Technology

Fly ash | From Trash to Cash

Published

9 years ago

July 4, 2016

admin

Many civil engineers are attracted to fly ash today, mostly due to commercial considerations. However, if it is looked upon as a performance improver, fly ash can solve many problems.

Fly ash is a by-product obtained while generating electrical power using coal as a fuel. For the last few decades, the demand for electricity has been increasing continually due to growing population and new industries being launched across the world.

During the year 2014-15; the total generation of fly ash has been 184.14 Million Tonnes out of which 102.54 Million tonnes is used, i.e.about 55.69 per cent of generated fly ash. (Information sourced from Central Electricity Authority, Govt. of India) But since fly ash contains a lot of heavy metals, its production causes problems to the environment. Because of this reason, it has become necessary to invent some newer aspects for utilising fly ash, rather than stick to the conventional ways. Fly ash disposal is a serious environmental concern due to its hazardous properties, impact on agriculture and long-term risks to both ecosystems and human beings. Fly ash is a coal-combustion product, composed of the fine particles that are driven out of the boiler with the flue gases. Ash that falls in the bottom of the boiler is called bottom ash. In modern coal-fired power plants, fly ash is generally captured by electrostatic precipitators or other particle filtration equipment before the flue gases reach the chimneys. Together with bottom ash removed from the bottom of the boiler, it is known as coal ash.

Depending upon the source and makeup of the coal being burned, the chemical composition of fly ash will vary considerably; but in general, all fly ash includes substantial amounts of silicon dioxide (SiO2) – both amorphous and crystalline, aluminium oxide (Al2O3) and calcium oxide (CaO), the main mineral compounds in coal-bearing rock strata.

Past Processes
In the past, fly ash was generally released into the atmosphere, but air pollution control standards now require that it be captured prior to release by fitting pollution control equipment. In many countries, fly ash is either stored at coal power plants or placed in landfills. A substantial part of fly ash goes to the cement industry as a cement substituting material, to produce hydraulic cement or hydraulic plaster and a replacement or partial replacement for Portland cement in concrete production. Pozzolans ensure the setting of concrete and plaster and provide concrete with more protection from wet conditions and chemical attack.

Cenospheres are the most important ingredient of fly ash. These are unique free-flowing powders composed of hard-shelled, hollow, minute spheres. Cenospheres are made up of silica, iron and alumina. These have a size range from 1 to 500 microns with an average compressive strength of 3000+ psi. Colours range from white to dark grey.

Chemical composition
Fly ash particles are generally spherical in shape and range in size from 0.5?m to 300?m. The major consequence of the rapid cooling is that few minerals have time to crystallise, and that mainly amorphous, quenched glass remains. Nevertheless, some refractory phases in the pulverised coal do not melt entirely, and remain crystalline. In consequence, fly ash is a heterogeneous material. SiO2, Al2O3, Fe2O3 and occasionally CaO are the main chemical components present in fly ash. The mineralogy of fly ash is very diverse. The main phases encountered are a glass phase, together with quartz, mullite and the iron oxides hematite, magnetite and/or maghemite. Other phases often identified are cristobalite, anhydrite, free lime, periclase, calcite, sylvite, halite, portlandite, rutile and anatase. The Ca-bearing minerals anorthite, gehlenite, akermanite and various calcium silicates and calcium aluminates identical to those found in Portland cement can be identified in Ca-rich fly ash. The mercury content can reach 1 ppm, but is generally included in the range 0.01 – 1 ppm for bituminous coal. The concentrations of other trace elements vary as well according to the kind of coal combusted to form it.

The fineness or the particle size of fly ash is a very critical property. The commercial value of fly ash depends on the particles and percentage of unburned carbon. A total of 75 per cent of the ash must have a fineness of 45 -?m or less, and have carbon content, measured by the loss on ignition (LOI), of less than 4 per cent. The quality of fly ash also depends on the type of technology used in the boiler and the quality of coal. Indian coal generally has high percentage of ash compared to either Australian or South African coal.

The bottom ash, which is still a neglected portion of the same waste, can also find its way into concrete, replacing the stone aggregates. But a lot needs to be done on this material in our country.

Benificiation, the value addition
By using air separators, the fly ash can be divided into different grades depending on the particle size. The best example is that of Dirk India, a company which is only into selling of fly ash, and thriving. Dirk sources its fly ash from state electricity generating companies, and by using air classifiers, produces four different varieties of fly ash which have a good demand in the market.

