Economy & Market
Prioritise durability—use premium basic bricks
Published
10 months agoon
By
admin
Sunil Kumar Gupta, Chief Project Officer, Star Cement, discusses how evolving refractory technologies and smarter pyro-processing strategies are redefining performance, durability and cost efficiency.
In recent years, increase in use of alternative fuels, volatile operating conditions and tighter thermal-efficiency targets have reshaped how kilns and preheater lines are designed, lined and monitored. In this interview, Sunil Kumar Gupta shares with how these innovations are strengthening uptime, clinker quality and the future-readiness of India’s pyro-processing systems.
How have refractory demands changed in your kiln and pyro-processing line over the last five years?
Over the past five years, the operational demands on kiln and pyro-processing refractories have intensified, driven by higher kiln throughput and more impact on volume requirements, more stringent thermal-efficiency targets, and the accelerated adoption of alternative fuels (AFR) and mine life- day by day it’s a big challenge.
These factors have necessitated a shift away from conventional alumina-based brick systems toward engineered basic refractories, spinel-forming linings, and high-performance monolithic materials capable of withstanding greater thermal fluctuation, mechanical stress, and chemical attack.
What is the biggest refractory-related challenges you face in preheater, calciner and cooler zones?
Every zone has its own challenges:
A. Preheater
B. Calciner
C. Cooler
A. Preheater
- Fluctuating feed chemistry increases coating instability and causes lining erosion.
- High-speed gas streams and dust-laden environments accelerate abrasion, especially around bends and risers.
B. Calciner
- AFR combustion introduces reducing conditions and alkali–sulphur interactions, which attack conventional refractories.
- Localised hotspots form due to fuel injection patterns, leading to thermal shock and micro-cracking.
C. Cooler
- Clinker breakage patterns cause heavy mechanical wear near the bull nose and in the tertiary
air duct. - Modern coolers operate with rapid thermal cycles, which stresses monolithics and metallic anchors.
The overarching challenge is selecting materials that balance chemical resistance, thermal shock capability, and mechanical strength under constantly changing process conditions.
With the kiln, we are facing the problem of frequent breakdowns of the kiln bricks, specifically in the burning zone. So far, we were using high alumina but now we are planning to go with basic bricks to have more reliability and the longer operation duration of the kiln.
How do you evaluate and select refractory partners for long-term performance and life-cycle cost?
We evaluate the refractive suppliers based on the following four aspects:
A. Technical Capability
B. Engineering and Design Support
C. Life-Cycle Economics
D. Partner Support and Collaboration
Selecting a refractory partner is not simply a materials purchase, it’s a strategic procurement decision that directly affects plant uptime, process stability, and long-term operating cost. An effective evaluation approach should consider below pillars:
A. Technical Capability
The refractory supplier must demonstrate strong materials performance backed by reliable laboratory testing and consistent production quality. Key technical criteria include:
- Cold Crushing Strength (CCS), abrasion and erosion resistance-Indicates mechanical durability against clinker dust, gas flow, and material movement.
- Chemical resistance and corrosion testing-Confirms the refractory’s ability to withstand alkali attack, clinker phases, alkali sulphates/chlorides, and reducing/oxidizing atmospheres.
- Thermal shock resistance and spalling index-Evaluates resistance to rapid temperature changes and cycling—critical in cement kilns, coolers, risers, and cyclones.
- Density and porosity consistency across batches-Ensures uniform behavior in service and
reduces the risk of localized weaknesses or premature failures. - PCE (Pyrometric Cone Equivalent) testing-Measures refractoriness—the temperature at which the refractory begins to soften under its own weight—ensuring suitability for high-temperature zones.
B. Engineering and Design Support
A strong partner provides engineering expertise that prevents failures before they occur.
This includes:
- Proper lining design and zoning
- Thermal calculations, heat loss modeling, and expansion joint design
- Wear-profile analysis and historical performance audits and installation specifications
Engineering support directly influences service life, coating stability, and thermal efficiency.
