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Failures can be avoided by selection of right quality of refractory bricks

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– Sumanta Mukhopadhyay, Head’ Sales & Marketing, Cement Business Unit, Dalmia-OCL

Kiln being the heart of the plant, what kind of products you are offering for it? What different kind of bricks you offer for the cement industry?
We offer bricks and castables for the entire pyro system of cement manufacturing process. This includes the preheater, calciner, kiln, cooler and tertiary air duct. In preheater area, the charge is heated up. This part consists of various stages of cyclones and ducts. Both brick and castables are used for lining the preheater area. Calciner is the equipment, which heats up the charge in the preheater. This is also lined with both bricks and castables. Kiln is the heart of the pyro process where charge gets converted into clinker. This is lined entirely with bricks. Castable is used only in two areas ‘ tip casting and burner lance. Cooler and tertiary air duct are the last parts of the pyro system. Both are lined with both bricks and castables.

Please elaborate on different types of bricks used in a rotary kiln.
Brick selection for a kiln depends on factors such as kiln size and production load on the kiln. For large kilns with high production loads, [sometimes] it is necessary to use basic bricks in the burning zone. Different qualities of alumina bricks are used for the rest of the kiln. Kilns with moderate production loads are generally lined with special alumina and normal alumina bricks. Nowadays, increasing usage of alternative fuels pose challenges like coating formation, ring formation, etc. Special alumina bricks are available to solve specific problems. Special bricks of very low thermal conductivity are used towards inlet area to reduce heat losses due to thermal radiation.

Dalmia-OCL manufactures specialised range of bricks for cement kilns. Our product range includes basic bricks, special alumina bricks, normal alumina bricks as well as castables for tip casting and burner lance. We study the process and offer optimised lining concepts for maximising refractory performance.

What is the life expected at burning zone as a thumb rule?
Normal life expectancy for burning zone is about one year. Cement plants want to take only one shutdown in a year when the burning zone bricks are changed.

What can be the general causes of failure? How it could be avoided?
Performance of refractory broadly depends on three factors ‘refractory selection, installation and usage conditions. Assuming first two conditions were fulfilled as per requirement, the various stresses in usage condition cause refractory failure, such as chemical, thermal or mechanical.

Most common chemical stresses come from alkali or sulphur vapours present in the kiln atmosphere. Bushy burner flame, improperly centred burner flame or unstable coating condition might cause thermal stress on the refractories. Shell deformation, shell ovality at tyre area or axial thrust near retainer area might cause mechanical stress on the lining.

Failures can be avoided by selection of right quality of refractory bricks or castables with sufficient resistance towards the stress expected at the area of usage. Proper installation procedure and stable usage conditions also help to avoid unforeseen stoppages due to refractory failures. Every stoppage is stressful for the refractory lining. Continuous kiln operation always ensures better lining life.

Tell us something about the coatings formed on brick lining in the burning zone. How is it formed?
Most common and desirable coating in the burning zone is cement clinker coating. Liquid phase starts appearing the upper transition zone as a part of clinker formation. Charge gets mixed with this liquid and forms semisolid mud like substance, which sticks to the refractory lining in the burning zone. This coating is desirable as it reduces thermal radiation from the kiln, thereby saves fuel and also protects the burning zone bricks from getting exposed to flame.

There is another type of coating that is undesirable. Nowadays most of the kilns are being fired with pet coke, which contains 6 to 8 per cent sulphur. This sulphur reacts with lime and forms calcium sulphate or sulphur spurrite at the calcining zone. Very often deposition of sulphur spurrite on the calcining zone tends to form a dam ring blocking smooth passage of charge from inlet to the burning zone. Often kilns need to be stopped to break the dam rings manually and normal operation is hampered.

What types of refractories are used in preheater and calciner?
Preheaters and calciners are lined with both alumina bricks and castables. Preheaters have cyclones located at different stages from bottom to top, which are connected by ducts. Conditions are more severe towards the bottom where temperatures are higher and atmosphere is laden with dust particles therefore more abrasive for the refractories.

Chemical corrosion is also higher at the bottom cyclones as different gases coming out from kiln inlet try to go up the preheater; get mixed with charge coming down the preheater and go back to the kiln along with charge. Therefore bottom cyclones and ducts need to be lined with superior quality of bricks and castables having high resistance to chemical corrosion and abrasion. Usage condition is comparatively less severe as we go up the preheater towards the top.

Similarly superior grades of alumina bricks and castables are used in the calciner where pet coke and alternative fuels are generally fired to calcine the charge inside the preheater. Temperature in this area often ranges from 900 to 1,100 degree Celsius. Lining should therefore have high refractoriness as well as high resistance to chemical corrosion.

What kind of refractories is used for coolers?
Both alumina bricks and castables are used in the cooler area. For cooler, most critical part is the area towards the kiln. These include the front wall, bull nose and first compartment area. Here temperature and abrasion both are much higher than the rest of the cooler. Very special quality alumina bricks and castables with high resistance to thermal shock and abrasion are used in critical zones of the cooler. Depending on severity of working condition, refractories are selected for the rest of the areas.

Anywhere in the plant if refractory bricks are used? What is the location and application?
Insulating bricks are generally used in the kiln from calcining zone to inlet area to save fuel by reducing heat losses.

What is tip casting and what kind of refractories are used for it?
Tip casting refers to the tip of the kiln at the outlet side. Generally this area is fitted with outlet sector plates. This area being outermost part of the kiln is highly prone to thermal shock at every stoppage. It also undergoes continuous abrasion from falling clinkers and dust laden secondary air. Generally silicon carbide or and alusite-based castables having high refractoriness; thermal shock resistance and abrasion resistance are selected for this area.

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Economy & Market

Power Build’s Core Gear Series

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

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Economy & Market

Conveyor belts are a vital link in the supply chain

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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.

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Economy & Market

Impactful Branding

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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.

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