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Pre-cast, pre-fired solutions for critical areas

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Unplanned refractory shutdown not only reduces production, impacts profitability but also increases refractory cost. A few critical areas of a cement plant like tip casting (nose ring) and cooler beam (bull nose) are very sensitive, say Dr Saumen Sinha, Alok Nagar, Rajeev Kumar Laharia, R Chokkar and Satwinder Kalsi.

All cement manufactures always showcase efforts to achieve ideal kiln operational condition, i.e., one shutdown in a year. Targeting for more refractory life in the critical areas of cement plant enables to meet the objective. Refractory relining is time taking, hence maximising the refractory performance in any areas would provide financial benefits along with mental/operational satisfaction.

Most of the cement plants use substantial volume of refractory during shutdown, which calls for huge workforce deployment during installation. Safety concerns over the temporary manpower engaged during shutdown are of paramount importance today.

Refractory shutdown destabilises cement kiln operation, so avoiding production interruption is one of the major targets for cement manufacturers today. There are many instances where unproductive hours were greater than the actual shutdown duration. Unplanned refractory shutdown not only reduces production, impacts profitability but also increases refractory cost. A few critical areas of a cement plant like tip casting (nose ring) and cooler beam (bull nose) are very sensitive.

Tip casting (TC) is exposed to the:

  • very high clinker abrasion,
  • thermal shock due to unstable coating, and
  • severe mechanical stress due to kiln rotation, first tyre migration and bolting system of metal blocks.
  • Normally bricks are being used in TC and they are matched with performance of burning zone bricks lining performance. This is an ideal condition. Over a period of time, due to outlet shell ovality/well mouth there arises difference in hole positions and various issues of tip casting metal blocks resulting in misalignment of the outlet ring. This results in reduction of tip casting refractory performance. Position of metal retainer ring and its design also plays an important role in the performance of bricks used in tip casting.

    To overcome this situation, most of the cement plants started using various grades of castable (monilithic lining). The dismantling of castable and relining it with new castable takes approximately two to three days more than that it takes for brick lining. Utmost precaution during castable installation and controlled dryout of refractories are prime requirements for castable lining performance. Matching the performance of castable lining in tip casting with other area of kiln lining is always a challenge for cement kilns and normally extends the downtime.

    Moreover, damage of small portion of brick lining or failure of castable lining, in a few tip-casting panels, leads to total shutdown of the plant and wastage of minimum four to five days with an additional cost of Rs 15 to Rs 20 lakh (only refractory cost/stoppage).

    The cooler beam (bull nose) is exposed to:

  • Very high clinker dust abrasion
  • High temperature
  • Heat accumulation and more height of clinker bed (for heat recovery) damage refractory in Cooler Bull nose. Shape of bull nose and its position etc. are also responsible for its poor performance.

    Assured solution – Calde ready shapes BN (Calde RDS BN)
    N G Johnson (Northern) of United Kingdom was pioneer in providing refractory ready shape solutions for cement plant critical areas. Acquisition of N G Johnson by Calderys has provided access to this advance technology for TC, BN and damper.

    At present, these blocks are being manufactured at Calderys Nagpur Works, Maharashtra. Calderys Provides tailor-made pre-cast- pre-fired solutions for:

  • Tip casting (nose ring)- Calderys RDS TC
  • Cooler bull nose beam – Calde RDS BN
  • Hoisting damper – Calde RDS DP
  • For more demanding applications, such as where abrasion resistance, chemical resistance and higher temperature strength is desirable, Calderys Ready Shapes can be used. It has the best resistance to acid and alkali attack and also possesses a much higher thermal conductivity, meaning that heat up and cool down more quickly to save energy costs. These blocks are being manufactured with very high grade special castable and state-of-the-art manufacturing techniques to ensure superior and reliable performance.

    Benefits:

  • Safe and reliable installation
  • Installation time reduced by 50 per cent
  • Castable hardening/dry out time is not required
  • Easy repair, option of changing only damage portion
  • Reduce specific cost
  • For TC, separate steel casting blocks not required
  • The performance of various grades of castables installed in some of the cement plants at cooler bull nose, kiln tip castings are indicated below.

    User list (TC Block)

  • Ambuja Cement, Bhatapara (being installed in February 2020)
  • Prism Johnson Limited, India, Satna Works (yet to be installed)
  • Hanson UK Heidelberg Cement Group – Ketton Works > 18 months
  • Hanson UK Heidelberg Cement Group – Padeswood Works > 18 months
  • Hanson UK Heidelberg Cement Group – Ribblesdale Works >18 months
  • CRB (formerly Lafarge) – Dunbar Cement Plant > 18 months
  • Conclusion
    It is evident from the present user that use of ready shapes provides immense benefits and improved performance (almost double the existing performance). These shapes are easy to use within least possible time. Manufacturing of Calde Ready Shape blocks in controlled condition with state of the art technology would ensure its superior performance. These blocks would help in reduction of unplanned shutdown and also to control the cost of refractory as it is already established in overseas.

    References
    -National Cement and Building materials, Publication
    -Survey of Cement Industry & Directory

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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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