Economy & Market

Technology is the cornerstone of clinker cooling

Published

2 years ago

December 24, 2024

Roshna

Madhusudan Rasiraju, Country Head, IKN India, talks about enhancing cement plant efficiency with energy-saving, reliable, and customised solutions while supporting sustainability through innovations like oxy-fuel plants and AFR adaptability.

Could you explain what IKN Engineering is, what the company specialises in, and share insights about your clinker cooling solutions?
IKN is a Germany-based company that specialises in providing advanced clinker cooling solutions to the cement industry. Our expertise lies in developing and supplying innovative cooling systems that focus on energy efficiency, durability and cost-effectiveness.
The clinker cooling process is a critical stage in cement production, as it significantly influences the energy efficiency of the entire plant. Our coolers are designed with cutting-edge technology to recuperate a substantial amount of heat from the clinker. This recovered heat is redirected back into the cement production process, enabling our customers to reduce their fuel consumption significantly. Moreover, IKN coolers are engineered for reliability. They are built to operate with minimal maintenance, which helps to lower operational costs and reduce downtime. By focusing on high performance and long-term reliability, we ensure that our solutions are both economically and environmentally beneficial.

How does IKN contribute to improving the efficiency of cement plant operations and supporting sustainability goals?
IKN plays a pivotal role in enhancing the operational efficiency of cement plants while aligning with global sustainability objectives. Historically, clinker coolers required frequent maintenance, with intervals as short as five to six months. This led to regular shutdowns, which disrupted operations and increased costs. With IKN’s advanced cooling solutions, cement plants can now operate their coolers for extended periods without significant maintenance. Our coolers are not only more reliable but also consume less power, which directly reduces energy costs. Additionally, the high heat recuperation efficiency of our systems ensures that less fuel is required for the cement-making process, contributing to a lower carbon footprint.
Sustainability is embedded in our solutions. By reducing energy consumption, optimising processes, and minimising maintenance, we help our customers achieve their operational goals while supporting their commitment to environmental stewardship.

What role does technology play in the clinker cooling process, and how does IKN leverage it to provide advanced solutions?
Technology is the cornerstone of clinker cooling and a driving force behind our innovative solutions at IKN. The cement industry’s needs are constantly evolving, and to stay ahead, we ensure our technologies remain dynamic and adaptable. We adopt a customer-centric approach, continuously collecting feedback from our clients to improve our systems. Every clinker cooler we supply is tailored to meet the specific requirements of the plant it serves. For instance, the physical layout, production capacity, and operational challenges of each facility are unique, and we ensure our solutions address these specific needs.
Moreover, our ongoing research and development efforts focus on enhancing reliability, improving heat recovery, and lowering energy consumption. By integrating the latest technological advancements, we make sure our coolers set new benchmarks in performance and sustainability.

Do you offer customised solutions for each cement plant, and how does the increasing use of alternative fuels (AFR) impact your clinker cooling solutions?
Absolutely, customisation is at the core of what we do at IKN. In the case of retrofits, every cooler is custom-designed to fit the specific layout and operational needs of the existing cement plant. For new installations, we collaborate closely with our clients to design coolers that are precisely sized and configured to meet their requirements.
Regarding alternative fuels (AFR), their increasing use in cement plants presents unique challenges. AFR often results in the production of finer clinker, which can be more difficult to handle during the cooling process. To address this, we optimise the operating parameters of our coolers, such as airflow density and cooler speed, to ensure they perform effectively with the type of clinker being produced. This adaptability ensures that our coolers remain efficient and reliable, even in plants using diverse and non-traditional fuels.

What challenges do you face in providing clinker cooling solutions, both from your operations and from the cement industry’s perspective?
Challenges are inevitable in any advanced technological field, and clinker cooling is no exception. One of the primary challenges we face is adapting to the changing demands of our customers. For example, frequent shifts in fuel types or the introduction of AFR can disrupt the cooling process. These changes often result in variations in clinker properties, requiring us to make adjustments to maintain optimal performance. Additionally, the grid surfaces in coolers may face increased wear and tear due to these changes. At IKN, we address such challenges by reinforcing the grid surfaces and fine-tuning our systems to handle these dynamic conditions.
From an industry perspective, there is an increasing emphasis on efficiency, sustainability, and cost reduction. Meeting these expectations while maintaining high performance is challenging, but it is a challenge we embrace through innovation, research, and collaboration with our clients.

