Product development
Basic Refractory Bricks for Cement Kilns
Published
9 years agoon
By
admin
With given options, choice of refractories is extremely important for smooth running of the kiln. Obvious choice has been basic bricks. Made in India Basic Refractory Bricks for Cement Kilns
Cement manufacturing has under gone a sea change in the recent past. The wet process which had been the main technique until 1960 has been replaced by dry process. The dry technique with suspension Preheater and later by Preheater with Precalciner helps deal with increased demand in production and energy efficiency requirements, both of which impact refractory selection.Changing trends:
To meet the growing demand of cement world over, particularly in Asian countries, cement manufacturers are under tremendous pressure to increase production at a competitive cost. They now need a longer life of the kiln, with minimum down time and low specific energy consumption. The cement industry has been able to achieve this by installing multistage Preheater with Precalciner upstream of the cement rotary kiln, which has led to transferring the Preheating and calcining reaction from the kiln to the Preheater and Precalciner. The shortened kiln now needs a balanced one-year life to meet the growing demand with minimum energy cost. Further, to decrease fuel cost, cement manufacturers are focusing towards alternative fuels like pet coke, used tyre, oil sludge, municipal waste etc. These and a variety of other influences affect refractories in cement rotary kiln, causing a chemical, mechanical and thermal loading of the lining. To achieve high performance of refractories in the rotary kiln, it is therefore necessary to have a proper understanding of the quality of bricks and location of the bricks in the kiln.Basic refractory bricks from the Indian refractory pioneer:
Refractories for the cement industry have also progressed with the changing manufacturing techniques. Conventional alumino silicate refractories have made way for more sophisticated basic refractories to cope up with energy efficient ways of manufacturing and to deal with increase in cement production. Increase in demand of clinker production, results in high thermal, thermo mechanical and pyro chemical load, which ordinary refractory bricks fail to stand and need frequent replacement. Since past five decades, basic bricks have been used to line cement kiln where they have proved to be over three times more durable than conventional high alumina bricks.
Dalmia Refractories, a part of the USD 1.5 billion Dalmia Bharat Group has been a pioneer in the entire range of alumino silicate and alumina bearing refractories for the past six decades. With its advanced R&D facilities and dedicated refractory design, application and management teams, Dalmia serves cement customers across the country. Now, with the integration of OCL Refractories, a pioneer in Basic bricks, with the Dalmia Bharat Group, Dalmia Refractories provides the entire range basic bricks apart from tailor made refractory solutions. The India Advantage:
For top-quality, high-performance Basic Refractory Bricks for cement rotary kilns in India, so far there was no choice but to turn to imports. Aside from currency related challenges, this also meant that the plant had to maintain unusually high inventories to protect against unforeseen delays or disruptions in the midst of long delivery cycles. The result – higher-than-necessary investments and poor cost-benefit scenarios. The damage to the inventory due to hydration during prolonged storage could also not be denied.
Dalmia has effectively addressed these challenges by being the only Indian company now to make these top-quality bricks right here in India. Made from imported raw material at OCL Refractories’ state-of-the-art manufacturing facility at Rajgangpur, Odisha, Dalmia’s ‘Made in India’ basic refractory bricks are at par with the best in the world in terms of quality, finish and performance.
More importantly, customers now have the option to choose to lower and unlock their investments, pay in local currency, manage inventories smartly thanks to shorter local delivery cycles. And last but not the least, customers can get faster service support in view of the geographical convenience, all of which are impediments in the case of imported bricks. The Dalmia-OCL range of Basic refractory bricks includes:
1.Magnesia Alumina Spinel bricks – Made from high-purity SWM/DBM/FM (Sea Water Magnesite/Dead Burnt Magnesite/Fused Magnesite) and sintered/fused spinel, the environment-friendly Magnesia-Alumina Spinel refractory bricks are available both with and without special additives. These bricks are best-suited for application in burning and transition zones of a cement rotary kiln operating under severe conditions with high thermal loads.
2.Magnesia Alumina Spinel bricks with Zirconia – Made from high purity Magnesia, Spinel and Zirconia, these bricks are highly suitable for Burning zones characterised by very high salt infiltration and thermal loads. Their special composition and resulting properties also make them highly suitable for kilns making clinker for white cement plants.
3.Magnesia Chrome bricks – Due to their superior coating ability and high structural flexibility, these bricks are always in much demand for Burning and Transition zones. Special high-iron bearing chromite is added to ferrite-bonded Magnesia to achieve the unique properties of these bricks, including corrosion resistance to clinkering phases and alkali salts infiltration.
4.Chrome free bricks – Manufacturers across the world today are shifting to materials and processes that are environmentally friendly. Refractory technology is also continuously evolving in line with this focus on sustainability. Chrome-free basic bricks are a welcome result of this evolution.
5.Magnesia Hercynite bricks – Dalmia-OCL’s environment-friendly Magnesia-Hercynite refractory bricks are made from special ferrite-bonded Magnesia & fused Hercynite. These bricks are best-suited for Burning and Upper Transition zones of a cement rotary kiln operating at moderate thermal loads.
Overall, these bricks made from high purity Magnesia and Alumina with special additives help in effectively preventing alkali sulphur attacks, corrosion to clinker melt, along with good coating abilities, high structural flexibility, high resistance to thermal and structural spalling. These extend the refractory service life and help cement manufacturers optimize their production without worrying about importing and storing expensive bricks from foreign manufacturers.
Author Dr. B Mishra, Head – R&D, Dalmia Refractories Limited.
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Economy & Market
Conveyor belts are a vital link in the supply chain
Published
8 months agoon
June 16, 2025By
admin
Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.
In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.
Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.
How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.
How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.
What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.
How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.
What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.
How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.
What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.
Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.
Our strategy is to establish reliable local partnerships
Power Build’s Core Gear Series
Compliance and growth go hand in h and
Turning Downtime into Actionable Intelligence
FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe
Our strategy is to establish reliable local partnerships
Power Build’s Core Gear Series
Compliance and growth go hand in h and
Turning Downtime into Actionable Intelligence


