Concrete

Making gains with OKâ„¢ cement mill

Published

5 years ago

October 19, 2021

admin

Since 1982, the OK??vertical roller mill (VRM) has provided the cement industry an energy-efficient, flexible ??both in terms of size and the ability to handle variable feed materials ??and reliable solution for cement grinding. These benefits are ever more relevant today, as cement producers focus on reducing both operating costs and their environmental footprint through the increased use of supplementary cementitious materials added to the mill?? feedstock.

Nowhere are the benefits of the OK mill more appreciated than in the Indian subcontinent, where cement plant requirements vary widely in terms of grinding plant size and capacity to produce multiple cement types in each unit. In 2018 and 2019, a total of 15 VRMs were sold by FLSmidth in the region for raw, coal and cement applications.

The same trend applies to the neighboring countries, Nepal and Bangladesh; one such notable example is the OK 81-6 cement mill at Shah Cement in Bangladesh, which has been certified by Guinness World Records as the world?? largest VRM. The mill is 25.6m tall, weighs in at 1,904 tonnes and features the latest MAAG MAX Drive technology providing 11.6 MW of power. Successfully operating for two years since August 2018, the mill recently exceeded its performance guarantee testing.

??e are proud to have the world?? largest vertical roller mill as part of our operations,??said Hafiz Sikander, Director of Operations, Cement Division of Shah Cement Industries. ??e selected the FLSmidth OK 81-6 mill for its exceptional efficiency and reduced power consumption ??and it is living up to its promise. As the largest single-unit grinding mill in the industry, we expect it to meet our production requirements for many years.??/p>

Variable feed ??but invariably high product quality

Product quality is a function of cement particle size distribution (PSD) and the dehydration of the gypsum within the cement. In the OK mill, parameters such as mill air flow, separator speed and grinding pressure, can be easily adjusted during operation to control or alter the PSD curve to a (steeper or flatter) profile that achieves the desired quality standards. When needed, the PSD curve can match that of an existing ball mill.

The instant adjustability of operating parameters, as well as a short retention time, also means that switching between different types of products can be performed with almost immediate effect. The OK mill has also proven to be effective for grinding blended cements with one or more wet components, not only because of its highly-effective drying performance, but also due to its ability to maintain a stable grinding material bed. As a result, OK mills have been used to grind a wide range of materials from 100 per cent slag with feed containing more than 20 per cent moisture to limestone, pozzolan and fly ash.

Moreover, the OK Mill with ROKSH separator regularly grinds products with fineness above 5500 Blaine, further proving its versatility, as well as its capability for consistent, stable operation throughout a range of cement, blended cement, and slag cement products.

Figure 1: The composition of cement products produced using the OK??cement mill

Lower OPEX and maintenance with the FLSmidth OK??mill

Compared with other VRMs, the OK mill consistently operates with lower airflow and the lowest power consumption. As a result of the patented cement grinding profile and integral ROKSH separator with industry-leading high efficiency, the mill consistently uses 15 to 20 per cent (3 to 5 kWh/MT) less power than other cement VRMs.

The latest mill design adopts mechanical improvements based on actual operating and maintenance practices and the most recent metallurgical developments. A simple layout and fewer number of machines in the mill circuit ensure high run-factor, reduced civil construction costs and low long-term maintenance costs.

Modular design across applications and sizes allows for common spares, including roller assembly, lube systems, hydraulic systems and cylinders, and gear units. It also incorporates design elements in the roller and table profile that improve operating stability and reliability, regularly giving availability of 95 per cent of scheduled operating time. The OK mill can be operated with half of its rollers out of service and still achieve 60 to 70 per cent of the nominal output, minimising risk of lost production due to unplanned stoppages and guaranteeing long-term availability.

The ROKSH separator design has also been improved, allowing producers to achieve better product quality and ease of maintenance. Additionally, internal components have been adapted to improve airflow and mill velocity profile, reducing wear from jet abrasion. New features have also been added to provide easier maintenance access to the static guide vanes and rotor.

