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The need for new-gen refractories

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Expectations from newly-developed products by refractory manufacturers are being discussed in this cover story.

Today every cement plant is focusing on the efficiency of clinker production and reduction in the specific cost of operation. A permanent cost reduction programme is running in every plant to optimise its competitiveness and profitability. New modern plants are characterised by sophisticated new technologies, i.e., 6-stage preheater/pre-calciner system with tertiary air duct, more efficient burning and cooling system, and a more efficient refractory lining system. However, the required attention is still not given to refractories.

To optimise the energy cost, a significant change of fuels have been developed by using low-grade coal or alternative fuels in kind of waste components. Besides quality and cost improvements, cement manufacturers are also committed to follow environmental regulations.

Considering the cost factors, the refractory materials have a key function by optimising the specific cost of operation. The new generation of refractory materials have been developed to address these existing problems. The main burning zone of cement rotary kiln is traditionally lined with basic refractory materials.

Chrome-free ‘refractories’
There is a high demand for high-efficient refractory material matching with the need of a new modern cement plant. A new generation of chrome-free refractory concepts have been achieved. In case the traditional basic spinel/chrome bricks are suffering from severe corrosion due excessive thermal attack, instable burning conditions or attack by clinker phases, the material has to be replaced by a more thermal stable refractory material supplied by different manufacturers.

The use of high purity fused raw materials show an outstanding resistance to liquid phase and thermal wear. The thermal flexibility and thermal shock resistance is similar to the well proven magnesia spinel bricks.

High thermal/chemical resistant: In order to counteract the infiltration of liquid phases due to the use of alternative fuels and to prevent any chemical reactions with liquid and volatile compounds, tailormade refractory materials have to be developed. Alkali-resistant high alumina material: In case of high alkali attack in the safety or calcining zone, high alumina refractory material has been developed to counteract the unwanted alkali-spalling reactions as described above. This could be achieved due to the use of silicon carbide (SIC) technology.

Use of alternate fuels
To use alternative fuels to reduce the specific energy costs, the clinker firing unit ‘rotary kiln’ in Europe has become a useful incinerator for the disposal of hazardous material due to their favourable properties. Eg: tyres, plastics, household waste, animal fat, bone meal, waste oil and solvents. There are a number of cement kilns in Europe [meanwhile] running on that way without any fuel costs, i.e., with negative energy consumption.

On the other hand, the use of alternative and ordinary fuels lead to an introduction of a number of secondary phases and trace elements, which demand a high degree of performance of the installed refractory lining and is on high influence to the environment.

As a result of the introduction of secondary phase, the refractory lining is subjected to a high thermal/chemical wear. There are a number of reactions and interactions experienced between a refractory brick work, kiln gas atmosphere and a kiln feed, which is responsible for the chemical wear rate of refractory materials, i.e., compounds chlorides, sulfates and alkalis. The compounds-SiO2 , Al2O3, Fe2O3, CaO, and MgO-are not affecting the refractory lining, since these compound are a part of the clinker composition itself. In many cases, these compounds are included in the raw material design.

Due to the increasing use of burnable residues as alternative fuels in addition to normal raw material mix, there has been a considerable increase in the chemical load in the atmosphere of cement rotary kiln. The alkalis, sulfates and chlorides are introduced to the kiln atmosphere from two sides either from the kiln inlet with the kiln feed or from the kiln outlet with the burner system.

Degradation of ‘refractory lining’
There are three important reaction phenomena observed that is responsible for the premature wear of a refractory lining:

  • Reaction with alkali – sulphate – chloride
  • High temperature attack on basic refractories
  • Attack on high alumina refractories

Al2O3 + K2O + SiO2 K2O Al2O 32 SiO2 + (2,5% vol)
3Al2O32SiO2 + 3K2O + 4 SiO2 3K2OAl2O32SiO2 + (29% vol)

Conclusion
In today’s context, running highly-efficient new modern cement plants and following the environmental regulations, the refractory lining has changed to new generation of basic refractory technologies for the cement industry. There is a wide range of basic refractory materials on the market starting with the standard basic chrome contenting brick to chrome ore free high sophisticated basic refractory materials which are going to stay long.

Source: Lothar Kilb, Refratechnik GmbH, Germany

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Economy & Market

Power Build’s Core Gear Series

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

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Economy & Market

Conveyor belts are a vital link in the supply chain

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Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

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Economy & Market

Impactful Branding

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Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.

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