Concrete

How Upgrades Can Deliver Energy Savings Across the Cement Process

Published

9 months ago

May 13, 2025

admin

Jacob Brinch-Nielsen, Vice President of Professional Services, FLSmidth Cement, brings together recommendations from experts across the flow sheet to demonstrate the role of upgrades in optimising the cement manufacturing process.

The Energy Challenge in Cement Manufacturing
Reducing energy consumption is a core goal for all cement producers, sitting alongside alternative fuels, reduced clinker content and carbon capture as one of the four pillars of decarbonisation. As we look to the future, when new emissions abatement technologies will skyrocket energy use once more, that goal becomes ever more important.
While automation and digitalisation have a critical role to play in optimising energy use, advances in mechanical equipment are often focused on reducing energy consumption – meaning there are many equipment upgrades that could help lower your energy bills, providing a relatively swift ROI in exchange for minimal disruption to your process. By optimising key process areas—grinding, dosing, preheating, and more—plants can reduce energy costs while improving operational performance. But where should they start?

Easy Upgrades to Optimise the Grinding Process
“One of the biggest sources of inefficiency in cement grinding is overgrinding,” explains Nick Litzenberger, Design Engineer. “Every extra pass through the mill consumes energy but does not necessarily improve product quality. This is especially critical in Type 1L cement, where fine limestone particles can lead to excessive power consumption and reduced throughput. Many cement plants still operate second- generation separators, which lack the precision of modern designs. Upgrading to a third-generation separator can optimise particle size distribution, lower energy use, and boost mill output.”
Third-generation separators for ball mills like the O-SEPA® or SEPAX™ utilise more hard-wearing materials, improving seal performance and separating more efficiently. These types of upgrades require just a 2 – 3-week shutdown, as much of the work can be done while the mill remains operational and deliver a 5 per cent to 10 per cent reduction in power consumption.
Among third-generation separators for VRMs, options like the ROKS-H separator specifically address overgrinding in Type 1L cement, delivering energy savings of about 2 – 3 per cent while improving product quality. Even an upgrade from an early 3rd generation separator, like a ROKS, to one of the latest separator designs, like a ROKS-H, can reduce power consumption and improve cement quality in a grinding circuit.

Reducing Energy Use in Feeding and Dosing
Even small inefficiencies in feeding and dosing can result in wasted energy and increased operational costs. If your dosing system struggles to maintain consistent feed rates, the inevitable result is instability in pyroprocessing and impacting power consumption.
“We’re continually exploring ways to reduce energy consumption in feeding and dosing applications,” says Peter Norek, Global Product Manager-Feeding and Dosing Technologies. “We’ve introduced digital features like Pfister® Smart Aeration, which reduces compressed air usage by up to 90 per cent, patented FEEDFlex™ technology, which enables much lower fossil fuel dosing, and the FDC controller upgrade, which includes a new motor, enhancing efficiency and reducing electricity consumption. These are all simple upgrades with a positive environmental impact.”

Part 1 of 3. Read parts 2 and 3 in the June and July issues of Indian Cement Review

(Communication by the management of the company)

Up Next

We are actively working on sludge utilisation

Don't Miss

Global Aggregates Production

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.

Published

7 hours ago

January 31, 2026

admin

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…

To read the full article Click Here

Concrete

JK Cement Commissions 3 MTPA Buxar Plant, Crosses 31 MTPA

Company becomes India’s fifth-largest grey cement producer

Published

1 day ago

January 30, 2026

admin

JK Cement has commissioned its new 3 MTPA grey cement plant in Buxar, Bihar, taking the company’s total installed capacity to 31.26 million tonnes per annum (MTPA) and moving it past the 30 MTPA milestone. With this addition, JK Cement now ranks among the top five grey cement manufacturers in India, strengthening its national presence.

Commenting on the development, Dr Raghavpat Singhania, Managing Director, JK Cement, said, “Crossing 31 MTPA is a significant turning point in JK Cement’s expansion and demonstrates the scale, resilience, and aspirations of our company. In addition to making a significant contribution to Bihar’s development vision, the commissioning of our Buxar plant represents a strategic step towards expanding our national footprint. We are committed to developing top-notch manufacturing capabilities that boost India’s infrastructure development and generate long-term benefits for local communities.”

