Economy & Market

Optimising Cement Grinding

Published

1 year ago

February 12, 2025

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Kanika Mathur explores the role of grinding aids in enhancing the efficiency and sustainability of cement production by reducing energy consumption, improving particle size distribution, and extending equipment life.

The grinding process is a crucial step in cement production, directly impacting the final quality and efficiency of cement manufacturing. With growing demands for energy efficiency, cost optimisation, and sustainable production, cement manufacturers are continuously seeking ways to improve grinding operations. Grinding aids, introduced into the process, have emerged as an essential component in achieving these objectives by enhancing the efficiency of
grinding mills and improving the performance of cement. This article explores the significance of the grinding process, the challenges faced in cement grinding, and the role of grinding aids in optimising cement manufacturing.

The Importance of the Grinding Process in Cement Manufacturing
Grinding is a fundamental process in cement production, where clinker, gypsum, and other additives are ground into fine powder to create the final product. The fineness of cement particles influences the hydration reaction, strength development, and overall durability of the cement. The efficiency of the grinding process directly affects the energy consumption, production costs, and environmental impact of cement plants.
The grinding process primarily takes place in ball mills, vertical roller mills (VRMs), and roller presses. Each of these grinding technologies has its advantages and limitations, influencing factors such as energy consumption, operational efficiency, and product quality. In recent years, there has been a shift towards more energy-efficient grinding systems, such as VRMs and roller presses, which offer better control over particle size distribution and reduce specific energy consumption.

Grinding Technologies
The grinding process is a critical component of cement manufacturing, influencing energy consumption, production efficiency, and product quality. Traditional ball mills, vertical roller mills (VRMs), and roller presses are the primary grinding technologies used in the industry. While ball mills have been widely used, they are energy-intensive and require frequent maintenance. VRMs and roller presses, on the other hand, offer better energy efficiency and control over particle size distribution, making them attractive alternatives. The shift toward advanced grinding systems has helped cement manufacturers reduce operational costs and improve sustainability.
However, cement grinding presents several challenges, including high energy consumption, inconsistencies in particle size distribution, and equipment wear. Grinding consumes nearly 60 to 70 per cent of a cement plant’s total electricity, making it one of the most energy-intensive processes. Additionally, friction during grinding generates heat, leading to agglomeration and efficiency losses. Optimising grinding operations requires careful control of raw materials, mill performance, and energy inputs to ensure sustainable and cost-effective production.
Ashok Dembla, Director, KhD Humboldt says, “The use of alternative fuels and raw materials (AFR) is continuously evolving within the cement industry. As a machinery supplier, we are adapting to these changes by providing advanced solutions for handling and processing AFR. One of our most significant innovations is the PyroRotor, an equipment designed specifically for feeding up to 85 per cent of alternative fuels into the pyroclone, which is far beyond what conventional methods can achieve. This has greatly enhanced our ability to replace traditional fuels with more sustainable alternatives.”
“In addition, we have developed solutions to address nitrogen oxide (NOx) emissions, a critical environmental concern. Our NOx reduction equipment significantly minimises NOx generation during the production process, helping plants meet stringent regulatory requirements” he adds.
Grinding aids play a vital role in enhancing grinding efficiency by reducing agglomeration, improving dispersion, and minimising energy consumption. Chemical additives such as amine-based compounds, glycols, and organic acids help improve cement properties by ensuring better flowability, reducing coating on mill internals, and extending equipment life. These additives also enhance cement hydration, leading to stronger and more durable concrete. As cement manufacturers seek ways to reduce costs and carbon footprints, grinding aids have become an essential tool in improving overall plant performance.
Looking ahead, the future of grinding in the cement industry will be shaped by advancements in eco-friendly grinding aids, digital process optimisation, and AI-driven automation. Research into bio-based and waste-derived additives is gaining traction, as companies aim to align with global sustainability goals. Additionally, integrating digital technologies into grinding operations will allow real-time monitoring and process control, further enhancing efficiency. By embracing these innovations, the cement industry can achieve greater sustainability, reduce emissions, and enhance profitability while maintaining high-quality production standards.

Challenges in Cement Grinding
Despite advancements in grinding technology, cement manufacturers still face several challenges in optimising the grinding process. Some of the key challenges include:

Energy Consumption: Grinding is an energy-intensive process, accounting for nearly 60 to 70 per cent of the total electricity consumption in a cement plant. The high energy demand for clinker grinding results in increased operational costs and contributes to CO2 emissions. Reducing energy consumption while maintaining cement quality remains a primary goal for manufacturers.
Particle Size Distribution: Achieving the right particle size distribution (PSD) is crucial for cement performance. A well-optimised PSD improves the workability of concrete, enhances strength development, and reduces the risk of segregation. However, variations in raw materials, mill operations, and grinding media can lead to inconsistencies in PSD, affecting the quality of the final product.
Mill Performance and Wear: Grinding equipment is subject to continuous wear and tear due to the abrasive nature of clinker and additives. The efficiency of grinding media, liner design,
and mill internals plays a significant role in optimising mill performance and reducing maintenance costs.
Heat Generation and Agglomeration: During grinding, friction generates heat, which can lead to issues such as agglomeration and coating on grinding media. This reduces the efficiency of the grinding process, requiring additional efforts to control mill temperature and ensure proper dispersion of cement particles.
Dyanesh Wanjale, Managing Director, Gebr. Pfeiffer says, “One of the major challenges we face is the demand for expedited deliveries. While customers often take time to decide on placing orders, once the decision is made, they expect quick deliveries. However, our industry deals with heavy and highly customised machinery that cannot be produced off the shelf. Each piece of equipment is made-to-order based on the client’s unique requirements, which inherently requires time for manufacturing.”
“Another significant challenge comes from competition with Chinese suppliers. While the Indian cement industry traditionally favoured our technology over Chinese alternatives, a few customers have started exploring Chinese vertical roller mills. This is concerning because our German technology offers unmatched quality and longevity. For example, our mills are designed to last over 30 years, providing a long-term solution for customers. In contrast, Chinese equipment often does not offer the same durability or reliability. Despite the cost pressures, we firmly believe that our technology provides superior value in the long run” he adds.

