Concrete

Promoting a circular economy is the key

Published

4 years ago

July 18, 2022

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Prakhar Shrivastava, Corporate Quality, JK Cement, sheds light on the use of automation and sustainability in processing gypsum.

Explain the role of gypsum in the cement manufacturing process?
Gypsum plays a crucial role in manufacturing cement. It is used to delay cement setting by slowing down the reaction of mixing cement with water to prevent rapid hardening of cement and increase its workability for construction. Gypsum enhances cement strength at all ages. If we grind the clinker without gypsum, then the cement will set immediately after mixing with water and the strength development will be lesser.

What are the proportions of gypsum that are added in various types of cements produced? Tell us in details of the composition and percentage.
Presently different types of gypsum are available and are being added to meet the SO3 in cement, like mineral gypsum, chemical, phospho, marine gypsum, anhydrite, FGD and synthetic gypsum. The composition and percentage depend on the chemistry of clinker and gypsum to adhere to the desired SO3 target in cement. Normally the percentage addition of gypsum is 5 to 8 in cement mix as per gypsum quality and its availability. Few gypsums, which have higher purity above 85 per cent like imported mineral, anhydrite and phospho gypsum usage are less, whereas, Indian mineral gypsum having purity <40 per cent required higher percentage usage to meet the SO3 requirement.

Tell us about the process of obtaining gypsum by your organisation. What are the key resources utilised?
The different sources of gypsum and vendors are identified by our central procurement team. After getting the test report and sample from the supplier, and its testing in our laboratories then clearance by the QC team about the desired quality of gypsum, the procurement of bulk quantity of gypsum gets initiated. The gypsum is transported by road and rail to the plant. The receipt quality and quantity of gypsum is continuously monitored and if any deviation is found, it is immediately informed to the procurement team as well as the vendor. After this, the gypsum is used to feed into the hopper by Raw material handling equipment (eg. JCB, Payloader etc.) and its usage control through a weight feeder from CCR (central control room) to get the desired SO3 level according to the product requirement during the cement manufacturing process.

Tell us about the key technical feasibility factors that make gypsum viable for mixing with cement.
The size, purity, P2O5, chloride and moisture content of gypsum are the key technical feasibility factors that make gypsum viable for its usages. High moisture content and powdery gypsum are a major concern during cement production whereas the dry and adequate size gypsum is easy to use.
Similarly, low purity gypsum required higher usage to meet the SO3 requirement in cement resulted in increased insoluble residue (IR), which affected the product quality and also the fly ash addition in PPC. To consume such a low purity gypsum requirement of high purity gypsums like imported mineral gypsum to meet the SO3 and IR requirement which is not a cost effective solution.
Phospho gypsum has higher P2O5, which causes delay in the setting of cement and lesser early days compressive strength. Hence, it is mandatory to use it in a very controlled manner by blending it with other available gypsums to meet the product quality requirement.

What is the preparation or processing required to make gypsum ready to mix with the clinker?
Presently, preparation or processing of the different types of gypsum is done by handling equipment manually (eg. loader, dozer and JCB, etc.) as per recommended target and quality. Mixed gypsum is then fed to a separate hopper and controlled by a weight feeder and a controlled quantity of gypsum is mixed with clinker in the cement grinding process.
A more suitable solution to prepare uniform gypsum is to mix it separately before feeding
by blending various types of gypsums through
multi hoppers and controlled dosage to get targeted gypsum quality.

How does automation help in obtaining this mineral and increasing productivity of the unit?
The automation gives a timely update about the whole process to track the status and progress of procured material which saves time and avoids delays in procurement. It also helps to increase efficiency by fast process, productivity, growth and profitability of the organisation.
In all our units, the LIMs System has been implemented. All the quality test equipment is linked with the LIMs software and test results are directly transferred in LIMs and SAP. The quality analysis results of each type of gypsum and vendor wise are available in the automation system which helps to identify the deviation and consistency in quality thereby reducing error and confusion.

What are the sustainability measures taken by your organisation in obtaining and processing the desired quality of gypsum?
As part of our sustainability goals we have taken significant measures to replace natural or mineral gypsum with industrial waste. All our manufacturing units are utilising available industrial waste such as chemical gypsum, anhydrite gypsum, FGD, synthetic gypsum etc.
Blending of mineral gypsum with industrial waste as an economical and sustainable solution to replace natural minerals. Promoting a circular economy is our key pillar of the sustainability journey to reduce the environmental impact of our product by replacing natural resource consumption with industrial wastes which in turn has reduced our dependency on natural resources and is economical as well. It benefits our business, society and the environment by eliminating waste and decoupling our growth from the consumption of natural resources.

What are the major challenges faced in handling and obtaining gypsum for the manufacturing process?
The major challenges in handling and obtaining gypsum are moisture, SO3 and purity, which are the key parameters in deciding the quality of gypsum. Some minor elements also affect the quality of gypsum like phosphorus pentoxide and chloride percentage.
The deviation in SO3 content increases or decreases the quantity of gypsum in cement. Also, typically, a decrease in the SO3 content increases the insoluble residues, especially in Indian mineral gypsum, which causes higher IR in cement and lowers the performance/durability of cement.
In chemical gypsum, the main concern is the moisture of material and colour, which directly affects the operation with reference to jamming, choking and product quality.