Challenges in handling fly ash
In a typical fly ash handling system, the material that is generated as a result of combustion is captured by an electrostatic precipitator (ESP) or a bag house before the flue gases reach the stack. These ESPs and bag houses generally have multiple pyramidal hoppers at the bottom, in which the ash is collected by gravity and is then transferred to a storage silo. These storage silos generally have provisions for a truck load-out to carry the fly ash for disposal or reuse. As a result of the frictional nature and fine particle size distribution, fly ash handling systems often experience problems if they are designed without following a prudent engineering approach.

Flow rate limitation
The permeability of fly ash is typically very low, due to its fine particle size distribution. As a result, when de-aerated, fly ash provides considerable resistance to the flow of air or other gases. During discharge from a silo or hopper outlet, air counter-flow through the fly ash bed provides an opposing force to gravity. This air ingress occurs as a result of the natural expansion of the ash bed within the hopper as it flows, or simply due to leakage from the conveying system below. As a result, fly ash hoppers and silos are limited in terms of the maximum discharge rates that they can provide by gravity alone.

Flooding or uncontrolled flow
As a fine powder, fly ash can behave like a fluid when sufficient air is present. Flooding can result, particularly when the handling rate is too high to allow sufficient time for the entrained air to escape. In this case, the fly ash may become fluidised and flush through the outlet unless the feeder can contain it. Flooding not only creates a challenge in metering the discharge, it can also lead to serious environmental, health and safety concerns.

Wear
The presence of a significant portion of silicon dioxide makes fly ash very abrasive and frictional. As a result of material sliding and impacting within the handling equipment, wall surfaces undergo tremendous wear.

Dust generation
Dusting can particularly occur at transfer points where the air entrained in the powder is suddenly expelled, carrying these finer particles with it. Dust generation also occurs when local air currents have sufficient velocity to pick up particles from the surface of a pile. Dust by itself is a nuisance and, more importantly, it can result in safety concerns including the health effects of operator exposure and the potential for explosions.

Other problems
Agglomerated lumps of fly ash and foreign materials can create flow problems, especially when handling fly ash with air slides or aerated bin bottoms. Therefore handling of fly ash always requires proper engineering inputs. The progress made so far has been reasonable, but a lot still needs to be done considering the potential of the material. Let us look at some of the possibilities.

Fly ash as cement replacement and high-volume fly ash concrete
Indian codes permit use of fly ash up to 35 per cent as cement replacement in cement manufacturing. However, in the case of concrete, the percentage will depend on the mix design recipe. If we see the practise abroad, up to 65 per cent of fly ash can be used in concrete.

Two researchers, Dr PK Mehta and Dr VM Malhotra, have made a significant contribution to the engineering community. Dr Mehta is well known for his work on high-volume fly ash concrete. Here is an extract from one of his papers called ?Cement & Concrete Mixtures for Sustainability?:

"For a variety of reasons, the concrete construction industry is not sustainable. First, it consumes huge quantities of virgin materials. Second, the principal binder in concrete is Portland cement, the production of which is a major contributor to greenhouse gas emissions that are implicated in global warming and climate change. Third, many concrete structures suffer from lack of durability which has an adverse effect on the resource productivity of the industry. Because the high-volume fly ash concrete system addresses all three sustainability issues, its adoption will enable the concrete construction industry to become more sustainable."

In this paper, a brief review is presented of the theory and construction practice with concrete mixtures containing more than 50 per cent fly ash by mass of the cementitious material. Dr Mehta is a champion of using more than 50 per cent fly ash by mass of the cementitious material. Mechanisms are discussed by which the incorporation of high volume of fly ash in concrete reduces the water demand, improves the workability, minimises cracking due to thermal and drying shrinkage, and enhances durability to reinforcement corrosion, sulfate attack, and alkali-silica expansion. For countries like China and India, this technology can play an important role in meeting the huge demand for infrastructure in a sustainable manner, says Dr Mehta.

High-performance concrete (HVFA)
As per Dr Mehta, the characteristics defining a HVFA concrete mixture are, minimum of 50 per cent of fly ash by mass of the cementitious materials must be maintained, low water content, generally less than 130 kg/m3 is mandatory and for cement content, generally no more than 200kg/m3 is desirable. For concrete mixtures with specified 28-day compressive strength of 30 MPa or higher, slumps more than 150 mm, and water-to-cementitious materials ratio of the order of 0.30, the use of high-range water-reducing admixtures (super-plasticizers) is mandatory. For concrete exposed to freezing and thawing environments, the use of an air-entraining admixture resulting in adequate air-void spacing factor is mandatory. For concrete mixtures with slumps less than 150 mm and 28-day compressive strength of less than 30 MPa, HVFA concrete mixtures with a water-to-cementitious materials ratio of the order of 0.40 may be used without super-plasticizers. Dr Mehta further concludes in his paper, that throughout the world, waste-disposal costs have escalated greatly. At the same time, the concrete construction industry has realised that coal fly ash is a relatively inexpensive and widely available by-product that can be used for partial cement replacement to achieve excellent workability in fresh concrete mixtures.

