15 December 2018

Table of Contents for Cement & Cement Equipment

Cement & Cement Equipment

Cementing developmental prospects


Cement has been an integral part of the construction industry since decades and the phenomenon will continue as the established and new age players are bringing new age materials, equipment as well as technologies to make it more long-lasting and most importantly sustainable. While India will rise in construction activities globally, the companies would need to ascertain that they also ace the technology and automation and offer industry newer & green cement expanse by upping its R&D capabilities significantly reports Prerna Sharma.


Today, cement represents a vital commodity for the fast-growing economies. It is widely used in the production of concrete, which is a key building material for mass constructions such as civil works, dwellings and industrial estates. According to IMARC Group, the global cement market reached a volume of around 5 billion tonne in 2016, growing at a CAGR of around 7 per cent during 2009–2016. As cement manufacturing is an energy intensive process and becomes uneconomical if transported over long distances, most of the countries now have their own production units and only a limited quantity of cement is currently being traded in the global market. Factors such as increasing urbanisation and industrialisation are currently fueling the growth of the global cement market. The report finds that a continuously rising global population coupled with an increase in the number of nuclear families are resulting in a huge demand for shelter and infrastructure, thereby strengthening the global demand for cement.


Another report from Technavio states that in terms of geography, APAC accounted for the majority market share during 2016 and will continue to dominate the market for the next four years. Some of the major factors responsible for the market's growth in the region is the increasing number of construction projects with the growing number of development projects, environmental regulations on the emission of carbon dioxide and NOx gasses, and the use of alternative fuels such as hydroelectric power in the production of cement and concrete. IMARC Group reports that China currently dominates the global cement market accounting for the majority of the total global consumption. China is followed by India, the United States, Brazil, Iran, Vietnam, Russia and Turkey. China National Building Materials (CNBM) currently represents the world's largest player followed by Lafarge Holcim, Anhui Conch, Jidong Development and Heidelberg Cement.The portland cement segment accounted for the majority market share during 2016 and will continue to dominate the market for the next four years. One of the major factors responsible for the market segment's growth is the increasing use of portland cement more than the other types of cement in various construction activities.






India’s total cement production capacity is nearly 425 million tonnes, as of September 2017. The growth of cement industry is expected to be 6-7 per cent in 2017 because of the government’s focus on infrastructural development. The industry is currently producing 280 MT for meetings its domestic demand and 5 MT for exports requirement. The country's per capita consumption stands at around 225 kg. The Indian cement industry is dominated by a few companies. The top 20 cement companies account for almost 70 per cent of the total cement production of the country. A total of 210 large cement plants account for a cumulative installed capacity of over 350 million tonnes, with 350 small plants accounting for the rest. Of these 210 large cement plants, 77 are located in the states of Andhra Pradesh, Rajasthan and Tamil Nadu.On the back of growing demand, due to increased construction and infrastructural activities, the cement sector in India has seen many investments and developments in recent times.According to data released by the Department of Industrial Policy and Promotion (DIPP), cement and gypsum products attracted Foreign Direct Investment (FDI) worth $5.25 billion between April 2000 and September 2017.






Riding on the back of growing construction activities, leading companies are eyeing expansion and are investing heavily into the development of the cement industry. Some of the recent investment portfolios are:


Emami Ltd, a fast-moving consumer goods (FMCG) company, plans to invest around `8,500 crore ($1.32 billion) to scale up its cement production capacity from 2.4 million tonnes (MT) to 15-20 MT in the next three to five years. Meanwhile,UltraTech Cement has got the go-ahead for its limestone mining project in Bhavnagar district, Gujarat that would entail an investment of about `60 crore, as per official documents. The proposal is to mine limestone in a lease area of 632 hectare with production capacity of 2.07 million tonne per annum (TPA). Total mineral reserves are 63.58 million tonne and life of the mine is 32 years. UltraTech Cement, the Aditya Birla Group firm, is the largest cement producer in India with the production capacity of 68 million tonne per annum. Additionally, the company will be setting up a 3.5 mtpa integrated cement plant at Pali, Rajasthan, at an investment of around `1,850 crores. Commercial production from the plant is expected to commence by June 2020. This plant is being set up in one of the fastest growing markets in the country and the highest cement consuming State in the North Zone. It will cater to the markets in western Rajasthan where UltraTech does not have a significant presence.With this expansion UltraTech will have a foot print across the country with 50 plant locations, alongwith 103 ready mix concrete plants, committed to supporting the growth of the nation.