C. Life-Cycle Economics
Assess the total cost of ownership rather than just initial material costs. This includes installation expenses, refractory maintenance frequency, downtime costs during replacement or repair, and energy efficiency improvements. Refractory partners who provide detailed life cycle cost analysis and emphasise value over initial price help optimise long-term operational costs. Transparent communication about the refractory’s expected service life and maintenance needs is crucial for selecting partners focused on minimizing life-cycle cost.
D. Partner Support and Collaboration
Select refractory partners who offer technical support, expert consultation, and a collaborative approach to tailor solutions. Partners committed to understanding your specific operational conditions, providing training, and proactively addressing performance issues tend to enhance overall refractory service life and reliability.
Can you share a recent instance where improved refractory selection enhanced uptime or clinker quality?
We recently deployed magnesium–iron spindle bricks, which perform exceptionally well across burning, pre-burning and post-burning zones. Their coating-friendly behaviour in the burning zone improves brick life, while their high density in other zones allows stable operation with minimal coating.
By combining coating bricks in the burning zone with non-coating bricks elsewhere, we avoided issues like excessive coating near the tyre area, which can push the kiln into reduction conditions and affect clinker quality. Modern burners with short, hot flames and lower primary air have also helped stabilise coating and heat distribution.
Overall, optimised brick selection paired with the right burner design has improved uptime, reduced wear and delivered more consistent clinker quality.
Use of advanced spinel bricks in kiln linings:
- One 2025 case study described how a cement plant replaced its conventional magnesia-chrome refractory lining in a large dry-process rotary kiln with Magnesium Iron Spinel Brick (and in some cases synthetic magnesium-iron-aluminum spinel) for the kiln’s hot zones.
- After the switch, the plant saw its kiln-lining life extended by over 20 to 30% compared to previous linings — raising lining life from the typical ~8 to 9 months to ~12 to 15+ months without relining.
- This led to a significant reduction in unplanned shutdowns (fewer relining, fewer maintenance events), improving overall operational uptime.
- Because the refractory was more chemically and thermally stable under high temperature and corrosive conditions, the kiln could maintain a more stable thermal profile, which supports consistent clinker formation and improved clinker quality (more uniform mineralogy, less variation due to thermal or chemical stress).
How is the increased use of alternative fuels impacting refractory behaviour in your pyro-line?
Usage of alternative fuels has adverse effect on refractory behaviour in the pyro-line:
A. Higher chemical attack
Alternative fuels (RDF/SRF, biomass, sludge, waste oils) introduce more alkalis, chlorides, and sulphur, cause corrosion of basic bricks, softening of castable, and loss of lining in kiln inlet, riser, and calciner and leads to unstable coating and accelerated wear.
B. More aggressive ash chemistry
AF ash often contains reactive SiO2, Fe2O3, CaO, metals, increases abrasion in kiln inlet and preheater and Generates slag and fluxing reactions that weaken MgO-based bricks.
C. Higher thermal instability
AFs vary in moisture and calorific value, as a result it results in less predictable combustion, produces temperature swings, spalling, microcracks and falling rings and creates hot spots due to irregular flame shape.
D. Changed coating behaviour
AF-related chemistry modifies coating growth and stability. More volatile coating exposes burning zone bricks and overcoating or build-ups in inlet and riser resulting in mechanical damage and choking.
What are plants doing to counter it:
- Switching to MgO–spinel bricks and alkali-/chloride-resistant castables.
- Adding SiC or abrasion-resistant linings in high-velocity or high-ash zones.
- Improving burner control, AF dosing, and raw mix balancing.
- Using sacrificial layers, redesigned anchors, and better insulation to protect main linings.What role does digital monitoring or thermal profiling play in your refractory maintenance strategy?
Thermal profiling and digital monitoring have become essential predictive-maintenance tools for managing kiln and preheater performance. Online shell scanners now provide continuous thermography from inlet to outlet, helping teams assess coating behaviour and refractory health. Drone-based thermography is gaining popularity because it captures hotspots in areas manual checks cannot reach, especially inside cyclones and the calciner during shutdowns. Alongside kiln and cooler cameras, emerging instruments such as cooler-bed thickness sensors further optimise operation. Together, these technologies deliver better KPIs, more stable coating and improved refractory life.A. Kiln Shell Temperature Monitoring (IR scanners and cameras)
Continuous kiln shell scanning identifies: - Hot spots signaling refractory thinning or brick loss
- Misalignment, ovality, and ring formation through temperature pattern changes
- Overloaded or under-performing burners by observing flame/heat profile
- This allows maintenance teams to plan brick patching or section repairs before a shell deformation or blowout occurs.