Consequently, in the modern construction practice, 15 to 20 per cent of fly ash by mass of the cementitious material is now commonly used in North America. Higher amounts of fly ash in the order of 25-30 per cent are recommended when there is a concern over thermal cracking, alkali-silica expansion or sulfate attack. Such high proportions of fly ash are not readily accepted by the construction industry due to a slower rate of strength development at an early age.

The high-volume fly ash concrete system overcomes the problems of low early strength to a great extent through a drastic reduction in the water-cementitious materials ratio by using a combination of methods, such as taking advantage of the super-plasticizing effect of fly ash when used in a large volume, with the use of a chemical super-plasticizer, and a judicious aggregate grading.

Consequently, properly cured high-volume concrete products are very homogenous in microstructure, virtually crack-free, and highly durable. Because there is a direct link between durability and resource productivity, the increasing use of high-volume concrete will help to enhance the sustainability of the concrete industry.

In conclusion, high-volume fly ash concrete offers a holistic solution to the problem of meeting the increasing demands for concrete in the future in a sustainable manner and at a reduced or no additional cost. At the same time, it reduces the environmental impact of two industries that are vital to economic development – the cement industry and the coal-fired power industry. The technology of high-volume fly ash concrete is especially significant for countries like China and India, where, given the limited amount of financial and natural resources, the huge demand for concrete needed for infrastructure and housing can be easily met in a cost-effective and ecological manner.

Concrete

Decarbonisation is a focus for our R&D effort

Published

2 weeks ago

February 12, 2025

admin

Dyanesh Wanjale, Managing Director, Gebr. Pfeiffer discusses the need to innovate grinding technologies to make the manufacturing process more efficient and less fuel consuming.

Gebr. Pfeiffer stands at the forefront of grinding technology, delivering energy-efficient and customised solutions for cement manufacturers worldwide. From pioneering vertical roller mills to integrating AI-driven optimisation, the company is committed to enhancing efficiency and sustainability. In this interview, we explore how their cutting-edge technology is shaping the future of cement production.

Can you tell us about the grinding technology your company offers and its role in the cement industry?
We are pioneers in grinding technology, with our company being based in Germany and having a rich history of over 160 years, a milestone we will celebrate in 2024. We are widely recognised as one of the most efficient grinding technology suppliers globally. Our MBR mills are designed with energy efficiency at their core, and for the past five years, we have been focused on continuous improvements in power consumption and reducing the CO2 footprint. Innovation is an ongoing process for us, as we strive to enhance efficiency while supporting the cement industry’s sustainability goals. Our technology plays a critical role in helping manufacturers reduce their environmental impact while improving productivity.

The use of alternative fuels and raw materials (AFR) is an ever-evolving area in cement production. How does your technology adapt to these changes?
Our vertical roller mills are specifically designed to adapt to the use of alternative fuels and raw materials. These mills are energy-efficient, which is a key advantage when working with AFR since alternative fuels often generate less energy. By consuming less power, our technology helps bridge this gap effectively. Our solutions ensure that the use of AFR does not compromise the operational efficiency or productivity of cement plants. This adaptability positions our technology as a vital asset in the industry’s journey toward sustainability.

What are some of the challenges your company faces, both in the Indian and global cement industries?
One of the major challenges we face is the demand for expedited deliveries. While customers often take time to decide on placing orders, once the decision is made, they expect quick deliveries. However, our industry deals with heavy and highly customised machinery that cannot be produced off the shelf. Each piece of equipment is made-to-order based on the client’s unique requirements, which inherently requires time for manufacturing.
Another significant challenge comes from competition with Chinese suppliers. While the Indian cement industry traditionally favoured our technology over Chinese alternatives, a few customers have started exploring Chinese vertical roller mills. This is concerning because our German technology offers unmatched quality and longevity. For example, our mills are designed to last over 30 years, providing a long-term solution for customers. In contrast, Chinese equipment often does not offer the same durability or reliability. Despite the cost pressures, we firmly believe that our technology provides superior value in the long run.

