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Strategic Capacity Enhancement

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Amarkant Pandey, Deputy General Manager (Process), Prism Johnson (Cement Division), Satna, presents a case study on capacity enhancement of clinker production in an existing kiln.

This case study outlines the strategic initiatives taken to enhance production capacity of Prism Johnson (Unit-2) from 8000 TPD to 9100 TPD. This would help the company to expand its market share, develop new products and fortify our position in the cement industry.
With a consistent increase in regional demand and a positive market outlook, it was imperative for Prism Johnson’s Unit-2 to augment its production capacity from 8000 TPD to 9100 TPD in FY 2020-21. This enhancement aligned with our commitment to provide high-quality cement products while maintaining operational efficiency.

Cement capacity and production
The production capacity of Prism Johnson’s Unit-2 in FY-21 was at 8000 TPD. The plant was operating close to full capacity, with production data indicating steady growth trajectory, and it was evident that the current capacity was reaching its limits, thereby necessitating the need for expansion.
New capacity: The project entailed increasing the production capacity from 8000 TPD to 9100 TPD, thereby accommodating the rising market demand.
Timeline: The project was anticipated to span across 60 days.
Technology and process improvements: To optimise efficiency, the capacity enhancement project incorporates state-of-the-art technologies and process improvements. These advancements aim to reduce energy consumption, enhance product quality and ensure sustainable production practices.
The following technical upgradations has been implemented in order to support the upgraded production:

  1. 1. Kiln feed transport bucket elevators 352.BE250 and BE340 were upgraded (to 723 tph) to increase kiln tonnage.
  2. 2. Preheater ID Fans (2) were retrofitted to suit 9100 TPD.
  3. 3. Kiln feed rotary valves, ID Fan motors and VFDs have been changed.
  4. 4. Cooler was upgraded from SF 5×6 to SF-CB 5×7 (177 to 206 m2 grate area).
  5. 5. Clinker crusher was changed from hammer to heavy duty roller breaker HRB MF-418.
  6. 6. Expansion of kiln riser duct and connection of TAD to calciner.
  7. The areas where major upgradations took place are highlighted in these figures:
    Risk assessment: Potential risks, including construction delays, regulatory approvals and associated delays, and market fluctuations, have been identified. A comprehensive risk mitigation strategy is in place to address and minimise these challenges.
    Performance evaluation: Kiln started operating in January 2023 following the upgrade. We encountered several problems with M/s FLS’s cooler hydraulics. In January and February of 2023, a new hydraulic system was installed to replace the entire one. Kiln has produced 9100 TPD of clinker since April 2023. The plant performance before and after upgrading is tabulated below.
    The chart indicates that an increase in clinker production resulted in a specific heat consumption reduction of around 5 Kcal/kg of clinker.
    Presently, kiln volumetric loading is about 7.0, which is significantly higher than what is specified in the design. Additionally, with enhanced clinker production, we are meeting all quality targets (C3S, litre weight, free lime, etc.) for the clinker.

Challenges
• Crushed limestone size: Limestone size was in the higher side (+100mm to 5 per cent) and the gap between blow bar tip and lower grinding path was adjusted at 50mm previous the same was 70mm
• Pile homogeneity: The homogeneity of the pile was the biggest challenge due to huge variation in the mine’s limestone quality (6 different sources of mines). We increased the stacker speed from 11m/s to 13m/s to get better homogeneity. Also, CBA was installed to control variation in input materials from mines and standard deviation of pile was reduced from 80 to 20.
• Raw mills output: To fulfil raw meal requirements with increased kiln production, various modifications were done in the raw mill like replacement of old nozzle rings with new design nozzles etc.
• Kiln burner replacement: Old duo flex burner replaced with Pyrojet burner to reduce frequent snowman formation, increase utilisation of high sulphur petcoke and enhance flame quality.

Conclusion
The capacity enhancement by modification from 8000 TPD to 9100 TPD is a strategic move for Prism Johnson. It positions the company to meet market demands efficiently, contribute to regional development, and ensure the long-term sustainability and competitiveness of our operations.

ABOUT THE AUTHOR
Amarkant Pandey, Deputy General Manager (Process), Prism Johnson (Cement Division),
Satna, holds an engineering degree in mechanical with specialisation in heat and power from Institution of Engineers (India). He has an in-depth understanding of cement manufacturing processes, including raw material preparation, clinker production and cement grinding. His responsibilities include process optimisation, quality control, production planning, etc.


