Concrete

Ultratech sources VRM from Gebr. Pfeiffer

Published

3 years ago

April 27, 2024

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Ultratech Cement will once again use the state-of-the-art vertical roller mill technology from Gebr. Pfeiffer, to build three new clinker production lines.

As Ultratech Cement gears up for its three new clinker production lines, a corresponding follow-up order was awarded to Gebr. Pfeiffer SE, Germany, and its Indian subsidiary Gebr. Pfeiffer (India).

As the largest cement plant operator in India and one of the top ten in the world, Ultratech Cement from Mumbai, India, is contributing to shaping the future of the cement industry. At their Happy 3 plant, the cement raw material will be ground in an MVR 5000 R-4 mill. With a 5,300-kW drive, this mill can grind approx. 705 tph to a product fineness of 1.5 per cent R 212 µm. The integrated SLS 5300 VR high-efficiency classifier, with optimised flow and electrical efficiency, separates the product to achieve the target fineness.

For the grinding of approx. 45 t/h of pet coke or approx. 90 t/h of coal, three vertical roller mills of the type MPS 3550 BK will be supplied. These are equipped with a 1,300-kW gearbox, as standard. By using Pfeiffer MPS mills, Ultratech is able to process both pet coke and coal, as well as any mixture of these two materials, at the same speed of the grinding bowl, thus avoiding three expensive frequency converters. The new coal mills will be equipped with an integrated high-efficiency classifier type SLS 3750 BK of the latest design.

It is important for UltraTech’s stock of spare parts that the latest MVR mills are characterised by grinding rollers based on the R=C principle, as this brings significant advantages for the customer. It means that these mills are equipped with grinding rollers that, equipped with the corresponding grinding elements, can be used, along with the appropriate power modules, for raw meal grinding as well as for cement grinding.

As the components of rollers, grinding roller suspension system, roller arms in cement and raw mills are identical with the ones which the customer has already received from Gebr. Pfeiffer, he requires a smaller number of spare parts in stock. This is because the components mentioned can be used for all his cement and raw mills.

The MVR 5000 R-4 mill for the Happy 3 plant has four actively redundant grinding rollers and can also be operated with two grinding rollers in the event of planned or unplanned maintenance work. This mill can then still produce approximately 70 per cent of the nominal capacity, so that the cement rotary kiln can continue to be fed with raw material.

The MVR mills are equipped by Gebr. Pfeiffer with the modern systems for preventive, maintenance-oriented condition monitoring. This will enable the customer to implement modern, digital maintenance concepts. The MPS mills will be prepared to include such options at a later point in time.

Order execution will be jointly by the subsidiary Gebr. Pfeiffer (India) and Gebr. Pfeiffer SE (Germany). The entire customer support and plant engineering will be carried out by competent Pfeiffer engineers in Noida.

The core components, such as gearbox, grinding bowl, grinding roller suspension system and the grinding rollers, are supplied from Europe by Gebr. Pfeiffer SE. The remaining components, such as the foundation parts, the housings, the classifiers and most of the plant components will be provided by Gebr. Pfeiffer (India).

The Customer Support Centre in Noida, being close to the customer, will later also provide support for the plants. This can be done in real terms by sending personnel to the plants or via remote data access.

For this purpose, Gebr. Pfeiffer offers hardware and software solutions, which are supported by competent technical personnel during normal office hours, if possible, in the local language. The picture shows an MVR mill of similar size (Type MVR 5000 R-4).

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Concrete

India’s Cement Sector Cuts Energy Use, but Worker Safety Worsens

iFOREST finds efficiency gains alongside water and safety concerns

Published

2 days ago

November 2, 2026

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India’s cement sector has improved its energy and carbon efficiency, but rising groundwater use in water-stressed regions and deteriorating worker safety remain significant concerns, according to a report by the International Forum for Environment, Sustainability & Technology (iFOREST). The findings also highlighted weak policy implementation and gaps in sustainability reporting.

India, the world’s second-largest cement producer, uses about 2.54 gigajoules of energy per tonne (GJ/t), below the global average of 2.88 GJ/t. However, renewable sources accounted for only 5.1 per cent of the sector’s energy mix, indicating continued dependence on conventional sources.

The report assessed 18 cement companies against 107 Business Responsibility and Sustainability Reporting indicators for FY24 and FY25. The companies covered 87 per cent of India’s cement production. Carbon emissions intensity declined from 0.58 to 0.57 tonnes of carbon dioxide per tonne, but total emissions increased 4 per cent to 224.3 mn t, equivalent to about 6 to 7 per cent of India’s overall emissions.

