Economy & Market
Optimising plant utilisation
Published
11 years agoon
By
admin
Developments in pyro processing optimisation and technologies have made it possible to improve existing plants with high energy efficiencies and low emissions, while simultaneously reducing operating costs and preserving the environment and optimal use of fast depleting natural resources.
Kiln is said to be the heart of a cement plant, comparing the cement plant with that of human body. It is a continuous operation and the performance of a plant is judged by the number of days; the kiln runs without any stoppages. In the present economic scenario on an average, the plant utilisation is close to 70 per cent. For the operational function, it is much more challenging because if the production level further goes down for want of demand, then within no time, the plant operation runs into red. Therefore, it is extremely important to decide the equipment capacities precisely since it is a part of design. There is a tendency to go for higher capacity plants for the simple commercial considerations, but in the present situation, such plants in no time will turn into stressed asset if they are running below the bench mark level. Every unit knows its benchmark level to run it into profits. This is exactly the situation in few of the cement plants in the country as they were set up when there was a boom time for cement business which did last for few years but no further.
New approach
A few cement producers in the industry have been smart to decide on the capacities of the plant. Generally at design stage, while deciding on preheater it is preferred to have a single string of operation as a starting phase. Then after stabilisation and proper understanding of the market conditions, it is better to add another string. But then the kiln in the first phase must have been designed with sufficient margins. This has been the case with a few of plants in our country. The plant capacities have been enhanced over a period of time. Our design engineers along with FLSmidth, ThyssenKrupp, KHD Humboldt etc, have done wonderful jobs to add to the capacities of the plant in the country without diluting the performance of the kiln on any count like gaseous pollution or compromising on operational part. However, we strongly feel this has created tremendous load on the coolers and to some extent compromised its performance. The cooler as a hardware has limitations to enhance its capacity or either have modifications in the given space. In many cases, it has been noticed that it is the cooler which throttles the production and not the kiln or grinding.
Use of alternate fuels
Regarding the technology front, there is not much to say on the pyro process per se specifically that has happened in the last decade except more and more players in our country have been experimenting on alternate fuels or industrial waste which is encouraging. With more support coming from the government departments like Central Pollution Control Board (CPCB) and State Pollution Control Boards, the number of usage is only going to grow. There are some changes required in the kiln burner design before the fuels are changed or replaced. Plant would prefer to have a common burner for conventional fuel like coal and for alternate fuels like industrial waste and petcoke. The plants need to address the issue of safety while using hazardous waste since our experience in doing jobs in a safe manner is far below expectations.
Waste Heat Recovery (WHR) can reduce the operating costs and improve EBITDA margins of cement factories by about 10-15 per cent. On average, electric power expenses account for up to 25 per cent of total operating costs of a cement factory. However, to realise the full potential of WHR as of now $1,400 million is required, which is too high.
The other major advantage for Indian cement industry is minuscule presence of volatile matters like sulphur, chlorine, potassium etc. Therefor a majority of plants in India do not have bypass system as a part of design whereas the plants in Gulf countries have this as an additional system. In future as more and more plants will go for alternate fuels in the country they may have to go for by pass system as additional feature.
Focus emission
In pyro processing, the area of focus has been, reduction of NOX and SO2 emissions, and increase of production throughput without compromising on energy consumption but with flexible options on fuel.
Safety in pyro processing is extremely important since coal is used as a fuel. Generally, it is pulvisised at the plant and then fed into the kiln through burner. The conditions in the coal mill area are extremely hazardous and need more attention to reduce the number of unsafe incidences. Inertisation of coal mill is yet to be executed in many plants. There is a lot of scope for improvement here in the industry. Considering the capabilities exhibited till date, we feel Indian cement industry will fulfill this aspiration as well.
Conclusion
According to Kumar, developments in pyro processing optimisation and technologies have made it possible to improve existing plants with high energy efficiencies and low emissions, while simultaneously reducing operating costs and preserving the environment and optimal use of fast depleting natural resources. Process optimisation and performance improvement has become inevitable in cement industry. "Although every situation must be analysed carefully to evaluate real gains that can be achieved, most cement plants can achieve improved performance by implementing suitable modifications," he concludes.
TECHNOLOGY TRENDS IN PYRO PROCESSING
Kilns
- Redefinition of operating parameters – volumetric loadings up to 7.5 tpd/cu m
- Thermal loadings up to 5.5 Gcal/ sq m/kg clinker
- Filling % of 14-16 and kiln speeds up to 5.5 rpm
- 2-pier installations with a drop in L/D ratios to 10-11
- Low primary air, low NOx multi-channel burners
Pre-calciners
- Degree of calcination up to 95 per cent
- Calciner to kiln fuel ratio of 70:30
- Increased residence time up to 5.5 sec to improve combustion efficiency specially in case of petcoke
- Low NOx systems Pre-heater
- 6-stage, twin string preheaters with clinkering capacities up to 10,000 tpd
- Increased cyclone efficiency up to 96 per cent
- Reduction in L/D ratio in cyclones resulting in a pressure drop reduction from 700 to 400 mm WG and a tower height reduction of 10-15 m
- Reduction in the total sp. air requirement from 1.6 to 1.45 Nm3/kg clinker Improvement in fan efficiencies.