Concrete

Cement Prices To Hold Steady Amid Monsoon Slump

Centrum report says demand weakness will limit hikes

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Centrum, a financial services firm, has reported that cement prices are likely to remain largely unchanged in July as weak demand during the monsoon season constrains pricing power. The report noted that construction activity remained subdued in the first quarter of fiscal year 2027 owing to labour shortages and slower execution of government projects. While June showed some volume recovery driven by delayed monsoons and quarter end sales, dealers are cautious about sustaining any price increases.

The analysis suggested that seasonal slowdown related to monsoon will prolong demand and pricing challenges through the second quarter. Dealers saw most recent attempts at price hikes as protective measures rather than genuine shifts in market fundamentals. They signalled that pockets of demand in select regions could prompt isolated adjustments but that broad based increases were unlikely while construction activity remained weak. Market participants therefore expected a cautious stance on pricing.

The report highlighted that despite intermittent recovery in shipments during June, the underlying demand trajectory remained muted as monsoon hampered site level activity and logistics. Commercial builders and retail dealers both reported constrained order books and slower payment cycles, which in turn reduced room for margin expansion among manufacturers. Analysts noted that unless government project execution accelerates markedly, demand improvement would be gradual. Price setters were thus likely to focus on protecting market shares rather than pursuing aggressive increases.

Market watchers said the near term outlook would be shaped by monsoon progress and fiscal spending patterns, with any acceleration in public works offering the most tangible support. Traders expected that regional variations would persist and that trade flows between surplus and deficit centres would determine local price movements. The report concluded that stakeholders should prepare for a period of subdued pricing until demand signals strengthen.

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Concrete

Cement Prices Set To Stay Under Pressure In July

Monsoon and weak demand keep prices under strain

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A report by Centrum said cement prices are expected to remain largely flat in July as the monsoon and weak demand weigh on the sector. The report said demand during the first quarter of FY27 remained range-bound and below expectations, with dealers across markets pointing to subdued construction activity, labour shortages, elections, heatwaves and slower execution of government projects as key reasons. It noted that some recovery was witnessed in June due to delayed onset of the monsoon and quarter-end volume push.\n\nDealers across most markets do not expect any meaningful price increases in July, the report said, adding that attempts to raise prices in some markets are aimed at defending existing levels rather than achieving significant gains. The sharp correction following the rollback of April hikes has largely played out across most regions, limiting scope for further immediate increases. Seasonal slowdown in construction activity during the monsoon is expected to continue affecting demand and pricing in the coming months.\n\nCentrum indicated that pricing pressure is likely to persist through the second quarter of FY27 as monsoon-related softness continues. Dealers remain cautious about sustainability of any price rise attempts and do not rule out further weakness during the peak monsoon period. The combination of subdued demand and seasonal factors is likely to constrain the industry’s ability to raise prices in the near term. While June saw some improvement in volumes because of delayed rains and quarter-end sales efforts, the broader demand environment remains challenging.\n\nCement companies are therefore expected to focus on maintaining current price levels rather than pursuing aggressive increases as the sector navigates weak demand and seasonal headwinds. The report suggested that unless demand conditions improve significantly, limited scope will exist for meaningful price recovery. Market participants remain watchful for any shifts in execution of infrastructure projects or construction activity that could alter the outlook.

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Concrete

TARIL Secures Ultra Mega Transformer Order From PGCIL

Order for manufacturing transformers to be delivered in 30 months

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Transformers and Rectifiers (India) Limited has received Notifications of Awards from Power Grid Corporation of India Limited (PGCIL) for multiple contracts to manufacture transformers and undertake associated works. The company submitted the disclosure to BSE and the National Stock Exchange under Regulation 30 of the SEBI Listing Regulations. The submission cited security code 532928 and trading symbol TARIL, and the filings cite the award reference and confirm execution in accordance with the terms and conditions stipulated in the notifications.

The contracts are described as an Ultra Mega Order under the company classification, indicating a value at or above Rs 10 billion (bn) on conversion. The filing identifies the contracts as domestic orders and specifies a scheduled delivery period of 30 months. The scope covers manufacturing of transformers of various ratings together with all associated work. The order size places it in the highest project classification defined in the company’s disclosure.

The disclosure states that the promoter group and group companies have no interest in the awarding entity and that the contracts do not constitute related party transactions. The company noted that the awards will be executed in the normal course of business and not fall within related party transactions. The document reiterates that the company is committed to delivering high quality products and services and has established itself as a leading manufacturer of transformers in the country over time.

Chief Financial Officer Mehul Shah authorised the filing and requested the exchanges to take the information on record, with the company providing the requisite filing reference in its submission. The company indicated that the orders will be executed as per the notifications of awards and the applicable regulatory framework. The original filing is available on the stock exchange portal at the provided link.

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