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

Up Next

Optimising Pyroprocessing with Refractories

Don't Miss

The systems we design are energy-efficient by nature

Concrete

Wonder Cement appoints Mahesh Singh as VP Corporate Brand Communication

Published

6 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 at Nagaur

Published

7 days ago

October 8, 2026

admin

With this commissioning, JSW Cement’s total cement grinding capacity has increased to 25.10 MTPA,
Mumbai

JSW Cement, one of India’s leading green cement producers and part of the diversified JSW Group, today announced the successful commissioning of an additional 1.00 MTPA cement grinding unit at Nagaur, Rajasthan. The commissioning marks another significant milestone in the Company’s growth strategy.

With this commissioning, JSW Cement’s total cement grinding capacity has increased to 25.10 MTPA, while its total clinker manufacturing capacity, including clinker capacity at its joint venture, JSW Cement FZC, stands at 9.74 MTPA.

JSW Cement had commenced operations in North India in March 2026 with the Nagaur Integrated Plant, comprising a 3.30 MTPA clinkerisation unit and 2.50 MTPA cement grinding unit. With the commissioning of the additional 1.00 MTPA cement grinding unit, the plant’s total cement grinding capacity has increased to 3.50 MTPA, enhancing the company’s ability to cater to the growing cement demand across Rajasthan, Haryana, Punjab and the National Capital Region (NCR). The expansion has been funded through a strategic mix of equity and long-term debt.

During the quarter ended 30th September 2026, JSW Cement has also commissioned the Alternate Fuel Handling System and the Waste Heat Recovery system (WHRS) at the Nagaur Integrated Plant.

Nilesh Narwekar, CEO, JSW Cement, said: “The commissioning of additional 1.00 MTPA grinding capacity at Nagaur is a key strategic priority for us and will accelerate JSW Cement’s expansion into North India. We look forward to servicing the growing needs of the region and contributing to the economic growth of Rajasthan, Haryana, Punjab and the NCR area. I am delighted to share that the company has commissioned this grinding unit within the expected timeline, showcasing our project execution capabilities. Further, the Alternate Fuel Handling System and the Waste Heat Recovery system (WHRS) are expected to substantially reduce our production costs going forward.”

Concrete

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

Published

1 week 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.