Sawan Jasoliya

Question: Since my student days, I have had a strong interest in working in the cement industry. However, I never got the right opportunity despite making several attempts. Later, I tried in the renewable energy sector and today I am working as the in-charge of a 40 MW solar power plant at Prism Johnson Cement Limited. Still, my passion remains in the core cement industry. If I could get an opportunity through your guidance or support, it would be of great help to me. I do not have any external backing — only hope. --------------------------- My reply: Dear friend, Your current experience in handling a 40 MW solar power plant is a strong technical foundation, especially since it is within a cement company environment. While direct entry into a core cement plant electrical role may be challenging without prior process experience, it is not impossible. I suggest you explore opportunities within your current company for exposure to cement plant electrical maintenance, even if on a short...

Kiln Back-End Temperature: The Heartbeat of Clinker Quality and Kiln Efficiency Having visited several cement plants across India and abroad, I’ve consistently observed that precise control of kiln back-end temperature, ideally at 1050°C, is the heartbeat of clinker quality and stable kiln operation. A fluctuation of just ±30°C can disrupt the entire pyroprocessing line. When this temperature drops below 1020°C, calcination falls under 90%, leading to unburnt raw meal, high free lime (>1.5%), reduced C₃S (<60%), and a 5–10 MPa drop in cement strength.  It also causes sticky deposits, chokes cyclones, and leads to unscheduled stoppages. On the other hand, temperatures above 1080°C promote alkali volatilization, ring formation, unstable O₂ levels, and higher CO emissions. Refractory linings suffer micro-cracking, shortening their life by up to 20%. Recent technological advances offer solutions. In 2025, leading plants are using hybrid AI systems with physics-informed neural net...