Role of Grinding Aids in Cement Grinding
Grinding aids are chemical additives that are introduced into the grinding process to improve efficiency and performance. These additives work by reducing the surface energy of clinker particles, preventing agglomeration, and enhancing the flowability of the cement powder. Some of the key benefits of grinding aids include:
Enhanced Grinding Efficiency: Grinding aids help in breaking down clinker particles more effectively, reducing the energy required for grinding. This leads to higher mill output, lower specific energy consumption, and improved overall plant performance.
Improved Particle Size Distribution: By minimising agglomeration and promoting dispersion, grinding aids contribute to a more uniform particle size distribution. This results in better cement hydration, improved strength development, and enhanced durability of concrete structures.
Reduction in Coating and Mill Wear: Grinding aids help prevent the accumulation of cement particles on grinding media and mill internals, reducing coating issues. This minimises wear and tear on equipment, leading to lower maintenance costs and extended mill life.
Better Flowability and Handling: Cement produced with grinding aids exhibits improved flow properties, reducing the risk of blockages in silos and conveying systems. This facilitates smoother handling, packaging, and transportation of cement.
“The performance evaluation of grinding aids is crucial in determining their efficiency and overall contribution to cement manufacturing processes. A systematic assessment involves analysing key performance indicators (KPIs) such as energy consumption, mill output, and particle size distribution, while also evaluating their impact on cement hydration, setting time, and compressive strength. These evaluations, carried out both in laboratories and real-world industrial settings, provide critical insights into the effectiveness of grinding aids” says Dr SB Hegde.

Types of Grinding Aids
Grinding aids can be classified into different categories based on their chemical composition
and functionality. The most commonly used grinding aids include:
Amine-Based Grinding Aids: These additives, such as triethanolamine (TEA) and diethanolamine (DEA), enhance the grinding process by reducing surface tension and improving dispersion. They are widely used to improve early strength development and reduce setting time.
Glycol-Based Grinding Aids: Polyethylene glycols (PEG) and ethylene glycols are commonly used to improve mill efficiency and reduce energy consumption. They help in reducing agglomeration and enhancing cement flowability.
Organic Acids and Their Salts: Organic acid-based grinding aids, such as acetic acid and citric acid derivatives, function by modifying surface interactions between clinker particles. They contribute to better particle dispersion and enhanced cement performance.

Advanced Process Control and AI in Grinding Optimisation
The integration of Advanced Process Control (APC) and Artificial Intelligence (AI) in cement grinding has revolutionised the industry by enhancing efficiency, reducing energy consumption, and improving product quality. APC systems use real-time data from sensors to automatically adjust operating parameters, such as mill speed, grinding media distribution, and material flow, ensuring optimal performance. AI-driven predictive analytics further refine this process by identifying patterns and trends, allowing for proactive adjustments that minimise downtime and maximise throughput.
Rajeev Manchanda, Director, Christian Pfieffer says, “Technology plays a vital role in both our operations and those of the cement industry. We have established several collaborations with leading European companies to provide cutting-edge technology and services. These partnerships allow us to offer energy-efficient and environmentally friendly solutions to our clients. For example, we work closely with Semprotect to optimise the calorific value of clinkerisation plants, which significantly reduces coal consumption. By saving coal, we not only cut costs but also contribute to environmental preservation.”
“All our equipment is designed with the primary objectives of saving energy, minimising coal usage, and increasing production efficiency. Our approach involves replacing outdated systems with modern, optimised ones, which have consistently delivered substantial benefits to our clients. These improvements are aligned with our commitment to reducing the industry’s carbon footprint while enhancing operational efficiency” he adds.
One of the key benefits of AI in grinding optimisation is its ability to handle complex variables that affect grinding efficiency, such as raw material variability, feed rate fluctuations, and mill conditions. Machine learning algorithms continuously analyse historical and real-time data to make intelligent decisions, reducing human intervention and improving accuracy. This results in lower specific energy consumption, better particle size distribution, and increased cement strength.

The Future of Grinding Aids and Sustainable Cement Production
With increasing emphasis on sustainability and reducing the environmental impact of cement production, the development of eco-friendly grinding aids is gaining attention. Researchers are exploring bio-based and waste-derived additives that can improve grinding efficiency while minimising the carbon footprint of cement manufacturing. Additionally, advancements in digitalisation and AI-driven process control
systems are expected to further optimise grinding operations, leading to smarter and more sustainable cement production.

Conclusion
The grinding process plays a crucial role in cement manufacturing, influencing energy consumption, production efficiency, and final product quality. While challenges such as energy demand, particle size distribution, and mill performance persist, the use of grinding aids has proven to be an effective strategy in overcoming these obstacles. By enhancing grinding efficiency, improving cement properties, and reducing operational costs, grinding aids contribute significantly to the sustainability and competitiveness of the cement industry. As technology advances, further innovations in grinding aids and process optimisation will continue to shape the future of cement grinding, ensuring a more sustainable and efficient production process.

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Cement Makers Reaffirm Commitment to Sustainable Growth

Published

3 hours ago

June 5, 2026

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

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Building a Greener Future Together

Published

21 hours ago

June 4, 2026

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

Published

2 weeks ago

May 25, 2026

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Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.