Recognised as one of the country’s most trusted names, ACC is a Consumer Super Brand, with a unique track record of innovative research and product development. The brand ACC is a hallmark of quality and durability in cement and ready mixed concrete to build homes for the masses of India in its cities, towns and villages as well as enduring structures for infrastructure and industry.ACC Gold is the only one of its kind, specially formulated cement with high quality water repellent properties. ACC Gold is a result of minutely controlled process changes under sustainable environment along with adjustments in the input raw material dosage in order to get the desired water repellent properties.ACC Foundation To Roof (F2R) is manufactured at a world class manufacturing facility, designed to withstand the attack of salt and toxins. The use of blast furnace slag, which is a byproduct of the steel industry, as a supplementary cementitious material, enhances the durability of the structures and helps building long lasting homes.


JSW Cement recently inaugurated its 2.4 million tonne per annum (mtpa) manufacturing unit at Salboni in West Bengal.The state-of-the-art manufacturing unit will produce eco-friendly PSC cement for Eastern markets. The inauguration of JSW Cement's Salboni unit underscores JSW Group's commitment to West Bengal's economic growth and the state's emergence as India's leading manufacturing and business hub.Commenting on JSW Cement's commitment to stay invested in West Bengal, Parth Jindal, MD, JSW Cement said, “The Salboni unit supports our nation-building goals. Today's inaugural function marks a significant milestone for both JSW Group and West Bengal. West Bengal has been a preferred state for setting up one of our biggest cement manufacturing units. We are committed to stay invested in this state and are in fact planning to increase the capacity of our Salboni cement unit to 3.6 mtpa. This will not only mean additional investments but also create new employment opportunities and community initiatives at Salboni.”


Meanwhile, it recently commenced manufacturing of Heavy Duty Concreel HD cement at its 2.2MTPA Dolvi Unit Maharashtra to fulfil demand for Concreel HD in the western belt. In the initial phase, Concreel HD will be available in the Mumbai, Thane, Navi Mumbai and Raigad region and then covering the rest of Maharashtra including key cities of Pune, Nasik, Ratnagiri, Satara in the initial months of 2018. Concreel HD provides exceptional early and final strength along with quick setting, thus making it ideal for strength bearing applications such as beams, columns, slabs and foundations. A result of world class manufacturing process, Concreel HD is an environmentally friendly product with improvedchemical resistance and superior cohesion, thereby providing more durability and increased safety to your structure.JSW Cement has been doing very well in the South and to add to its excellence JSW Cement has launched theConcreel HD cement, which will help the company to add more to its turnover which will in turn help the company togrow leading to its expansion and diversification.


JK Cementis also planning to add up to 8 million tonne per annum (MTPA) capacity in the next five years, taking the total installed capacity to around 18 MTPA for grey cements, said a top company official.The company is planning to expand to 3.5 to 4 million tonne in brownfield and greenfield projects separately. The JK Organisation group firm would also invest around `1,200-1,500 crore in brownfield expansion at its Mangrol facility in Rajasthan in the next 24-30 months. Rajnish Kapur, Business Head, JK Grey Cement, said, “We are looking, in the next 4-5 years to add at least 7-8 million tonne to our capacity and go from 10.5 MTPA to 18 -19 MTPA. Now we are looking at a couple of options which we have in grey cement business. We are looking in terms of brownfield expansion at our existing plants to 3.5 to 4 MTPA.”


