January 29, 2025
Intern: Nikhil Kirti
PhD Project: Calcination of clay for the role of supplementary cementitious material: kinetics and morphological studies
Supervisor: Dr Woei Saw, University of Adelaide
HILT CRC-supported PhD candidate Nikhil Kirti recently completed an industry internship with FCT Combustion, developing a model of clay behaviour during calcination (heating the clay to remove moisture and impurities) in the cement-making process.
FCT Combustion is a world leader in high-temperature processing plants for heavy industry. Headquartered in Australia but with operations around the world, they are a HILT CRC Key Partner.
By validating his model with real-world data provided by FCT, Nikhil’s research offers practical insights into tailoring calcination conditions to different clay types. This can help the industry optimise the production of activated clays for use as supplementary cementitious materials (SCMs), which can be used in place of clinker (the main ingredient of cement, made by heating limestone and clay), a major source of CO2 emissions in cement manufacturing.
Nikhil highlighted the value of connecting academic theory with industry challenges.
“My research provides a detailed understanding of clay calcination at a microscopic level, enabling more precise control of parameters for different clay compositions,” he said.
“This helps in optimising activation conditions for SCMs, resulting in better process efficiency, reduced energy costs and consistent product quality, directly supporting the industry’s shift toward sustainable cement production.”
“This internship has helped me realise the importance of focusing research on solving real-world industrial challenges, motivating me to pursue a career in developing sustainable materials and processes.”
Nikhil Kirti, HILT CRC-supported PhD candidate
at the University of Adelaide
In hosting Nikhil, FCT sought to foster closer ties with academia to advance industry knowledge. Nikhil’s work provided valuable insights into the calcination process, comparing ‘pure’ kaolin behaviour with clays tested in FCT’s pilot flash calciner.
The internship informed the need for further analysis on impact of impurities and mineralogical phases, and FCT will supply Nikhil with a clay sample tested in the pilot plant for further laboratory analysis.
By advancing the understanding of calcination kinetics, the internship can help FCT work toward more efficient equipment as well as SCMs that reduce reliance on high-carbon clinker in cement production.
FCT Internal Technical Advisor Renato Greco noted that Nikhil demonstrated impressive commitment to the internship.
“Nikhil was very curious to understand the complexities of the calcination of clays and never shy to put hands on tasks assigned to him,” he said.
“It was an interesting, positive and fruitful experience. I believe we should repeat it.”
Renato Greco, Internal Technical Advisor, FCT