 per cent, reducing net debt to EBIDTA to 2.47 times. Management indicated the full impact of higher fuel costs is expected from Q2 FY27, while packing and diesel cost increases will be visible in Q1 FY27. The board has proposed a dividend of Rs two point five zero per equity share and the company flagged risks from elevated fuel and logistics costs, commodity volatility and competitive pricing.

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Concrete

Dalmia Cement to Acquire 5.2 MnTPA Capacity

Deal covers cement assets in Madhya Pradesh and Uttar Pradesh

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Dalmia Cement (Bharat), a wholly owned subsidiary of Dalmia Bharat, has executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra (India) to acquire cement assets with 5.2 MnTPA capacity in the Central region.

The acquisition covers cement plants located at Rewa in Madhya Pradesh, and Churk, Chunar and Sadwa in Uttar Pradesh. The assets include 5.2 MnTPA cement capacity, 3.3 MnTPA clinker capacity, 99 MW thermal power capacity, railway sidings at Rewa and Chunar, and a common railway siding at Churk. The enterprise value of the transaction is Rs 28.5 billion.

Following completion of the transaction, Dalmia Bharat’s cement capacity will increase to 54.7 MnTPA. Its ongoing expansion projects at Belgaum, Pune and Kadapa are expected to further raise capacity to 66.7 MnTPA by the second or third quarter of FY28. The transaction is expected to be completed within two weeks.

Dalmia Cement had entered into a framework agreement with Jaiprakash Associates in December 2022 for the sale of business assets and related agreements, including a business transfer agreement and cement sale purchase agreement. The agreements were intended to settle disputes between the parties, including those under the long-term clinker supply agreement. However, the transaction could not be completed after Jaiprakash Associates was admitted to insolvency.

Following approval of the Adani Group’s resolution plan for Jaiprakash Associates under the Insolvency and Bankruptcy Code, Dalmia Cement requested that the earlier agreement be considered to settle pending disputes. The company has now executed a fresh Business Transfer Agreement with Jaiprakash Associates and Adani Infra (India) for the cement undertaking.

The acquisition supports Dalmia Bharat’s strategy to become a pan-India cement player and provides faster access to Central markets compared to a greenfield project. The assets also offer expansion potential through debottlenecking and brownfield development.

Puneet Dalmia, Managing Director and CEO, Dalmia Bharat, said the assets are a strong strategic fit and will help the company serve high-potential markets in the Central region. He added that the expansion potential of the assets and their proximity to Dalmia’s captive mines could help create a future capacity hub.

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