B. Cooler Monitoring (grate cooler and tertiary air duct)
Thermal sensors and camera systems help:
- Spot grate cooler hot spots that indicate coating issues or refractory wear
- Track TA duct temperatures to avoid thermal shock or lining scouring
- Maintain proper heat recovery efficiency, which directly impacts refractory life
- Digital data ensures that refractory life is maximised by maintaining stable thermal conditions.
How do you balance cost, durability and installation speed when planning refractory shutdowns?
Balancing cost, durability and installation speed in cement plant refractory shutdowns is challenging because each section of the process line has different wear mechanisms, temperature profiles and maintenance needs. The strategy below is designed specifically for cement kilns, preheaters, calciners, coolers, riser ducts and cyclones:
A. Kiln burning zone: Prioritise durability—use premium basic bricks. They are more expensive and slower to install, but failures here are extremely costly.
B. Transition zone, calciner and riser ducts: Prioritise speed and cost—use gunning castable and lower-grade bricks. These provide fast installation, are economical, and offer adequate durability for these areas.
C. Cyclones and high-wear areas: Use low-cement castable combined with precast blocks to achieve a balance of durability and installation efficiency.
D. Cooler: Use precast shapes in the hot zones and abrasion-resistant castable elsewhere. The bottom (impact) area is especially critical and requires high-wear-resistant castable.
Use precast blocks to save time as and when justified and use conventional castable in areas
where cost and installation time are lower priorities. Always base decisions on life-cycle cost, not just material price.
Which refractory or pyroprocessing innovations will transform Indian cement operations?
The refractory and pyroprocessing landscape for cement plants in India (and globally) is evolving — and several innovations are taking shape that could significantly transform how cement operations are run: improving durability, lowering energy usage, cutting downtime, and boosting sustainability. Here are the key innovations likely to shape the future of cement-plant refractories and pyro-processing — along with what they mean for Indian operations.
A. Advanced refractory materials: Nano-engineered, spinel-rich, alkali-resistant bricks and ULCC/LCC castable for longer life and fewer shutdowns.
B. Precast and fast-install solutions: Precast blocks, engineered shapes, and fast-dry castable to reduce shutdown time and improve reliability.
C. Digitalisation and predictive monitoring: Kiln shell scanners, thermal imaging, IoT sensors, digital twins and AI-based kiln control for early detection and optimised operation.
D. Refractory recycling and low-carbon materials: Circular-economy reuse of spent refractories and development of low-CO2 refractory mixes.
E. Fuel-flexible and sustainable pyro-processing: Refractories and kiln designs adapted for alternative fuels (RDF, biomass), higher AF substitution, and eventually hybrid/electric kiln concepts.
Together, these innovations will help Indian plants achieve higher thermal efficiency, lower CO2 intensity, and more stable running conditions.
Concrete
Nuvoco Vistas, CleanMax Partner for Wind-Solar Hybrid Project in Rajasthan
Published
5 days agoon
September 29, 2026By
admin
The project – comprising 20 MW of wind and 26.4 MWdc of solar capacity – will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy.
Mumbai, September 29, 2026
Nuvoco Vistas Corp Ltd, part of Nirma Group and one of India’s leading cement companies, has partnered with Clean Max Enviro Energy Solutions Limited (CleanMax), a renewable energy solutions provider for the commercial and industrial (C&I) sector, to develop a 46.4 MW wind-solar hybrid renewable energy project in Rajasthan.
The project will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy. It is expected to increase the share of renewable energy in Nuvoco’s power mix, reducing fossil fuel consumption and associated emissions.
Developed by CleanMax, an Independent Power Producer (IPP), at Bhikamkhore, Rajasthan, the project will comprise 20 MW of wind capacity and 26.4 MWdc of solar capacity, along with a 2-MWh Battery Energy Storage System (BESS). Power generated from the facility will be supplied to Nuvoco through the State Transmission Utility (STU) Open Access network.