A mill to meet the needs of today?? cement producer

??s cement producers continually seek reduced energy consumption and lower maintenance costs, two emerging trends are changing the face of cement production: the increased use of grinding stations that support variable feed materials and more widespread use of vertical roller mills,??said John Terembula, FLSmidth Global Product Line Manager ??VRM. ??ement producers in India, Nepal and Bangladesh have achieved much success relying on the OK mill to meet these needs.??/p>

– Communication by the management of the company

Concrete

Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict

Crisil Sees Margins Easing Despite Steady Demand

Published

2 weeks ago

July 29, 2026

admin

Crisil said operating margins of Indian cement manufacturers are expected to decline by Rs 50-75 per tonne (t) this fiscal to Rs 925-950 per t due to higher input costs triggered by the West Asia conflict. The analysis covered 18 cement companies accounting for nearly 90 per cent of India’s domestic cement capacity and noted margins had improved sharply to around Rs 1,000 per t in fiscal 2026.

Crisil noted that the reduction would be driven mainly by higher power and fuel costs, which account for about 30 per cent of total costs, as petcoke and imported coal prices have surged amid geopolitical uncertainties. Freight costs, which account for about a quarter of total costs, are also expected to remain elevated because of higher diesel prices. The impact on profitability is likely to be more pronounced in the first half of the fiscal year before easing commodity prices moderate cost pressures later.

The rating agency said steady domestic demand and strong balance sheets should keep credit profiles stable despite the moderation in margins. Green energy currently accounts for 35-40 per cent of the sector’s total electricity consumption and is expected to partly cushion higher energy costs. Operating cash flows are likely to remain resilient, supported by projected 6-7 per cent growth in cement demand this fiscal.

Crisil highlighted that demand growth will be driven primarily by infrastructure spending, which meets about one-third of sector consumption, and by a nearly 18 per cent higher budgetary allocation for core ministries that should support project execution. Weaker rural housing demand amid pressure on agricultural incomes from a possible below-average monsoon may be offset by improved urban housing demand supported by favourable home-loan rates and a strong pipeline of Pradhan Mantri Awas Yojana-Urban projects. Ongoing capacity additions will keep capital expenditure elevated and may lift net debt to EBITDA to between 1.2 and 1.4 times from around 1.0 time last fiscal, though ratios are expected to remain healthy.

Concrete

UltraTech Board Approves Rs 50 bn Fundraise Via NCDs

Company to issue half a million debentures for expansion plan

Published

2 weeks ago

July 28, 2026

admin

UltraTech Cement’s board of directors has approved raising Rs 5,000 crore (Rs 50 bn) through non?convertible debentures issued in rupees.

The finance committee cleared a proposal to issue up to 500,000 fully paid, unsecured, listed, rated, redeemable, rupee?denominated, non?convertible, non?cumulative debentures of Rs 1 lakh each (Rs 0.1 mn each), aggregating to the Rs 5,000 crore programme.

As of June 2026 the firm reported net debt of Rs 15,875 crore (Rs 158.75 bn) and said its capacity expansion projects under execution are backed by capital expenditure of about Rs 17,000 crore (Rs 170 bn) over the next two to two?and?a?half years.

UltraTech spent Rs 9,500 crore (Rs 95 bn) on capital expenditure in financial year 2026 and in April the group crossed 200.1 mn tonnes per annum of domestic grey cement capacity and 205.5 mn tonnes per annum of global capacity.

The chief financial officer indicated the company would take consolidated capacity beyond 242 mn tonnes per annum, with grey cement capacity reaching 212.7 mn tonnes per annum by the end of financial year 2027. He noted the net debt?to?earnings before interest, taxes, depreciation and amortisation ratio stood at 0.87 times as of June 2026 and the company was confident of ending financial year 2027 with the ratio below one time.

In the first quarter of financial year 2026?27 UltraTech’s net profit attributable to owners rose 16.8 per cent year?on?year to Rs 2,599.3 crore (Rs 25.993 bn) and revenue from operations increased 15.9 per cent to Rs 24,648.20 crore (Rs 246.482 bn). The board approval is expected to complement internal cash flows as the company advances its expansion programme.

Concrete

Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa

Line-2 expansion to make Kadapa a major cement hub

Published

3 weeks ago

July 20, 2026

admin

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.