Ambuja Cements Ltd has launched an innovative green building offering– Ambuja Plus Cool Walls – for Individual Home Builders (IHBs) in Surat. The revolutionary product with ‘Heat Barrier Technology’ ensures maintenance of a 5°C temperature difference indoors; no matter how hot or cold the external temperature is, thus saving energy. The offering is made of heat-resistant concrete blocks and Blockol – Block JointingMortar - for joining these blocks.Traditionally, clay brick walls need to be cured, whereas, Ambuja Plus Cool Walls doesnot require curing, thereby saving huge quantities of water during the constructionprocess; and also reduces the hassles faced by the consumer.


Specifically engineered for high-impact concrete applications and served in revolutionary BOPP Laminated packaging, Dalmia DSP is not only a first-of-its-kind in the country, but also a quality-leader in the premium category of cements.Manufactured at ultra-modern plants, Dalmia DSP comes loaded with Delta 25 Power and is passed through stringent quality parameters. It is a premium-quality slag cement produced from high-grade Portland cement clinker, imported gypsum and superior ground granulated blast furnace silica rich slag (GGBS) obtained from the most reputed steel manufacturers of the country. This not only ensures optimal particle size (fineness), ease of working and the best setting time, but also the highest level of strength, making Dalmia DSP the best choice for casting.


Dalmia DSP Cement utilises Ground Granulated Blast Furnace Slag (GGBS), a by-product of steel manufacturing process, which otherwise would have to be disposed into the environment. The process is recognized by Leadership in Energy and Environmental Design (LEED) for improving sustainability of a project. Use of GGBS also makes the resultant cement less exothermic, enabling more time for casting of concrete. The utilisation of slag not only lessens the burden on landfills, but also reduces air emission at steel plants through the granulation process. It also directly impacts the environment, by considerably reducing greenhouse gas emissions. For instance, one tonne of Slag cement emits approximately one ton of carbon dioxide less than what is emitted by one ton of Portland cement. The manufacturing process also involves 90 per cent less energy consumption to produce one tonne of slag cement than to produce an equal quantity of Portland cement.






The global cement mixer market will grow steadily at a CAGR of almost 11 per cent by 2020 as per reports. Renewed thrust on construction activities worldwide is one of the primary growth factors for this market. Increasing government initiatives to encourage manufacturers to use energy-efficient equipment and materials for the production of cement and concrete will aid in the growth of the market. Additionally, the rapid urbanisation in emerging regions such as APAC and Latin America also aid in increasing the demand for cement mixers. The APAC region consists of major emerging markets such as China, India, Indonesia, Malaysia and Vietnam where the construction market is growing at a rapid rate. The increased focus on the development of transportation networks to encourage cycling and the use of public transports in Europe and the focus of the Americas to renovate and expand existing public infrastructures will contribute to the growth of the market. Moreover, the increasing investments towards the development of smart cities and renovation projects of existing cities in all major countries across the globe will also have a positive impact on the growth of the concrete mixer market in the next four years. Used for decades in all types of construction, the traditional concrete Hollow / Solid block Machine has evolved to levels never before seen. The production of concrete blocks today, with the greater variety of forms, sizes, textures and colours allows concrete Hollow / Solid block manufacturers, architects, engineers and builders to combine them to achieve spectacular aesthetic effects with significantly lower costs than other building products. High Strength, low cement consumption, dimensional accuracy and uniform density are the salient features of concrete blocks made on Columbia Machines. Due to the unique vertical mould vibration technology, concrete blocks made on Columbia Machines are superior to those made on German concrete Hollow block making machines or China / Chinese concrete Solid block making machines.