The hybrid project is expected to generate approximately 100 million units (MU) of renewable electricity annually and help avoid around 1,25,485 tonnes of CO₂ emissions every year across Scope 1 and Scope 2 emissions.
The initiative supports Nuvoco’s ongoing efforts to reduce the carbon intensity of its manufacturing operations through renewable energy adoption, Waste Heat Recovery Systems (WHRS), energy-efficiency measures and increased use of alternative fuels. It also aligns with the company’s DIRE (Digitalisation, Innovation and Renewables) agenda, which focuses on climate action, renewable energy transition, water stewardship, circularity and biodiversity conservation across its manufacturing ecosystem.
Commenting on the initiative, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said, “This marks an important step in advancing Nuvoco’s journey towards more sustainable and resilient operations. Our collaboration with CleanMax will increase the share of renewable energy across our Rajasthan operations, strengthening our energy mix while improving long-term cost efficiency and reducing our dependence on conventional power sources. Initiatives such as these reinforce our commitment to operational excellence and responsible growth, while supporting our vision of Building a Safer, Smarter and Sustainable World.”
Kuldeep Jain, Founder and Managing Director, CleanMax, said, “Cement plants run continuously, so the power behind them has to be dependable for decades, not years. We’re seeing manufacturing industries view clean energy as an integral part of their core operations and long-term strategy. Our partnership with Nuvoco reflects that shift, and we’re pleased to support its decarbonisation journey. This wind-solar hybrid project is designed to deliver long-term cost certainty while supporting the Company’s transition to cleaner power.”
Nuvoco has been advancing its sustainability initiatives through renewable energy, operational efficiency and technology-driven solutions. The company operates across Cement, Ready-Mix Concrete (RMX) and Modern Building Materials (MBM) segments, with a presence across East, North and West India.
The company began operations in 2014 with a greenfield cement plant in Nimbol, Rajasthan, and later acquired Lafarge India Limited, which entered India in 1999, along with Emami Cement Ltd in 2020 and Vadraj Cement Limited in April 2025. With planned expansion initiatives, including a new grinding mill at the Arasmeta Cement Plant and multiple debottlenecking projects, Nuvoco aims to achieve a cement capacity of 35 MMTPA.
The company reported total income of Rs 113.62 billion in FY 2025-26, reflecting its continued growth trajectory. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem brands, while its RMX business offers products under Concreto, Artiste, InstaMix, X-Con and Ecodure brands. Nuvoco also provides construction solutions under its Zero M range of modern building materials.
Concrete
UltraTech Cement achieves 100% green energy milestone at Chhattisgarh plant
Published
5 days agoon
September 29, 2026By
admin
UltraTech Cement’s Kukurdih Works becomes its first integrated unit to meet 100 per cent electricity needs through green energy every month.
Raipur (Chhattisgarh)
UltraTech Cement Limited, the world’s largest cement company outside China, has achieved a significant decarbonisation milestone, with its Kukurdih Cement Works integrated unit in Chhattisgarh meeting 100 per cent of its electricity requirement through green energy every month since April 2026.
Commissioned in 2024, Kukurdih Cement Works has an installed grey cement capacity of 3.3 million tonnes per annum. The unit achieved this milestone through a combination of renewable power sourcing and Waste Heat Recovery Systems (WHRS), which now collectively meet its entire electricity demand while ensuring operational reliability.
Since April 2026, nearly one-third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements. Five units, including Kukurdih, have exceeded 95 per cent green energy utilisation. The company is also progressively deploying Battery Energy Storage Systems (BESS) across its network to enable deeper renewable energy integration.
As part of its decarbonisation strategy, UltraTech has not invested in additional captive thermal power capacity for greenfield projects or brownfield expansions at its integrated units for over a decade.
As of Q1FY27, the company’s captive green energy capacity stood at 1,897 MW, comprising 1,463 MW of renewable energy capacity from solar, wind and hybrid sources, along with 434 MW of WHRS capacity. Under its RE100 commitment, UltraTech aims to increase the share of green power in its total energy mix to 85 per cent by 2030 and achieve 100 per cent by 2050.