What are your views on the net zero mission, and how is IKN contributing toward this goal?
The net zero mission is a vital initiative for energy-intensive industries such as cement, steel, and power. It requires a collective effort across the supply chain to achieve meaningful progress.
At IKN, we are committed to supporting this global goal. One of our key contributions is the development of oxy-fuel plants, which are designed to significantly reduce carbon emissions during production. We are also exploring innovative cooling methods, such as the use of nitrogen or other media, to further enhance sustainability. Currently, we have two oxy-fuel projects underway in Germany. These plants not only demonstrate our commitment to the net zero mission but also serve as examples of how advanced technology can drive sustainability in the cement industry. By focusing on durability, efficiency, and innovation, we help our clients reduce their environmental footprint while maintaining high operational standards.

– Kanika Mathur

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UltraTech becomes first Indian cement firm to cross 2 GW green energy

Published

12 hours ago

October 7, 2026

admin

UltraTech Cement has crossed 2 GW of captive green energy capacity, with renewables and waste heat recovery meeting 48 per cent of its power needs.

Mumbai

UltraTech Cement Limited has surpassed 2 GW of installed green energy capacity for captive use, becoming the first cement company in India to achieve the milestone. The Aditya Birla Group company commissioned 116.55 MW of wind capacity at its Inter-State Transmission System-connected wind-solar hybrid project in Barmer, Rajasthan, along with 10 MW of Waste Heat Recovery System capacity at Sarlanagar Cement Works in Karnataka.

With these additions, UltraTech’s cumulative installed green energy capacity has reached 2,024 MW. This includes 1,580 MW of renewable energy capacity and 444 MW of waste heat recovery capacity, together meeting around 48 per cent of the company’s current power requirements.

The company said the milestone reflects the progress of its long-term energy transition strategy. In FY27 so far, nearly one-third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements, while five units have crossed 95 per cent.

K C Jhanwar, Managing Director, UltraTech Cement Limited, said, “Crossing the 2 GW green energy milestone is the result of a strategy we have pursued consistently over the past decade. Cement is an energy-intensive, hard-to-abate sector, and showing that reliability and growth can go hand in hand with a rapid shift to green energy sets a benchmark for the industry. With nearly half of our power needs now met through green energy, we are significantly less exposed to fossil fuel supply constraints and power price volatility. As we scale up renewables, waste heat recovery and battery storage across our operations, we are building an energy foundation for stable, long-term growth.”

UltraTech commissioned 430 MW of green energy capacity in FY26 and continues to expand its renewable energy and waste heat recovery portfolio.

The company is also progressively integrating Battery Energy Storage Systems across its operations to improve renewable energy utilisation and supply reliability.

In 2025, UltraTech operationalised what it described as India’s first on-site hybrid round-the-clock renewable energy project at Sewagram Cement Works in Gujarat. The project combines solar, wind and battery storage.

As part of its decarbonisation strategy, UltraTech said it has not invested in new captive thermal power capacity for either greenfield projects or brownfield expansions at its integrated units for more than a decade.

The company said its expanding green energy portfolio is helping reduce dependence on conventional grid electricity and fossil fuel-based power, while lowering exposure to fluctuations in coal and electricity prices.

UltraTech aims to increase green energy’s share in its total power mix to 85 per cent by 2030. As a member of RE100, it has also committed to meeting 100 per cent of its electricity requirement through renewable sources by 2050.

UltraTech Cement, the cement flagship of the Aditya Birla Group, has a total grey cement capacity of 210.1 MTPA and white cement and putty capacity of 3.5 MTPA. The company is also a signatory to the GCCA Climate Ambition 2050 and has committed to the GCCA Net Zero Concrete roadmap.

Concrete

Shiva Cement Merges with JSW Cement

Published

15 hours ago

October 7, 2026

admin

JSW Cement has announced a scheme of arrangement to merge its listed subsidiary Shiva Cement with itself, creating a single unified cement platform. The boards of both companies have approved the proposal, which will require clearances from stock exchanges, the Securities and Exchange Board of India, the National Company Law Tribunal, Odisha Industrial Infrastructure Development Corporation and other applicable authorities.

The transaction is expected to be completed within 12 to 14 months, subject to the necessary approvals from regulators, shareholders and creditors. Under the scheme, JSW Cement will issue 5 equity shares with a face value of Rs. 10 each for every 41 equity shares with a face value of Rs. 2 each held by Shiva Cement shareholders other than JSW Cement.

The company said the merger would consolidate financial, managerial, technical, distribution and marketing resources while reducing administrative duplication and compliance requirements. It would also provide greater funding flexibility, potentially lower financing costs and eliminate inter-company guarantees.