NMF Equipments& Plants offers wide range of special design mixers that are specially designed to conform to different industrial needs. These are compactly designed and fabricated using qualitative material and are durable, high in strength and performance and low in maintenance. Available in various capacities, these are ideal for blending various materials. Tested on various quality parameters, its range of mixers are customised as per the specifications given by client. The company also offers offering Solid Storage Silos that are fabricated from qualitative steel and are acknowledged for their long working life, less maintenance, easy installation, ability to eliminate cross contamination and portability. These flat bottom silos are offered in varying capacities, diameters and configurations and is used in diverse areas for the purpose of storing of bulk material. Made as per the international standards, these are being tested stringently on various qualitative parameters.


To determine the fineness of cements, pozzolanas and other powdery materials, various international specifications recommend the use of ‘specific area’ method. Air Permeability Apparatus (Blaine Type) from AIMIL Instrumentation & Technology determines the specific surface as total surface area in cm2/g of material. Similarly, Supertech International manufactures and supplies a varied range of cement plant machinery for its clients. It is a single stop for all kind of cement plant machinery that are required to set up a cement plant – right from site selection, basic/detailed equipment engineering and design, manufacturing key components, procurement of bought-out items, project planning and monitoring, erection and commissioning, etc. Itscement plant machinery optimises the use of power and fuel, which makes the production process highly efficient. The company also implements turnkey cement projects for cement plants, clinker grinding units, slag cement grinding units, slag grinding project rotary kiln cement plants and vertical shaft cement plants. Compared with other kinds of crushers, CS Series spring cone crusher from Shanghai MIN is quite excellent in hard material crushing and the final product has good sharp. The innovations like stable lubrication system and excellent sealing system evidently reduce the production cost, thereby achieving the highest level of profitability. It has high yields and high grade final products. With grease seal and upstage sealing element imported from Japan, it provides sturdy guarantee for long-playing stable operation of machine.


Overload protective system can effectively ensure safety of crusher. Easy to control discharging size by using different crushing cavity and adjusting device.CS series cone crusher is applied to cement mill, mining, building construction, road &bridge construction, railway construction and metallurgy and some other industries. Materials like iron ore, granite, limestone, quartzite, sandstone, cobblestone and some others are easily crushed by cone crusher.


Chanderpur Group (CPG) holds deep domain knowledge of the industry and is equipped to offer customised service that are directed to meet the needs of clients from cement plants. CPG delivers reliable cement projects execution for cement plants using advance cement machineries. With the manufacturing of individual components of cement plants and with fabrication, installation & commissioning of entire cement plant, the Cement Division of CPG has supplied & commissioned more than 300 cement plants. The company executes turnkey cement projects for cement plants, rotary kiln cement plants, vertical shaft cement plants, clinker grinding units, slag cement grinding units and slag grinding project. For successful implementation of turnkey cement projects, they conduct various types of project development studies, feasibility studies, cement project consultant etc. These are followed by engineering, procurement & construction management (EPCM) services. The team supervises the construction, commissioning along with offering start-up and post start-up services. They have also upgraded existing cement plants for better productivity and energy savings and have already supplied to various cement projects in India, Latin America, Africa and other countries in Asia. Plant design and fabrication / construct are made to suit the conditions where the plant is to be installed. Likewise, Promac can supply most modern technology cement plants with TEC’S RSP (Reinforced Suspension Pre heater)/DDF(Dual Combustion & Denitration Furnace) Calciner and Asano Vertical Roller Mills for limestone and coal grinding, targeting the total power consumption @ 80 – 100 Units/ Tonne of Cement and fuel consumption in the range of 700 – 800 K-Cal/Kg. Clinker.