Overall water withdrawal declined 9.5 per cent during the study period, while withdrawals in water-stressed areas, mainly in Rajasthan, increased by more than 20 per cent. Groundwater’s share of withdrawals in these areas rose from 27 per cent to 38 per cent, raising concerns about the sector’s impact on vulnerable water resources.

The sector employs about 228,000 people, including 63 per cent contractual workers, 3.1 per cent women and 0.07 per cent persons with disabilities. Women in key managerial roles earned 26.8 per cent less than men, while median pay for women workers fell 11.1 per cent in FY25 as men’s pay increased. Worker injuries rose 36.5 per cent to 359, and fatalities increased from 17 to 22, with workers accounting for more than 90 per cent of deaths.

iFOREST recommended cement-specific reporting guidance, standardised metrics, mandatory production disclosure and third-party verification. It also called for environmental, social and governance policies to be integrated into business strategies and implemented more effectively on the ground.

Concrete

Ambuja Cements Expects Volume Growth to Outpace Industry in H2

Ambuja Cements sees stronger trade and institutional demand in H2 FY27.

Published

2 days ago

November 2, 2026

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Ambuja Cements expects its sales volumes to grow faster than the cement industry during the second half of fiscal year 2027, as it seeks a recovery in institutional demand after a weak first half. The Gautam Adani-owned company is aiming to rebuild volumes while protecting profitability.

The company reported a 90 per cent year-on-year decline in consolidated net profit attributable to owners of the parent to Rs. 1.93 bn for the quarter ended 30 September, from Rs. 17.74 bn a year earlier. The previous year’s profit included a reversal of income-tax provisions worth Rs. 16.97 bn. Revenue from operations rose marginally to Rs. 91.66 bn from Rs. 91.3 bn.

Trade volumes increased 8.6 per cent year-on-year in the September quarter, but weaker institutional sales left overall volumes broadly unchanged. Ambuja Cements expects both trade and institutional sales to turn positive in the third and fourth quarters. Trade sales are made through dealers and distributors, while institutional or business-to-business sales involve bulk supplies to infrastructure developers, government projects and real estate companies.

The company had earlier reduced institutional sales that did not generate adequate returns. It now plans to rebuild the business selectively, while continuing to prioritise trade sales and higher-value products. Trade accounted for 74 per cent of sales in the quarter, up six percentage points from a year earlier, while premium products increased to 37 per cent of trade sales from 35 per cent. Blended cement’s share rose to 82 per cent from 77 per cent.

Ambuja Cements commissioned 4.6 mn t of capacity during the quarter. Another 3.2 mn t at Bathinda in Punjab and Jodhpur has stabilised, with the facilities expected to ramp up in the second half. A further 2.4 mn t facility at Varkala in Bihar is scheduled for commissioning during the period. Higher fuel and logistics costs remain a challenge, while the company has realised a cement price increase of about Rs. 10 per bag in October and is targeting operating costs of Rs. 4,250 per t for the full year.

Concrete

JK Lakshmi Cement Begins Rs 110 Billion Assam Plant Project

The 2.5 MTPA integrated cement plant is expected to be completed by FY2029.

Published

4 days ago

October 31, 2026

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JK Lakshmi Cement has recently laid the foundation stone for Project Kamakshi, its first integrated cement manufacturing facility in Assam, marking its entry into Northeast India. The groundbreaking ceremony was held at Umrangso village in Dima Hasao district in the presence of Assam Chief Minister Himanta Biswa Sarma.

The project involves an investment of Rs 110 billion, including the mining lease, and will have an annual cement production capacity of 2.5 million tonnes, supported by a 1 million tonne clinkerisation unit. Scheduled for completion by FY2029, the facility is expected to generate employment for over 2,000 people while catering primarily to the growing Northeast market.

The integrated plant will feature dedicated railway sidings to facilitate efficient transportation of raw materials and finished cement, strengthening supply chain reliability and regional distribution.

Vinita Singhania, Chairperson and Managing Director, JK Lakshmi Cement, said, “”Project Kamakshi is the start of a long-term relationship with Assam and the wider North East. This is a region that is building fast, and it deserves quality cement made close to home. With this plant, we want to bring scale, jobs, and dependable supply to the region. At JK Lakshmi Cement, we believe that building a stronger India goes beyond infrastructure. It is also about growing together with the communities we serve.””

The investment aligns with the company’s strategy to expand into high-growth markets beyond its established presence in Northern, Western and Eastern India. The project is also expected to support regional economic development and infrastructure growth.

JK Lakshmi Cement aims to pursue its expansion plans while working towards its long-term target of achieving net-zero emissions by 2047.