The consolidation is expected to strengthen backward integration by enabling JSW Cement to use Shiva Cement’s clinker manufacturing facility. This would reduce dependence on external clinker procurement and improve supply-chain efficiency. Public shareholders of Shiva Cement would receive direct ownership in JSW Cement, which has a broader institutional investor base and a more liquid listed presence.

JSW Cement acquired a controlling stake in Shiva Cement through transactions that began in January 2017. Shiva Cement operates a clinker facility in Odisha, near the borders of Odisha, Chhattisgarh and Jharkhand, and commissioned a 1 mtpa cement grinding unit at Sambalpur in FY26 through a commercial arrangement with Bhushan Power and Steel.

JSW Cement has 24.10 mtpa of cement grinding capacity and 9.74 mtpa of clinkerisation capacity. Its Indian operations comprise nine plants, including two integrated units, one clinker unit and six grinding units. The proposed merger is intended to simplify the corporate structure and align the financial statements of the two companies.

Concrete

Nuvoco Vistas, CleanMax Partner for Wind-Solar Hybrid Project in Rajasthan

Published

1 week ago

September 29, 2026

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The project – comprising 20 MW of wind and 26.4 MWdc of solar capacity – will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy.

Mumbai, September 29, 2026

Nuvoco Vistas Corp Ltd, part of Nirma Group and one of India’s leading cement companies, has partnered with Clean Max Enviro Energy Solutions Limited (CleanMax), a renewable energy solutions provider for the commercial and industrial (C&I) sector, to develop a 46.4 MW wind-solar hybrid renewable energy project in Rajasthan.

The project will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy. It is expected to increase the share of renewable energy in Nuvoco’s power mix, reducing fossil fuel consumption and associated emissions.

Developed by CleanMax, an Independent Power Producer (IPP), at Bhikamkhore, Rajasthan, the project will comprise 20 MW of wind capacity and 26.4 MWdc of solar capacity, along with a 2-MWh Battery Energy Storage System (BESS). Power generated from the facility will be supplied to Nuvoco through the State Transmission Utility (STU) Open Access network.

The hybrid project is expected to generate approximately 100 million units (MU) of renewable electricity annually and help avoid around 1,25,485 tonnes of CO₂ emissions every year across Scope 1 and Scope 2 emissions.

The initiative supports Nuvoco’s ongoing efforts to reduce the carbon intensity of its manufacturing operations through renewable energy adoption, Waste Heat Recovery Systems (WHRS), energy-efficiency measures and increased use of alternative fuels. It also aligns with the company’s DIRE (Digitalisation, Innovation and Renewables) agenda, which focuses on climate action, renewable energy transition, water stewardship, circularity and biodiversity conservation across its manufacturing ecosystem.

Commenting on the initiative, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said, “This marks an important step in advancing Nuvoco’s journey towards more sustainable and resilient operations. Our collaboration with CleanMax will increase the share of renewable energy across our Rajasthan operations, strengthening our energy mix while improving long-term cost efficiency and reducing our dependence on conventional power sources. Initiatives such as these reinforce our commitment to operational excellence and responsible growth, while supporting our vision of Building a Safer, Smarter and Sustainable World.”

Kuldeep Jain, Founder and Managing Director, CleanMax, said, “Cement plants run continuously, so the power behind them has to be dependable for decades, not years. We’re seeing manufacturing industries view clean energy as an integral part of their core operations and long-term strategy. Our partnership with Nuvoco reflects that shift, and we’re pleased to support its decarbonisation journey. This wind-solar hybrid project is designed to deliver long-term cost certainty while supporting the Company’s transition to cleaner power.”

Nuvoco has been advancing its sustainability initiatives through renewable energy, operational efficiency and technology-driven solutions. The company operates across Cement, Ready-Mix Concrete (RMX) and Modern Building Materials (MBM) segments, with a presence across East, North and West India.

The company began operations in 2014 with a greenfield cement plant in Nimbol, Rajasthan, and later acquired Lafarge India Limited, which entered India in 1999, along with Emami Cement Ltd in 2020 and Vadraj Cement Limited in April 2025. With planned expansion initiatives, including a new grinding mill at the Arasmeta Cement Plant and multiple debottlenecking projects, Nuvoco aims to achieve a cement capacity of 35 MMTPA.

The company reported total income of Rs 113.62 billion in FY 2025-26, reflecting its continued growth trajectory. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem brands, while its RMX business offers products under Concreto, Artiste, InstaMix, X-Con and Ecodure brands. Nuvoco also provides construction solutions under its Zero M range of modern building materials.