With its Clean Technology solutions, KHD Humboldt Wedag offers innovative products and services that are not only energy efficient but also environmentally friendly. They claim to be the first to introduce many developments in the cement industry, including the world’s first pre-heater tower and, more recently, energy efficient Comflex modular grinding system. Comflex is a modular, compact and multitalented grinding solution for the cement and minerals industry. It is used for finish and semi-finish-grinding of raw materials, cement and slag. This new grinding system combines well proven KHD technologies: Roller Press with Swing Frame for easy and fast roller change and a tailor-made separating unit, taking care of separating, drying and conveying. The System enables production rates of more than 1000 t/h raw meal and 600 t/h cement to fit large kilns with single grinding units. COMFLEX® features high flexibility for wide range of applications and product qualities, lowest energy demand and favorable particle size distributions. Contrary to other grinding systems, with Comflex at least 50 per cent of the grinding capacity is available during maintenance of grinding tools. Open troughed belt conveyors from Beumer Group transport bulk goods for cement manufacture quickly across large distances and rough terrain, e.g. from the quarry to the cement plant. The narrow curve radii and long centre distances permit large mass flows, particularly where heavy and solid materials are involved. This makes Beumer troughed belt conveyors every bit as economical as they are flexible, and they pay for themselves quickly thanks to the low investment cost. The ef¬ficiency of the troughed belt conveyors can be increased still further thanks to energy recovery on downward slopes: this means the motors can be operated in motor-driven or in regeneration mode, and adjustably, to permit optimum load distribution over the drive unit under different operating conditions. The electrical energy that is recovered is fed back into the grid via a feedback unit, which helps keep the overall system costs down.


AMCL Machinery offers complete solutions in the field of cement and raw material grinding by undertaking brownfield expansion projects and split location grinding units. The vertical roller pre-grinding mill (VRPM) by AMCL ensures to reduce specific power consumption and substantially increase the production for all capacity Ball mills. AMCL signed a co-operation agreement with Hefei (CNBM) for supply and installation of roller press in India on exclusive basis to cater greenfield projects. The state-of-the-art three lobe positive displacement blowers are manufactured by incorporating the technical expertise from Unozawa Gumi Iron & Works, Japan. The three lobe blowers are known for its high efficiency, long service and uniform pressure and are commonly used for cement Kilns firing system. AMCL has contributed significantly in the field of energy conservation by designing and installing systems to save electric energy and increase in the outputs.




By 2020, Gartner analysts predict there will be 526 million pieces of manufacturing equipment capable of communicating through sensor-enabled networks, with 90 million of those designed specifically for the mining industry. In fact, the predicted 25 per cent annual growth rate of connected mining products is among the fastest of the industries tracked by Gartner. These connected machines stream health and status data, which is captured by other machines or by monitoring systems. Should the data fall outside of normal parameters, alerts are triggered, allowing workers to immediately resolve the problem, or in some cases prompting the equipment to self-adjust. Real-time issue resolution or problem identification can save significant time and money.Traditionally, many cement plants have relied on either expert systems, or PID control for kiln optimization. Both have become dated technologies that struggle to show information holistically and can only provide information about current conditions.PID controls operate with a single variable in and a single variable out. Disturbances are reacted to and cannot be predicted. And, expert systems require a lot of maintenance or operator oversight to function properly. We have learned that there’s a better way. Model Predictive Control (MPC) from Rockwell Automation is a modern control strategy based on a holistic view of key process variables and their interdependencies: multivariable in and multivariable out. It has the capability to compensate for process delays, disturbances, interactions and non-linearity.With MPC technology, you can achieve a complete view of the full life of clinker production by putting in place dynamic predictive models. Monitoring and controlling production like this can significantly increase kiln stability, overall production rate, and reduce material losses as well as energy costs per ton of final product. Furthermore, real-time visibility of production and energy metrics compared to a baseline promotes a performance-driven culture. FLSmidth’s advance process control system, ECS/ProcessExpert, uses comprehensive data collection and intelligent event prioritization to increase production with lower specific power/fuel consumption and reduced emissions. The direct and indirect benefits of implementing an advanced process control system include operational stability, reduced maintenance costs and lower emissions.The system automates the sampling and analysis of raw materials and additives to give superior raw material chemistry control. Furthermore, stabilised raw meal quality results in reduced wear and maintenance issues.


