Concrete

Making gains with OKâ„¢ cement mill

Published

5 years ago

October 19, 2021

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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

Andhra Pradesh Clears Rs. 30 bn My Home Cement Plant

Project receives incentives of up to Rs. 11.29 bn from state

Published

8 hours ago

September 30, 2026

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The Andhra Pradesh government has approved a greenfield cement project worth Rs. 30 bn by My Home Industries, along with incentives of up to Rs. 11.29 bn. The decision comes amid a political controversy in Telangana involving allegations about landholdings associated with My Home Group.

According to an Industries and Commerce Department order issued on September 25, 2026, the project is expected to create 2,000 jobs and begin commercial production by March 2029. The proposed facility will have capacity to produce 3.5 MTPA of clinker and 3.5 MTPA of cement.

The total investment includes fixed capital investment of Rs. 25.97 bn, pre-operative expenses of Rs. 2.23 bn, contingencies of Rs. 1.26 bn and working capital margin of Rs. 540 mn. The incentive package is capped at Rs. 11.29 bn, equivalent to up to 43.48 per cent of fixed capital investment, subject to completion of the committed investment by March 2029.

The package includes a capital subsidy of 39 per cent of eligible fixed capital investment, capped at Rs. 9.43 bn, payable over 10 years from the start of commercial production. It also provides reimbursement of Rs. 1 per unit on electricity purchased from distribution companies for 10 years, subject to a ceiling of Rs. 1.86 bn. A further incentive equivalent to 2 per cent of fixed capital investment is linked to the creation of the committed jobs and other policy conditions.

The state has approved the allotment of 27.19 acres through the Andhra Pradesh Industrial Infrastructure Corporation at actual cost. The project also involves land linked to two temples and the realignment of a canal across approximately 9.93 acres, with conditions requiring alternative temple facilities and company-funded infrastructure work. Telangana Chief Minister A. Revanth Reddy has separately raised allegations concerning land associated with My Home Group, including 2,463 acres near Shamshabad. The allegations remain subject to verification through official records and any investigations.

Concrete

Nuvoco Vistas, CleanMax Partner for Wind-Solar Hybrid Project in Rajasthan

Published

1 day ago

September 29, 2026

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The project – comprising 20 MW of wind and 26.4 MWdc of solar capacity – will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy.

Mumbai, September 29, 2026

Nuvoco Vistas Corp Ltd, part of Nirma Group and one of India’s leading cement companies, has partnered with Clean Max Enviro Energy Solutions Limited (CleanMax), a renewable energy solutions provider for the commercial and industrial (C&I) sector, to develop a 46.4 MW wind-solar hybrid renewable energy project in Rajasthan.

The project will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy. It is expected to increase the share of renewable energy in Nuvoco’s power mix, reducing fossil fuel consumption and associated emissions.

Developed by CleanMax, an Independent Power Producer (IPP), at Bhikamkhore, Rajasthan, the project will comprise 20 MW of wind capacity and 26.4 MWdc of solar capacity, along with a 2-MWh Battery Energy Storage System (BESS). Power generated from the facility will be supplied to Nuvoco through the State Transmission Utility (STU) Open Access network.

The hybrid project is expected to generate approximately 100 million units (MU) of renewable electricity annually and help avoid around 1,25,485 tonnes of CO₂ emissions every year across Scope 1 and Scope 2 emissions.

The initiative supports Nuvoco’s ongoing efforts to reduce the carbon intensity of its manufacturing operations through renewable energy adoption, Waste Heat Recovery Systems (WHRS), energy-efficiency measures and increased use of alternative fuels. It also aligns with the company’s DIRE (Digitalisation, Innovation and Renewables) agenda, which focuses on climate action, renewable energy transition, water stewardship, circularity and biodiversity conservation across its manufacturing ecosystem.

Commenting on the initiative, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said, “This marks an important step in advancing Nuvoco’s journey towards more sustainable and resilient operations. Our collaboration with CleanMax will increase the share of renewable energy across our Rajasthan operations, strengthening our energy mix while improving long-term cost efficiency and reducing our dependence on conventional power sources. Initiatives such as these reinforce our commitment to operational excellence and responsible growth, while supporting our vision of Building a Safer, Smarter and Sustainable World.”

Kuldeep Jain, Founder and Managing Director, CleanMax, said, “Cement plants run continuously, so the power behind them has to be dependable for decades, not years. We’re seeing manufacturing industries view clean energy as an integral part of their core operations and long-term strategy. Our partnership with Nuvoco reflects that shift, and we’re pleased to support its decarbonisation journey. This wind-solar hybrid project is designed to deliver long-term cost certainty while supporting the Company’s transition to cleaner power.”

Nuvoco has been advancing its sustainability initiatives through renewable energy, operational efficiency and technology-driven solutions. The company operates across Cement, Ready-Mix Concrete (RMX) and Modern Building Materials (MBM) segments, with a presence across East, North and West India.

The company began operations in 2014 with a greenfield cement plant in Nimbol, Rajasthan, and later acquired Lafarge India Limited, which entered India in 1999, along with Emami Cement Ltd in 2020 and Vadraj Cement Limited in April 2025. With planned expansion initiatives, including a new grinding mill at the Arasmeta Cement Plant and multiple debottlenecking projects, Nuvoco aims to achieve a cement capacity of 35 MMTPA.

The company reported total income of Rs 113.62 billion in FY 2025-26, reflecting its continued growth trajectory. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem brands, while its RMX business offers products under Concreto, Artiste, InstaMix, X-Con and Ecodure brands. Nuvoco also provides construction solutions under its Zero M range of modern building materials.

Concrete

UltraTech Unit Runs Entirely on Green Energy

Kukurdih Cement Works meets its full electricity needs through green energy.

Published

1 day ago

September 29, 2026

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UltraTech Cement has achieved a decarbonisation milestone, with its integrated Kukurdih Cement Works in Chhattisgarh meeting 100 per cent of its electricity requirement through green energy every month since April 2026.

Commissioned in 2024, the plant has an installed grey cement capacity of 3.3 million tonnes per annum. It meets its entire electricity requirement through a combination of renewable power sourcing and Waste Heat Recovery Systems (WHRS), while maintaining operational reliability.

Since April 2026, nearly a third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements. Five units, including Kukurdih Cement Works, have exceeded 95 per cent green energy utilisation.

UltraTech is also progressively deploying Battery Energy Storage Systems (BESS) across its manufacturing network to enable deeper integration of renewable energy. The company has not invested in new captive thermal power capacity for greenfield projects or brownfield expansions at its integrated units for more than a decade.

As of Q1FY27, UltraTech’s captive green energy capacity stood at 1,897 MW, comprising 1,463 MW of renewable capacity across solar, wind and hybrid sources, and 434 MW of WHRS capacity.

Under its RE100 commitment, UltraTech aims to increase green power’s share in its total power mix to 85 per cent by 2030 and 100 per cent by 2050.