CementPDM - Invidious

CementPDM

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Our CementPDM (Cement & Power Plant Technology, Design & Maintenance) channel is only for education purpose.

This channel is related to Cement technology & Power Plant Management like plant design, operation, maintenance along-with management of soft skill development.

Mr. JK Singh has experience in project engineering, designing, operation & maintenance.

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CementPDM

1. Best Overall (Balanced Performance): UltraTech Cement
Highest revenue, volume, and EBITDA
Strong EBITDA/Ton (₹1,007–1,051)
Good EBITDA margin (18–19%)
Highest capacity utilisation (~77%)

Conclusion: From scale + profitability + utilisation perspective, UltraTech performed best overall.

2. Best Profitability (Efficiency Leader): Shree Cement
Highest EBITDA margin (19.7%)
Strong EBITDA/Ton (₹985–1,050) comparable to UltraTech
Lower utilisation (48–50%)

Conclusion: In terms of cost control & per-ton economics, Shree Cement performed best.

2 months ago | [YT] | 14

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CementPDM

Come back in 2026 with lots of joy & energy..

4 months ago | [YT] | 77

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CementPDM

🌟 “Only those reach great heights who search for ways to grow, not excuses to stop.”

🌟 "Become a little better every day… your future self will be proud of you.”

🌟 “Success is not about talent—it's about consistent improvement.”

🌟 “Small steps lead to big dreams.”

🌟 “Rest if you’re tired, but never quit.”

🌟 “Work hard today… tomorrow the world will ask you, ‘How did you do it?’”

🌟 “If you want to rise higher, let discipline become your best friend.”

5 months ago | [YT] | 23

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CementPDM

Here are some practical tips & tricks for the installation of refractory bricks in Kiln 1st lining (safety + quality + durability):

🔹 Preparation Before Installation

1. Surface Cleaning

Ensure kiln shell is clean, dry, and free from rust, dust, and old mortar.

Check for ovality and misalignment before installation.

2. Material Inspection

Verify brick quality, dimensions, and batch numbers (avoid mixing).

Store bricks in a dry, covered area to prevent moisture absorption.

3. Tools Ready

Wooden/nylon hammer (never steel to avoid brick cracks).

Wedges, spirit level, measuring tape, chalk line, templates.

Kiln keying jack / hydraulic jack for tight joints.

🔹 Installation Tips

1. Reference Line

Mark a clear longitudinal reference line inside the kiln shell for alignment.

Always start from bottom dead center (BDC) and move symmetrically.

2. Brick Orientation & Staggering

Use staggered (half-brick) jointing to avoid continuous vertical joints.

Maintain recommended brick ring thickness (as per design drawing).

3. Dry Laying First

Always trial-fit 2–3 rings without mortar to check sizing and alignment.

Adjust with wedges if necessary.

4. Keying System

Each ring should be “keyed” tightly with the last brick slightly larger or hammered into position.

Use a keying jack to achieve tight fit without hammering too hard.

5. Joint Gap

Maintain 1.5–2.0 mm average joint gap (max 3 mm).

Fill gaps with high-alumina mortar, avoid excessive mortar thickness.

6. Ring by Ring Progression

Complete one full ring before moving to next.

Work simultaneously from both sides of the kiln to avoid unbalanced thrust.

🔹 Special Tricks

1. Shell Ovality Handling

If ovality is high, adjust brick cutting slightly but do not force oversized bricks.

2. Anchor Brick / Key Brick

Place key brick at 10–2 o’clock position, not exactly on top (12 o’clock), to avoid load concentration.

3. Wedges Use

Use wooden wedges for temporary support till ring completion.

Remove wedges before heating.

4. Expansion Allowance

Provide small axial expansion gaps (~2–3 mm every 1 m length).

5. Safety First

Continuous ventilation during work (dust from refractory can be harmful).

Use helmet, goggles, gloves, and dust masks.

🔹 Post-Installation

1. Inspection – Check brick line uniformity, key tightness, no hollow sound (tap test).

2. Cleaning – Remove excess mortar inside kiln.

3. Curing – Allow mortar to set properly (minimum 24 hrs) before heating.

4. Controlled Heating-Up – Follow proper heating curve to avoid thermal shock and mortar cracking.