Spread across 100 acres, the Buxar plant is located on the Patna–Buxar highway, enabling efficient distribution across Bihar and neighbouring regions. While JK Cement entered the Bihar market last year through supplies from its Prayagraj plant, the new facility will allow local manufacturing and deliveries within 24 hours across the state.

Mr Madhavkrishna Singhania, Joint Managing Director & CEO, JK Cement, said, “JK Cement is now among India’s top five producers of grey cement after the Buxar plant commissioning. Our capacity to serve Bihar locally, more effectively, and on a larger scale is strengthened by this facility. Although we had already entered the Bihar market last year using Prayagraj supplies, local manufacturing now enables us to be nearer to our clients and significantly raise service standards throughout the state. Buxar places us at the center of this chance to promote sustainable growth for both the company and the region in Bihar, a high-growth market with strong infrastructure momentum.”

The project has involved an investment of Rs 5 billion. Commercial production began on 29 January 2026, following construction commencement in March 2025. The company said the plant is expected to generate significant direct and indirect employment and support ancillary industrial development in the region.

Concrete

JK Cement Crosses 31 MTPA Capacity with Commissioning of Buxar Plant in Bihar

Published

1 day ago

January 30, 2026

admin

JK Cement has commissioned a 3 MTPA Grey Cement plant in Buxar, Bihar, taking its total capacity to 31.26 MTPA and placing it among India’s top five grey cement producers. The ₹500 crore investment strengthens the company’s national footprint while supporting Bihar’s infrastructure growth and local economic development.

JK Cement Ltd., one of India’s leading cement manufacturers, has announced the commissioning of its new state-of-the-art Grey Cement plant in Buxar, Bihar, marking a significant milestone in the company’s growth trajectory. With the commissioning of this facility, JK Cement’s total production capacity has increased to 31.26 million tonnes per annum (MTPA), enabling the company to cross the 30 MTPA threshold.

This expansion positions JK Cement among the top five Grey Cement manufacturers in India, strengthening its national footprint and reinforcing its long-term growth strategy.

Commenting on the strategic achievement, Dr Raghavpat Singhania, Managing Director, JK Cement, said, “Crossing 31 MTPA is a significant turning point in JK Cement’s expansion and demonstrates the scale, resilience, and aspirations of our company. In addition to making a significant contribution to Bihar’s development vision, the commissioning of our Buxar plant represents a strategic step towards expanding our national footprint. We are committed to developing top-notch manufacturing capabilities that boost India’s infrastructure development and generate long-term benefits for local communities.”

The Buxar plant has a capacity of 3 MTPA and is spread across 100 acres. Strategically located on the Patna–Buxar highway, the facility enables faster and more efficient distribution across Bihar and adjoining regions. While JK Cement entered the Bihar market last year through supplies from its Prayagraj plant, the Buxar facility will now allow the company to serve the state locally, with deliveries possible within 24 hours across Bihar.

Sharing his views on the expansion, Madhavkrishna Singhania, Joint Managing Director & CEO, JK Cement, said, “JK Cement is now among India’s top five producers of grey cement after the Buxar plant commissioning. Our capacity to serve Bihar locally, more effectively, and on a larger scale is strengthened by this facility. Although we had already entered the Bihar market last year using Prayagraj supplies, local manufacturing now enables us to be nearer to our clients and significantly raise service standards throughout the state. Buxar places us at the center of this chance to promote sustainable growth for both the company and the region in Bihar, a high-growth market with strong infrastructure momentum.”

The new facility represents a strategic step in supporting Bihar’s development vision by ensuring faster access to superior quality cement for infrastructure, housing, and commercial projects. JK Cement has invested approximately ₹500 crore in the project. Construction began in March 2025, and commercial production commenced on January 29, 2026.

In addition to strengthening JK Cement’s regional presence, the Buxar plant is expected to generate significant direct and indirect employment opportunities and attract ancillary industries, thereby contributing to the local economy and the broader industrial ecosystem.