-Kanika Mathur

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Concrete

Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa

Line-2 expansion to make Kadapa a major cement hub

Published

5 days ago

July 20, 2026

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Andhra Pradesh Education and IT Minister Nara Lokesh on Wednesday laid the foundation stone for the Line-2 expansion of Dalmia Bharat Cement at Chinnakomerla village in Mylavaram Mandal in Kadapa district. The project carries an investment of Rs 31 billion (bn) and is slated for completion by the third quarter of the financial year 2028. The expansion is intended to boost industrial growth and employment generation across the Rayalaseema region.

Once commissioned, the Kadapa facility will become Dalmia Bharat’s largest integrated cement manufacturing ecosystem in southern India, creating over 1,000 direct and indirect jobs and opening new business avenues for regional micro, small and medium enterprises and transport operators. Lokesh said the expansion signalled growing corporate confidence in the state and reflected the practical ease of doing business that secured repeat investment.

He placed the project within the government’s wider economic targets and recalled the Yuvagalam padayatra commitment to generate two million (mn) jobs within five years, noting that the state would cultivate talent while industry created opportunities. Lokesh highlighted Andhra Pradesh’s competitive pursuit of major manufacturing accounts, mentioning past successes and a personal initiative to engage global investors when persuading them to anchor expansion in the state.

The plant will leverage Kadapa’s abundant limestone reserves to scale production and sustainability. Clinker capacity is planned to rise from two point five million tonnes per annum (mn tpa) to six point one mn tpa, while overall cement output will increase from three point six mn tpa to nine point six mn tpa. The unit is designed to operate on over eighty per cent renewable energy and deploy waste heat recovery, zero liquid discharge, water recycling and advanced AI systems to optimise efficiency. Industries Minister TG Bharat, BC Welfare Minister S. Savitha and Jammalamadugu MLA C. Adinarayana Reddy attended the ceremony.

Concrete

Cement Prices to Stay Flat in Q2 FY27 as Costs Squeeze Margins

HDFC Securities warns monsoon slowdown and higher fuel costs

Published

1 week ago

July 17, 2026

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HDFC Securities has said the cement industry is unlikely to register a sequential increase in prices in Q2 FY27 as monsoon-related demand moderation coincides with rising fuel and packaging costs that will squeeze margins. The brokerage observed that price gains remained modest, with increases of two to three per cent quarter-on-quarter across regions, and noted subdued offtake in May with improvement in June as a delayed monsoon supported construction activity. The brokerage added that modest pricing gains so far have been insufficient to offset the input cost escalation.

The report stated that input cost pressures intensified in Q1 FY27 owing to the West Asia conflict, which pushed up coal and pet coke prices and is expected to keep fuel costs elevated, with a likely peak in Q2 FY27. It assessed that total variable costs, including packing, could rise by around Rs 150 per t quarter-on-quarter and that lower offtake and seasonal operating deleverage could further raise operating expenditure by about Rs 50 per t quarter-on-quarter.

Overall, cement prices were estimated to remain flat in Q2 FY27 as monsoon-led demand weakness offsets limited upside in realisation, and rising fuel costs alongside seasonal deleverage were expected to compress industry margins by over Rs 100 per t quarter-on-quarter to below Rs 880 per t. The brokerage indicated that the combined impact of energy inflation and higher packing expenditure would be the principal drivers of margin contraction in the near term. HDFC Securities projected a recovery in margins in H2 FY27 should the West Asia turmoil subside and energy and packing costs cool off.

The brokerage expressed optimism on long-term demand fundamentals and said improving realisation together with an anticipated cost cool-off should support a margin rebound from H2 FY27 onward, underpinning favourable industry prospects over the medium term. Its outlook rests on monsoon normalisation and a decline in imported fuel prices in the second half of the fiscal year.

Concrete

Dalmia Bharat Begins Rs 31 Bn Green Cement Unit in Kadapa

New Andhra Pradesh plant to add 9.6 MTPA cement capacity by FY28

Published

1 week ago

July 16, 2026

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Dalmia Bharat Limited recently laid the foundation stone for its second manufacturing unit at Kadapa in Andhra Pradesh. The company will invest Rs 31 billion in developing the next-generation integrated cement manufacturing facility.

The foundation-laying ceremony was attended by Nara Lokesh, Andhra Pradesh Minister for Information Technology, Electronics and Communications, Real-Time Governance and Human Resources Development, along with Puneet Dalmia, Managing Director and Chief Executive Officer, Dalmia Bharat, senior government officials and company representatives.

Scheduled to be commissioned by the third quarter of FY28, the Kadapa unit will become Dalmia Bharat’s largest integrated manufacturing facility in southern India. It will have a clinker production capacity of 6.1 million tonnes per annum and a cement manufacturing capacity of 9.6 million tonnes per annum.

The facility is designed to produce what the company describes as one of the world’s greenest cements. It is also expected to generate approximately 1,000 direct and indirect employment opportunities while supporting local MSMEs, transporters, contractors and service providers.

Lokesh said the investment reflected Dalmia Bharat’s confidence in Andhra Pradesh and aligned with the state’s objective of promoting sustainable industrialisation, job creation and technology-led economic growth.

Puneet Dalmia said the project represented the company’s long-term vision of developing low-carbon cement manufacturing assets. He added that the facility would establish new benchmarks in operational efficiency and sustainability while supporting India’s infrastructure and environmental goals.

Dalmia Bharat will also expand its regional community development programmes in education, healthcare, skill development and welfare through its DIKSHa and Gram Parivartan initiatives.

The company currently has an installed cement manufacturing capacity of 54.7 million tonnes across 19 manufacturing units in 12 states. It is also the first cement company globally to commit to the RE100, EP100 and EV100 initiatives.