UltraTech Cement Ltd, the cement flagship company of the Aditya Birla Group, is a $10-billion building solutions company and the largest cement producer globally by sales volume outside China. The company has a total grey cement capacity of 210.1 MTPA and white cement/putty capacity of 3.5 MTPA. It is a signatory to the GCCA Climate Ambition 2050 and has committed to the Net Zero Concrete roadmap announced by GCCA.
Praveen Vashistha, Founder, Gxpress Solutions, speaks about building a holistic logistics network that encompasses latest technology and current challenges faced by logistics service providers.
Logistics may seem to only entail transporting a package from one location to another. However, there is more to this term than just that. Logistics refers to the entire process of controlling all movement, transfers and decisions in the correct way at the right time and cost and with the desired level of visibility.
People nowadays want to receive more than just the delivery. They want quick, efficient, reliable and transparent logistics service. On the other hand, companies are facing higher operating costs, broken supply chains, congested cities, changing habits of consumers and growing complexity of logistics services. In this situation, a full logistics package is gaining importance not only as a competitive advantage but also as a necessity for a successful business.
The main challenge lies in uniting the first mile, the middle mile and the last mile into one seamless process.
The journey begins before the package moves
First-mile logistics may be the least recognised part of the logistics chain, but they have a crucial influence on all that follows.
This stage starts from the moment the shipment leaves the manufacturer, supplier, farm, warehouse or distribution centre. Depending on the industry, first-mile logistics may involve grouping shipments from multiple suppliers, compiling paperwork and checking the inventory before sending the shipments to a central hub.
Flaws in first-mile logistics produce effects later down the supply chain. Delays in cargo pickup can affect warehouse operations; improper packaging can damage goods in transit; and incorrect inventory information may cause stockholding or unnecessary replenishments.
This is why building a reliable network involves simplifying the operations done at the beginning of the supply chain.

Companies require accurate demand forecasts, supplier visibility, standard procedures, and software to capture information from the moment a shipment enters the supply chain. Route planning and fleet management are also important at this stage, especially as it may involve contacting multiple suppliers.
The main goal is simply to make the first mile predictable.
The middle mile: Where scale meets complexity
When products leave the original site, they travel through the ‘middle mile,’ which connects fulfilment centres, warehouses, sorting centres, and regional distribution points. In this phase, logistics networks begin operating on a large scale. A shipment can pass through several facilities before reaching the final destination. Each additional transfer entails the risk of delay or damage and information losses. Accordingly, the ideal solution is not to minimise the number of transfers but rather to optimise them. The use of hub-and-spoke networks, regional distribution centres, and strategically placed distribution centres can help companies shorten transportation routes and optimise distribution costs. Besides, data can be used to determine the optimal placement of inventories.
For instance, a retailer may find that it takes more time and is more expensive to deliver goods to customers if everything is stored in a central warehouse. Meanwhile, regional distribution helps meet the customer’s needs quicker and more efficiently.
The last mile is where the customer judges you
When it comes to the logistics experience, the customer experience comes down to the delivery. While the last mile might comprise a small part of the entire journey in actual distance, it could also entail expensive and difficult processes. Delivery runs through densely populated cities, through traffic jams, through unsuccessful delivery attempts, and through changing consumer preferences and narrowed time frames.
Customers want to have control over their delivery. Delivery means that customers expect to know the exact moment when their order is delivered. They need to receive current updates about their orders and the ability to decide whether they want scheduled deliveries, or whether they want their order to be dropped off at a designated location far from their house.
As a result, last-mile logistics must incorporate both efficiency and experience. The technology may be used to ensure timely and accurate delivery, through such products as route optimisation and real-time delivery tracking.
However, technology is not enough to guarantee success in terms of last-mile delivery. Knowledge of the local area is still an important aspect that contributes to successful delivery.
One network, not three separate operations
First, the common mistake that organisations can make is treating the first mile, the middle, and the last mile separately.
An effective first mile of logistics does not matter much if the shipment waits in a hub for many hours. A perfectly working warehouse does not make a happy customer if the last-mile delivery fails. Therefore, even the fastest last-mile delivery can become an expensive operation if the supply is not well geographically positioned.
