Concrete

How Upgrades Can Deliver Energy Savings Across the Cement Process

Published

1 year ago

June 16, 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.

Improving Preheater Efficiency and Heat Retention
Preheaters play a critical role in cement plant energy efficiency, but outdated cyclone designs and corroded components can lead to excessive heat loss and higher fuel consumption. Plants that optimise preheater separation efficiency can reduce fuel use by up to 5 – 10 kcal/kg clinker while improving downstream performance. One area where upgrades can make a difference is in the central pipe elements. By switching to an advanced suspension design, plants can improve separation efficiency and extend wear life — offering both energy savings and operational benefits.
“The cast central pipe is installed in the preheater cyclones to improve separation and thermal efficiency,” explains Muthukumar Muthu, Senior Product Specialist, “Our patented design for the suspension of the cast pipe reduces corrosion (extending pipe life), while also making it easier to carry out maintenance work. Installation of one cast pipe in the lower cyclone stages can save customers 5 – 10 kcal/kg clinker, reducing power consumption in the ID fan drive by 4 to 8 per cent – a significant energy saving. Customers can choose whether to claim these benefits in cost savings or convert them to a 1 to 2 per cent increase in production. Either way, the cast pipe provides a quick ROI.”
The improvements to the cast central pipe elements reduce the stress across the element, and make it simpler to manufacture, which results in a more consistent quality, more durable product. This upgrade can be implemented during the annual maintenance shutdown with no disruption to operations.

Maximising Efficiency in Combustion
False air leaks and inefficient fuel combustion are two of the biggest sources of energy waste in cement kilns. Uncontrolled air ingress forces plants to burn more fuel to maintain operating temperatures, while the inefficient combustion of alternative fuels can create a volatile environment that reduces both efficiency and clinker quality. To address these issues, plants can implement sealing upgrades that prevent air leaks and burner modifications that optimise fuel-air mixing, ensuring more complete combustion and greater flexibility in alternative fuel use.
“We’ve introduced the new Spring Tensioned Graphite Seals to reduce false air entry and increase thermal efficiency – effectively lowering fuel consumption without affecting clinker quality,” says, Karthikeyan Arumugam, Senior Product Specialist.
In addition, advanced burner designs such as a JETFLEX® partial upgrade allow plants to retain the existing kiln burner pipe while improving fuel-air mixing, increasing alternative fuel utilisation and efficiency. This burner enables cement producers to use pulverised coal or petcoke, anthracite, oil, natural gas – or any mixture of these – as well as alternative fuels (such as plastic and wood chips, sewage sludge) with no difference in performance and minimal volatility in the kiln to support reliable and consistent production of high-quality clinker with low NOx emissions.

Cooling Efficiency as Easy as ABC Inlet
An inefficient or older generation cooler inlet leads to higher fuel consumption. Alternative fuels and petcoke produce dusty, sticky clinker that builds up easily, creating ‘snowmen’ in the cooler that disrupt the system, leading to inefficiencies and even unplanned shutdowns.
“The ABC Inlet upgrade continues to be one of our most successful cooler inlet upgrades because it resolves issues as a result alternative fuels usage and enables better heat recovery back to system,” explains Rene Hede, Cooler Product Specialist. “The ABC Inlet prevents snowmen formation with a patented in-grate design that pushes compressed air up through the grates, blasting agglomerations.”
In addition, the ABC Inlet’s rapid quenching process enables faster clinker cooling while maximising heat recovery to the pyro line, resulting in heat consumption savings of 10–30 kcal/kg of clinker. This also enhances clinker quality, providing greater flexibility in cement product formulation and allowing for clinker factor reductions that further improve grinding energy efficiency.

Part 2 of 3. Read Part 1 in the May issue of Indian Cement Review. Part 3 will be found in the July issue.

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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

1 day 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.

Concrete

JK Lakshmi Cement to Expand EV Fleet to 120 Vehicles by March 2027

JK Lakshmi Cement has deployed more than 70 EVs across its logistics network.

Published

2 days ago

October 30, 2026

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JK Lakshmi Cement has deployed more than 70 electric vehicles (EVs) across its logistics network and plans to increase the fleet to 120 vehicles by March 2027. The expansion is part of its decarbonisation strategy, which aims to reduce transport-related emissions and improve operational efficiency.

The company has achieved nearly 100 per cent EV-based clinker dispatches from its Sirohi plant in Rajasthan to the Kalol Grinding Unit in Gujarat. The transition marks an increased use of electric mobility for long-haul cement transportation and is intended to lower the environmental impact of logistics operations.

The existing fleet operates on routes connecting the Sirohi plant with the Kalol Grinding Unit, Palanpur Unit and Surat Grinding Unit. JK Lakshmi Cement is working with electric vehicle logistics providers SwitchLabs and Billion E to support fleet deployment and manage transportation requirements across these routes.

The company expects the planned expansion to increase the use of electric mobility throughout its logistics network for moving cement and clinker. Chairperson and Managing Director Vinita Singhania said the programme reflected the integration of sustainable practices with the company’s focus on long-term business efficiency, while describing the Sirohi–Kalol transition as an important step in its wider decarbonisation strategy.

The EV programme forms part of JK Lakshmi Cement’s green logistics and sustainability roadmap, alongside initiatives to improve efficiency and reduce emissions across its value chain. The company has set a long-term target of achieving net-zero emissions by 2047. It is part of the JK Organisation and operates integrated cement plants in Rajasthan and Chhattisgarh, along with grinding units in Gujarat, Haryana and Odisha. The company has an annual turnover of more than Rs. 60 bn, combined cement capacity of approximately 18 mn t per annum and a target to raise capacity to 30 mn t by 2030. Its portfolio includes ready-mix concrete, gypsum plaster, wall putty, primer, adhesives and fly ash blocks.

Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

2 days ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.