Concrete

How Upgrades Can Deliver Energy Savings Across the Cement Process

Published

6 months ago

May 13, 2025

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Jacob Brinch-Nielsen, Vice President of Professional Services, FLSmidth Cement, brings together recommendations from experts across the flow sheet to demonstrate the role of upgrades in optimising the cement manufacturing process.

The Energy Challenge in Cement Manufacturing
Reducing energy consumption is a core goal for all cement producers, sitting alongside alternative fuels, reduced clinker content and carbon capture as one of the four pillars of decarbonisation. As we look to the future, when new emissions abatement technologies will skyrocket energy use once more, that goal becomes ever more important.
While automation and digitalisation have a critical role to play in optimising energy use, advances in mechanical equipment are often focused on reducing energy consumption – meaning there are many equipment upgrades that could help lower your energy bills, providing a relatively swift ROI in exchange for minimal disruption to your process. By optimising key process areas—grinding, dosing, preheating, and more—plants can reduce energy costs while improving operational performance. But where should they start?

Easy Upgrades to Optimise the Grinding Process
“One of the biggest sources of inefficiency in cement grinding is overgrinding,” explains Nick Litzenberger, Design Engineer. “Every extra pass through the mill consumes energy but does not necessarily improve product quality. This is especially critical in Type 1L cement, where fine limestone particles can lead to excessive power consumption and reduced throughput. Many cement plants still operate second- generation separators, which lack the precision of modern designs. Upgrading to a third-generation separator can optimise particle size distribution, lower energy use, and boost mill output.”
Third-generation separators for ball mills like the O-SEPA® or SEPAX™ utilise more hard-wearing materials, improving seal performance and separating more efficiently. These types of upgrades require just a 2 – 3-week shutdown, as much of the work can be done while the mill remains operational and deliver a 5 per cent to 10 per cent reduction in power consumption.
Among third-generation separators for VRMs, options like the ROKS-H separator specifically address overgrinding in Type 1L cement, delivering energy savings of about 2 – 3 per cent while improving product quality. Even an upgrade from an early 3rd generation separator, like a ROKS, to one of the latest separator designs, like a ROKS-H, can reduce power consumption and improve cement quality in a grinding circuit.

Reducing Energy Use in Feeding and Dosing
Even small inefficiencies in feeding and dosing can result in wasted energy and increased operational costs. If your dosing system struggles to maintain consistent feed rates, the inevitable result is instability in pyroprocessing and impacting power consumption.
“We’re continually exploring ways to reduce energy consumption in feeding and dosing applications,” says Peter Norek, Global Product Manager-Feeding and Dosing Technologies. “We’ve introduced digital features like Pfister® Smart Aeration, which reduces compressed air usage by up to 90 per cent, patented FEEDFlex™ technology, which enables much lower fossil fuel dosing, and the FDC controller upgrade, which includes a new motor, enhancing efficiency and reducing electricity consumption. These are all simple upgrades with a positive environmental impact.”

Part 1 of 3. Read parts 2 and 3 in the June and July issues of Indian Cement Review

(Communication by the management of the company)

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Nuvoco Vistas Reports Record Q2 EBITDA, Expands Capacity to 35 MTPA

Cement Major Nuvoco Posts Rs 3.71 bn EBITDA in Q2 FY26

Published

3 days ago

October 22, 2025

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Nuvoco Vistas Corp. Ltd., one of India’s leading building materials companies, has reported its highest-ever second-quarter consolidated EBITDA of Rs 3.71 billion for Q2 FY26, reflecting an 8% year-on-year revenue growth to Rs 24.58 billion. Cement sales volume stood at 4.3 MMT during the quarter, driven by robust demand and a rising share of premium products, which reached an all-time high of 44%.

The company continued its deleveraging journey, reducing like-to-like net debt by Rs 10.09 billion year-on-year to Rs 34.92 billion. Commenting on the performance, Jayakumar Krishnaswamy, Managing Director, said, “Despite macro headwinds, disciplined execution and focus on premiumisation helped us achieve record performance. We remain confident in our structural growth trajectory.”

Nuvoco’s capacity expansion plans remain on track, with refurbishment of the Vadraj Cement facility progressing towards operationalisation by Q3 FY27. In addition, the company’s 4 MTPA phased expansion in eastern India, expected between December 2025 and March 2027, will raise its total cement capacity to 35 MTPA by FY27.

Reinforcing its sustainability credentials, Nuvoco continues to lead the sector with one of the lowest carbon emission intensities at 453.8 kg CO? per tonne of cementitious material.

Concrete

Jindal Stainless to Invest $150 Mn in Odisha Metal Recovery Plant

New Jajpur facility to double metal recovery capacity and cut emissions

Published

1 week ago

October 17, 2025

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Jindal Stainless Limited has announced an investment of $150 million to build and operate a new wet milling plant in Jajpur, Odisha, aimed at doubling its capacity to recover metal from industrial waste. The project is being developed in partnership with Harsco Environmental under a 15-year agreement.

The facility will enable the recovery of valuable metals from slag and other waste materials, significantly improving resource efficiency and reducing environmental impact. The initiative aligns with Jindal Stainless’s sustainability roadmap, which focuses on circular economy practices and low-carbon operations.

In financial year 2025, the company reduced its carbon footprint by about 14 per cent through key decarbonisation initiatives, including commissioning India’s first green hydrogen plant for stainless steel production and setting up the country’s largest captive solar energy plant within a single industrial campus in Odisha.

Shares of Jindal Stainless rose 1.8 per cent to Rs 789.4 per share following the announcement, extending a 5 per cent gain over the past month.

Concrete

Vedanta gets CCI Approval for Rs 17,000 MnJaiprakash buyout

Acquisition marks Vedanta’s expansion into cement, real estate, and infra

Published

1 week ago

October 17, 2025

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Vedanta Limited has received approval from the Competition Commission of India (CCI) to acquire Jaiprakash Associates Limited (JAL) for approximately Rs 17,000 million under the Insolvency and Bankruptcy Code (IBC) process. The move marks Vedanta’s strategic expansion beyond its core mining and metals portfolio into cement, real estate, and infrastructure sectors.

Once the flagship of the Jaypee Group, JAL has faced severe financial distress with creditors’ claims exceeding Rs 59,000 million. Vedanta emerged as the preferred bidder in a competitive auction, outbidding the Adani Group with an overall offer of Rs 17,000 million, equivalent to Rs 12,505 million in net present value terms. The payment structure involves an upfront settlement of around Rs 3,800 million, followed by annual instalments of Rs 2,500–3,000 million over five years.

The National Asset Reconstruction Company Limited (NARCL), which acquired the group’s stressed loans from a State Bank of India-led consortium, now leads the creditor committee. Lenders are expected to take a haircut of around 71 per cent based on Vedanta’s offer. Despite approvals for other bidders, Vedanta’s proposal stood out as the most viable resolution plan, paving the way for the company’s diversification into new business verticals.