The three moments should work together as one whole system.
This implies having a common view on inventory, transport capacities, shipment statuses and demand. The Transportation Management System, Warehouse Management System and order management system should give information to each other instead of acting like separate islands.
That is where real-time information comes into play!
If something happens, such as a vehicle gets delayed, the company has to know that from the start. If not, someone from Customer Service should be informed about the situation.
Visibility is the new infrastructure
Previously, companies had to rely on physical assets, such as warehouses, trucks, and sorting facilities, to create their logistics networks. Today, they have an additional layer of technology providing visibility.
Command-and-control systems now include GPS tracking, Internet of Things devices, bar-coding, RFID, cloud computing, artificial intelligence, and analytics, which allow companies to know what the goods are doing, how well they are doing, and what is going to happen next.
Predictive analytics reveal possible delays. AI-powered forecasting increases availability. Digital dashboards enable the manager to monitor all operations in one place. The efficiency of such technologies is not measured in the amount of information they gather, but rather in their capability of converting data into knowledge.
Logistics managers should be able to answer the following questions: Where is it? When is it supposed to arrive? What causes the delay? What impact does it have? Can it be delivered some other way? How much will it cost?
The sooner the answers are given, the more resilient the logistics system is.
Resilience must be designed into the network
The events of recent years have highlighted the vulnerability of interconnected supply chains. Geopolitical tensions, bad weather, a lack of labour, poorly developed infrastructure and an unexpected spike in demand are some events that can cause problems for logistics systems without prior notice. Thus, companies should create an end-to-end network not just for normal times but also capable of functioning quickly in problematic situations. In order to create such a network, it is necessary to find alternative suppliers, use several means of transportation, create several routes of delivery, and establish inventory. It is also important to use scenario planning to define what to do if the main hub becomes unavailable or any means of transportation is blocked.
Sustainability: Part of the delivery equation
The future of logistics will also be shaped by environmental considerations.
As delivery volumes rise, businesses are under increasing pressure to reduce emissions without compromising service. Better route planning, load optimisation, electric vehicles, alternative fuels, renewable-energy-powered warehouses and consolidated deliveries can all contribute. The most sustainable shipment is often the one that does not require unnecessary movement in the first place.
Better demand forecasting and inventory placement can reduce empty miles and avoid repeated transportation. Consolidating deliveries can improve vehicle utilisation. Reverse logistics can ensure that products, packaging and materials return efficiently instead of becoming waste.
Sustainability, therefore, should not be treated as a separate initiative. It should be incorporated into network design itself.
The future belongs to connected logistics
An end-to-end logistics network ultimately seeks to close existing gaps between various processes.
Every mile of the process should be interconnected with the other miles. Warehouses should be aware of the restraints imposed by transportation. Delivery crews should be able to know at every moment the inventory at their disposal. Clients must have access to this useful information.
Companies that will be successful in this area will not necessarily be the ones with the biggest fleets or the most warehouses. They will simply be the ones that can employ their resources in the most effective manner.
The future of logistics will be represented by an ecosystem consisting of the combination of the physical aspect, digital intelligence, and personnel decisions. Every mile in the process of delivery is important. However, the key advantage here is getting those miles to work together.
For companies, it means having minimal resistance, enhancing their efficiency and improving customer care. For clients, it means simply having the right product delivered at the right time.
About the author: Praveen Vashistha, Founder, Gxpress Solutions,
UltraTech’s Kukurdih unit runs fully on green energy
Cement Prices Rise Rs. 7 per Bag in September; October Hikes Expected
Andhra Pradesh Clears Rs. 30 bn My Home Cement Plant
Nuvoco Vistas, CleanMax Partner for Wind-Solar Hybrid Project in Rajasthan
UltraTech Unit Runs Entirely on Green Energy
UltraTech’s Kukurdih unit runs fully on green energy
Cement Prices Rise Rs. 7 per Bag in September; October Hikes Expected
Andhra Pradesh Clears Rs. 30 bn My Home Cement Plant
Nuvoco Vistas, CleanMax Partner for Wind-Solar Hybrid Project in Rajasthan
UltraTech Unit Runs Entirely on Green Energy
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