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ECS/ProcessExpert v9.1 (PXP) increases productivity at GCC Chihuahua

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Dinesh Sampath, Global Product Manager – Process Optimisation, FLSmidth Cement, discusses the results of a pyroprocess application of ECS/ ProcessExpert® (PXP) solution.

In 2023, Kiln 04 at GCC’s Chihuahua cement plant in Mexico was running manually. In pursuit of increased productivity, an advanced process control system was pursued with the specific aims including:

Reduce free-lime variation to improve clinker quality

  • Increase the substitution alternative fuels without risking carbon monoxide or sulphur spikes
  • Reduce stoppages and thus improve overall performance.
  • Avoid build-up, rings, and coating falls resulting from high temperatures
  • After another supplier’s advanced process control system did not deliver to expectation, the company turned to FLSmidth Cement and ECS/ ProcessExpert® (PXP) solution.
    We commissioned PXP v.8.5 at the Chihuahua plant in early 2024. It wasn’t long before the plant saw results. Production rose by two per cent while heat consumption reduced by one per cent.
    These numbers along with the new self-adaptive controller convinced GCC to upgrade the kiln line to PXP v9.1.

The ECS/ ProcessExpert (PXP) v9.1 effect
PXP v9.1 features our latest advanced self-adaptive controller. An alternative to traditional MPC-based systems, self-adaptive control enhances the software’s responsiveness to changing process dynamics without depending on detailed process models. It evaluates process information in real time, making it more resilient to process changes and better able to generate dynamic predictions. The result? Even more significant performance benefits than previous PXP iterations.
This manifested as a 4.2 per cent increase in production at the GCC Chihuahua plant compared to manual operations. Power and heat consumption also significantly reduced, while the free lime standard deviation dropped by 31 per cent. Implementing PXP v9.1 also enabled the plant to significantly increase alternative fuel consumption, supporting GCC’s aims to raise alternative fuel use at
its operations.

What made the difference?
So, what made the difference at the Chihuahua plant? PXP improved stability to a degree never seen before, and at the same time resulted in better control of NOx, carbon monoxide and oxygen such that allowed more alternative fuels could be used safely. Ring and coating formation was also reduced. Ultimately, there were fewer process upsets thanks to smarter, self-adaptative controller.

Concrete

JSW Paints to Raise Rs 33 Billion for Akzo Nobel India Deal

Funds to part-finance Rs 129.15 billion acquisition of 74.76 per cent stake.

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JSW Paints Limited (JSWPL) plans to raise Rs 33 billion through non-convertible debentures (NCDs) to partly fund the Rs 129.15 billion acquisition of a 74.76 per cent stake in Akzo Nobel India Ltd, according to an exchange filing. The deal, which will trigger an open offer for the remaining shares, forms part of the JSW Group’s Rs 65 billion capital infusion plan.

The bonds, to be issued on Friday, are rated ‘AA– (Stable)’ by ICRA, which noted that the NCDs will carry a five-year bullet repayment, with a call/put option after three years. Only a portion of the coupon will be paid annually, with the balance payable upon redemption.

ICRA said JSW Paints’ debt servicing obligations can be comfortably met through operating profits and dividends expected from Akzo Nobel India until maturity. However, it cautioned that the company’s leverage will remain elevated at over four times in the medium term.

JSW Paints, part of the JSW Group promoted by Sajjan Jindal and led by Managing Director Parth Jindal, plays a strategic role in supplying industrial coatings to JSW Steel. To date, JSW Steel has infused Rs 7.5 billion, while South West Mining Ltd has contributed Rs 1.5 billion towards capital expenditure, debt repayment, and working capital needs.

ICRA expects continued promoter support for the acquisition, which will be financed through a mix of borrowings and equity infusion at the JSW Paints level.

Post-acquisition, JSW Paints’ business profile is expected to strengthen significantly, benefiting from operational synergies, an expanded dealer network, and access to advanced coating technologies. The merger will position the combined entity — JSW Paints and Akzo Nobel India — as India’s fourth-largest decorative paint company and second-largest in the industrial segment. The acquisition will also give JSW access to premium brands like Dulux and new segments such as vehicle refinishes and marine coatings.

In FY25, JSW Paints recorded revenues of Rs 21.55 billion. The company expects a sharp rise in FY26 and beyond, supported by synergies in manufacturing, logistics, and marketing. ICRA projects healthy double-digit operating margins by FY27, marking a strong turnaround from operating losses in FY25.

The acquisition, initially announced in June 2025, valued the 74.76 per cent stake at Rs 94 billion and received Competition Commission of India (CCI) approval on 16 September 2025. The deal is expected to close within the current financial year.

Following the transaction, the Dutch parent company of Akzo Nobel India will retain the powder coatings business and R&D centre, while JSW Paints will integrate the rest of the operations.

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Concrete

SAIL Bokaro Develops New Electrical Steel Grade

BSL produces 1,100 tonnes of energy-efficient special steel.

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Steel Authority of India Limited (SAIL) has announced that its Bokaro Steel Plant (BSL) has developed a special grade of electrical steel for the first time, marking a significant milestone in the company’s efforts to expand its portfolio of high-value and advanced steel products.

The newly developed steel is designed for use in electric motors, generators, small power transformers, electrical appliances, and rotors for hybrid and electric vehicles, contributing to enhanced energy efficiency and supporting India’s growing green mobility and energy infrastructure sectors.

In a statement, SAIL said, “The Bokaro Steel Plant has achieved a major milestone in product development by successfully producing about 1,100 tonnes of 0.5 mm thick IS 18316 LS Grade Non-Grain Oriented (NGO) Electrical Steel for the first time.”

The innovation is expected to position SAIL as a key domestic supplier of specialised electrical steel, reducing dependence on imports for critical industrial applications. It also aligns with the company’s broader strategy to move up the value chain and contribute to India’s self-reliance in advanced materials manufacturing.

The Bokaro Steel Plant’s success in developing this new grade of steel underscores SAIL’s focus on technology-driven production, quality enhancement, and sustainable industrial growth.

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Steel Ministry to Launch Third Round of PLI Scheme

New PLI phase to boost specialty steel output and cut imports.

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The Ministry of Steel, Government of India, is set to launch the third round (PLI 1.2) of the Production Linked Incentive (PLI) Scheme for Specialty Steel, a flagship initiative under the Atmanirbhar Bharat vision. The launch will be led by Union Minister for Steel and Heavy Industries H.D. Kumaraswamy, in the presence of senior officials and industry stakeholders.

Approved by the Union Cabinet in July 2021 with an outlay of Rs 63.22 billion, the PLI Scheme aims to transform India into a global manufacturing hub for high-value, advanced steel grades. The scheme incentivises incremental production, investment, and innovation across selected product categories to enhance domestic value addition and reduce import dependence in critical sectors such as defence, power, aerospace, and infrastructure.

So far, the PLI Scheme has attracted a committed investment of Rs 438.74 billion, of which Rs 229.73 billion has already been realised, resulting in the creation of over 13,000 jobs under the first two rounds.

The scheme covers 22 product sub-categories, including super alloys, cold-rolled grain-oriented (CRGO) steel, alloy forgings, stainless steel (long and flat products), titanium alloys, and coated steels.

Under PLI 1.2, incentive rates will range from 4 to 15 per cent, applicable for five years starting from FY 2025–26, with payouts beginning in FY 2026–27. The base year for pricing has been revised to FY 2024–25 to better reflect prevailing market trends.

The third round of the PLI Scheme represents another significant step in advancing India’s self-reliance in specialty steel production, encouraging technological upgradation and private sector participation in one of the nation’s most vital industrial sectors.

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