The Polcid process control system from thyssenkrupp Industrial Solutions combines comprehensive process engineering know-how and ultra modern hardware and basic software from the world‘s leading manufacturers of process controlsystem components, creating an optimum systemstructure for our client industries. Being of consistent modular design, Polcid is predestined for individual configurations ranging from a single plant section to complete production lines. Thesystem is therefore optimally prepared for tomorrow‘s requirements.


The selection of the right components for the optimisation of internal processes is decisive for the efficiency and safety of transportation systems. In line with this, all Nord drive solutions are configured using the Nord function pyramid principle. For short and long-distance conveyor systems, mill and rotary kiln drives, as well as silo operation, Nord Drivesystems provides the very latest, energy-efficient drive solutions for every process stage in the cement industry. Nord Drivesystems plans and delivers reliable, low maintenance drive components for the entire drive chain, including electric motors, motor rockers, couplings, brakes, back stops and Taconite seals as well as heating and/or cooling.






The eastern states of India are likely to be the newer and virgin markets for cement companies and could contribute to their bottom line in future. In the next 10 years, India could become the main exporter of clinker and gray cement to the Middle East, Africa, and other developing nations of the world. Cement plants near the ports, for instance the plants in Gujarat and Visakhapatnam, will have an added advantage for exports and will logistically be well armed to face stiff competition from cement plants in the interior of the country.


Due to the increasing demand in various sectors such as housing, commercial construction and industrial construction, cement industry is expected to reach 550-600 MTPA by the year 2025. A large number of foreign players are also expected to enter the cement sector, owing to the pro fit margins and steady demand. In future, domestic cement companies could go for global listings either through the FCCB route or the GDR route. Sabyasachi Majumdar, Sr. VP & Group Head, ICRA Ratings, says Going forward the demand growth is likely to be driven by a pick-up in the housing segment – primarily affordable and rural housing and segment – primarily road and irrigation projects. However, new project announcements from the private sector continue to remain weak and revival of public-private partnership is crucial to improve the pace of infrastructure development. However, ICRA expects the capacity overhang and moderate demand growth to continue to keep the industry's capacity utilisation level between 60 and 65 per cent over the medium term...


As far as global cement market is concerned, according to Technavio research, it is anticipated to grow at a steady rate and will post a CAGR of more than 9 per cent during the forecast period. The increasing use of energy efficient technologies will drive the growth prospects for the global cement market until the end of 2021. According to the market research analyst, the manufacturing process of cement requires a lot of energy. Also, this process involves the emission of carbon dioxide in high volumes, which can be conserved and used in different aspects..


As a result, cement manufacturing units or cement plants are using new technological innovations that are designed with efficient working capabilities to conserve energy efficiently. For instance, with new technologies such as fillers and cement additives like DOW latex powder and MasterCem, the level of carbon dioxide emissions will reduce, which in turn, will drive the adoption rate of cement and cement additives across the globe.


Fast Facts

  • Global cement market registered volume of around 5 billion tonne in 2016, growing at a CAGR of around 7 per cent during 2009–2016.
  • India’s total cement production capacity is nearly 425 million tonnes, as of September 2017.
  • According to DIPP data, cement and gypsum products attracted FDI worth $5.25 billion between April 2000 and September 2017.


“Since our inception, innovation has been the hallmark of all our offerings. Ambuja Plus Cool Walls reinforces our strong commitment towards introducing products that deliver high strength, performance and sustainable development.The product gives multiple benefits of superior strength and durability as well as ensures ambient temperature in the house. We are confident that this new product will provide further impetus to our Group’s vision ‘So that the world builds better’.” Ajay Kapur, MD & CEO, Ambuja Cement




“As one of India’s leading cement companies, we believe that India continues to offer attractive opportunities for us to work with the Government’s vision on smart cities and infrastructure. ” Neeraj Akhoury, MD & CEO, ACC Ltd

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