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Material grinding is the largest electrical energy consumer in cement

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Indian cement plants are at par with global cement industry in adoption of latest energy efficient technologies such as VRM, roller press in semi-finish and finish mode, believes Dr Bibekananda Mohapatra, Director General- National Council for Cement and Building Materials (NCCBM).

Indian cement plants are at par with global cement industry in adoption of latest energy efficient technologies such as VRM, roller press in semi-finish and finish mode, believes Dr Bibekananda Mohapatra, Director General- National Council for Cement and Building Materials (NCCBM).

Today, the requirement for the cement industry is to reduce power consumption and make the grinding process more energy efficient. Please share your views on how this can be achieved.

Material grinding is the largest electrical energy consumer in cement manufacture. For raw material grinding, the most preferred energy efficient technologies are Vertical Roller Mill (VRM), roller press with ball mill and roller press in finish mode. For coal grinding, VRM is the most energy efficiency technology. VRM is most preferred for using different type of fuels like coal, petcoke etc.

The introduction of an external re-circulation system for material, adjustable louvre ring, latest generation classifier, vortex rectifier, thin liners for ball mill, use of Computational Fluid Dynamics (CFD) to improve classification efficiency, multi-drive systems, secondary classification in the grid cone, installation of high-efficiency fans, the use of slide gates instead of dampers for major fans with Variable Frequency Drives (VFD) and modification of mill body in VRM to improve the air and material trajectories are examples of such changes which increase throughput and improve energy efficiency.

What are the latest energy efficient grinding/technologies/solutions that could benefit Indian cement companies in achieving energy efficiencies?

There are several energy-efficient grinding technologies/solutions available in grinding. Some of them are ceramic grinding media for mono-chamber ball mills, thin liners for ball mills and online particle size distribution analyser for cement mills. In (VRM) grit cone water injection concept can reduce the water consumption by up to 50 per cent and stabilise the grinding bed with less vibrations. Moreover, feeding solutions like rotary feeder, sandwich sealing system for clinker/slag mills results in less wear rate. Comparing different grinding systems, high pressure grinding rolls are at par in energy efficiency as compared to VRMs for grinding purpose. In VRMs, recent development in support rollers is also providing grinding force enabling high energy efficiency. Advancements in VRM main drive gear box is leading to lower cooling requirement and reduction in energy loss. Reduction in mills pressure drop, optimisation of grinding media in ball mills, separator fan volume loading, addition of grinding aids are some of the optimisation measures adopted by cement plants as seen in recent PAT cycles. Some high energy efficient plants have already achieved overall specific electrical energy consumption of 63-65 kWh/t cement. It is anticipated that with the improvements in motor efficiencies, fan efficiencies, implementation of above mentioned technologies and innovations, there is a scope for further electrical energy savings in grinding section.

How is the adoption level of the latest grinding techniques in India as compared to the global cement industry?

Indian cement plants are at par with global cement industry in adoption of latest energy efficient technologies such as VRM, roller press in semi-finish and finish mode. The specific power consumption of grinding section of a cement plant depends on various factors such as type of grinding technology adopted, type of cement produced, fineness requirement, clinker/additives characteristics etc. While it is not possible to trace reduction in specific energy consumption of grinding section over the decades, however, for the Indian cement industry as a whole, the average specific electrical energy consumption for complete plant was around 122 kWh/t of cement in 1960 and started decreasing in late 80’s due to technology change in large cement plants to present level of average of 82.5 kWh/t of cement. The best achieved specific energy consumption for integrated cement plant in India is 63 kWh/t of cement when compared to global best achieved specific energy consumption of 65 kWh/t of cement in Japan.

How have we evolved in terms of innovation in grinding mills at cement plants? What are the latest developments observed in this area?

Innovation is the need of the hour. Grinding technology suppliers are also working consistently in this direction. Some of the innovative grinding technologies are:

Beta-mill: This mill works on the pressure grinding principle. By having defined feeding velocity, material height and width, a defined layer of material is fed to the pressure transaction zone (grinding zone). Energy savings of up to 30 per cent for mill motor as compared to Roller Press and up to 70 per cent as compared to ball mills is possible.

Ultrasonic comminution: Latest development in comminution is based on the application of ultrasonic energy. Ultrasonic comminution efficiently transfers the energy needed for crushing to the raw material, by means of acoustic ultrasonic pulses that are generated by two counter-rotating disks with special aerodynamic surfaces. The small-pulse durations exert pressure waves that pulverize the particles.

Microwave comminution: Grinding is very energy intensive process. Typically, only 1 per cent of the energy input is used to create new surfaces, the rest is turned into noise and heat. Now, prior to mechanically grinding the material, microwaves can be used to selectively heat parts of the rock, causing them to fracture along grain boundaries. This significantly reduces grinding power when the microwave treated material enters into the mill.

Applying ultrasonic field in a roller -press mill: The required energy consumption for grinding is significantly reduced by careful application of an ultrasonic field in the grinding zone. It is also expected to prolong the life of mechanical components. A lower stress on the shafts and a reduction of the required torque can be observed. The lower mechanical stress should also cause less abrasive wear on the rolls. Experimental results obtained by using ultrasound to enhance the performance of a roller-press mill are very encouraging. An experiment was carried out for coal grinding in which the energy consumption was as low as 3 kWh/t of material when compared to 20 kWh/t of material in hammer mills.

Further investigations are required for possible implementation of the above technologies in the cement industry.

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Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

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FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

 

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Concrete

Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

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Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

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Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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