Coolers
- New generation (eg, walking-floor) coolers resulting in increased cooler recuperating efficiency from 68-76 per cent resulting in increase of secondary/tertiary air temperature to 1,000oC
- Drop in air requirement from 2.2 to 1.6 Nm3/ kg clinker
- Increase in cooler loading up to 50 t/d/sq m
Bypass system
Raw materials and fuels used for the manufacture of clinker generally contain some volatile constituents. These are mainly the compounds of potassium, sodium, sulphur and chlorine. Volatiles may also originate from water, refractory and wearing parts of equipment. These volatile constituents generally have low melting points. Hence, condensation of the volatile matters takes place on raw meal particles and the surrounding walls in the colder zones of the kiln. This causes build-ups on the cyclone walls and riser ducts that lead to blockages in the passage areas in the cyclones. The bypass system allows a high proportion of volatiles to be removed through the kiln gas stream and improves the performance and product quality.
Fuel solutions
Alternative fuels such as lignite, petcoke, tyres, bagasse, rice husk, industrial wastes etc, are being in use for sometime now. Several plants are using/ investigating hospital refuse and municipal waste as workable alternatives. The current reported thermal substitution rates (TSR) in the Indian cement industry is about one per cent. However, TSR levels as high as 60 per cent have been achieved in some of the developed nations. Action plans are needed to overcome technical, financial and regulatory barriers to the growth of alternate fuel (AF) usage. Technical solutions are in place for storage, handling and dosing the AF to the system.
– Kamal Kumar, Chief General Manager, Holtec
Diagnosis
Based on process measurements conducted following observations were made:
- The PH system is operating with about 28% leakage air. This is resulting in higher PH fan power consumption.
- The cooler vent gas volume of 1.63 Nm3/kg clinker and temperature of 369oC.
- High clinker temperature of 165oC value against the normal value of around 100oC.
- The heat balance of the pyro processing system indicated that the total heat consumption works out to 888 kcal/kg clinker.
| Implementations | |||||||||
| Following suggestions were implemented: | |||||||||
| Area | 2,000 t/d | ||||||||
| Kiln size | 3.95 m dia x 56 m L | ||||||||
| Preheater (PH) | Single string 5-stage suspension preheater with in line calciner (ILC) | ||||||||
| Kiln burner | Duoflex | ||||||||
| Fuel used | Furnace oil | ||||||||
| Preheater fan | 7,000 m3/min at 900 mm WG, 320oC | ||||||||
| Cooler vent fan | 5,133 m3/min at 190 mm WG, 300oC | ||||||||
| Clinker cooler | Reciprocating grate cooler | ||||||||
| Cooler effective area | 52.8 m2 | ||||||||
| No. of grates | 2 | ||||||||
| Specific heat consumption | |||||||||
| (A mass and heat balance conducted jointly) |
854 kcal/kg clinker | ||||||||
| Implementations | ||
| Following suggestions were implemented: | ||
| Area | Recommendations | Result |
| Fuel firing | Conversion of oil firing to coal firing in kiln and PC | Reduction in operation cost |
| Preheater | Reducing preheater exhaust gas quantity to 1.60 Nm3/kg clinker by arrest false air leakage, reduce the PH outlet draft | Reduction in heat consumption |
| PC primary air fan volume reduced, smaller capacity fan motor installed | Reduction in power consumption | |
| Coal transport air quantity to PC was reduced in phases | Reduction in heat consumption | |
| Maintaining PC outlet temperature as 840oC.A PID loop was provided for the PC firing. | Reduction in heat consumption | |
| Kiln | Increase the kiln speed from 3.0 to 3.3 rpm | Increased kiln output |
| Coal transport air to quantity to kiln was reduced in phases | Reduction in heat consumption | |
| Position of the inner burner pipe was retracted by 30 mm and pressure at burner pipe was increased by 10 per cent | Sharp and intense flame resulting in saving in heat consumption | |
| Clinker cooler | To reduce the cooler vent air temperature | Reduction in heat consumption. |
| Optimisation of cooler operation, commissioning of water spray system. | Reduction in clinker temperature | |
| First grate of the cooler is to be modified with the new generation static grate plates/grate systems. | Improved heat recuperation to handle increased clinker production |
|
| Stable cooler operation | ||
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India’s roads and highways community gathered in full strength at the Jio World Convention Centre, Mumbai, for the 16th edition of the RAHSTA Expo (Roads and Highways Sustainable Technologies & Advancement). Over two action-packed days, the event brought together policymakers, contractors, consultants, developers, equipment manufacturers, material suppliers, technology providers and investors to deliberate on the future of India’s ,infrastructure while showcasing the latest innovations driving the sector.
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Economy & Market
Fornnax Names Lukas Baur as Authorised Service Partner to Bolster EU Operations
Published
3 weeks agoon
July 23, 2026By
admin
Strapline: Fornnax Technology has appointed NOBA Maschinenservice’s Lukas Baur as its authorised service partner for the European Union, strengthening its commitment to delivering fast, reliable, and localised after-sales support across the region.
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Having spent years servicing Eldan, Lindner, and Vecoplan shredders across the European recycling industry, Mr. Baur’s decision to collaborate with Fornnax is rooted in his understanding of market needs and customer expectations. His experience has provided valuable insight into what recycling plant operators require—not only from their machinery but also from the service teams supporting them.
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Concrete
Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint
Published
4 weeks agoon
July 13, 2026By
admin
Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.
Surat (Gujarat)
Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.
Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.
Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.
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The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.
Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”
He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”
Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.
Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.
The Road Ahead Begins Here
Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict
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Fornnax Names Lukas Baur as Authorised Service Partner to Bolster EU Operations
Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa
The Road Ahead Begins Here
Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict
UltraTech Board Approves Rs 50 bn Fundraise Via NCDs
Fornnax Names Lukas Baur as Authorised Service Partner to Bolster EU Operations