You mentioned that your machinery is made-to-order. Can you elaborate on how you customise equipment to meet the specific requirements of different cement plants?
Absolutely. Every piece of machinery we produce is tailored to the specific needs of the customer. While we have standard mill sizes to cater to different capacity requirements, the components and configurations are customised based on the client’s operational parameters and budget. This process ensures that our solutions deliver optimal performance and cost efficiency. Since these are heavy and expensive items, maintaining an inventory of pre-made equipment is neither practical nor economical. By adopting a made-to-order approach, we ensure that our customers receive machinery that precisely meets their needs.

The cement industry is focusing not only on increasing production but also on decarbonising operations. How does your company contribute to this dual objective, and how do you see this evolving in the future?
Decarbonisation is a key focus for our research and development efforts. We are continuously working on innovative solutions to reduce CO2 emissions and improve overall sustainability. For example, we have significantly reduced water consumption in our processes, which was previously used extensively for stabilisation. Additionally, we are leveraging artificial intelligence to optimise mill operations. AI enables us to monitor the process in real-time, analyse feedback, and make adjustments to achieve optimal results within the given parameters.
Our commitment to innovation ensures that we are not only helping the industry decarbonise but also making operations more efficient. As the cement industry moves toward stricter sustainability goals, we are confident that our technology will play a pivotal role in achieving them.

Can you provide more details about the use of digitalisation and artificial intelligence in your processes? How does this improve your operations and benefit your customers?
Digitalisation and AI are integral to our operations, enabling us to offer advanced monitoring and optimisation solutions. We have developed three distinct models that allow customers to monitor mill performance through their computer systems. Additionally, our technology enables real-time feedback from our German headquarters to the customer. This feedback highlights any inefficiencies, such as when a parameter is outside the optimal range,
and provides actionable recommendations to address them.
By continuously monitoring every parameter in real time, our AI-driven systems ensure that mills operate at peak efficiency. This not only enhances production but also minimises downtime. I am proud to say that our mills have the lowest shutdown rates compared to other manufacturers. This reliability, combined with the insights provided by our digital solutions, ensures that customers achieve consistent and efficient operations. It’s a game-changer for reducing costs and enhancing overall productivity.

Concrete

Technology is the cornerstone of clinker cooling

Published

2 months ago

December 24, 2024

Roshna

Madhusudan Rasiraju, Country Head, IKN India, talks about enhancing cement plant efficiency with energy-saving, reliable, and customised solutions while supporting sustainability through innovations like oxy-fuel plants and AFR adaptability.

Could you explain what IKN Engineering is, what the company specialises in, and share insights about your clinker cooling solutions?
IKN is a Germany-based company that specialises in providing advanced clinker cooling solutions to the cement industry. Our expertise lies in developing and supplying innovative cooling systems that focus on energy efficiency, durability and cost-effectiveness.
The clinker cooling process is a critical stage in cement production, as it significantly influences the energy efficiency of the entire plant. Our coolers are designed with cutting-edge technology to recuperate a substantial amount of heat from the clinker. This recovered heat is redirected back into the cement production process, enabling our customers to reduce their fuel consumption significantly. Moreover, IKN coolers are engineered for reliability. They are built to operate with minimal maintenance, which helps to lower operational costs and reduce downtime. By focusing on high performance and long-term reliability, we ensure that our solutions are both economically and environmentally beneficial.

How does IKN contribute to improving the efficiency of cement plant operations and supporting sustainability goals?
IKN plays a pivotal role in enhancing the operational efficiency of cement plants while aligning with global sustainability objectives. Historically, clinker coolers required frequent maintenance, with intervals as short as five to six months. This led to regular shutdowns, which disrupted operations and increased costs. With IKN’s advanced cooling solutions, cement plants can now operate their coolers for extended periods without significant maintenance. Our coolers are not only more reliable but also consume less power, which directly reduces energy costs. Additionally, the high heat recuperation efficiency of our systems ensures that less fuel is required for the cement-making process, contributing to a lower carbon footprint.
Sustainability is embedded in our solutions. By reducing energy consumption, optimising processes, and minimising maintenance, we help our customers achieve their operational goals while supporting their commitment to environmental stewardship.

What role does technology play in the clinker cooling process, and how does IKN leverage it to provide advanced solutions?
Technology is the cornerstone of clinker cooling and a driving force behind our innovative solutions at IKN. The cement industry’s needs are constantly evolving, and to stay ahead, we ensure our technologies remain dynamic and adaptable. We adopt a customer-centric approach, continuously collecting feedback from our clients to improve our systems. Every clinker cooler we supply is tailored to meet the specific requirements of the plant it serves. For instance, the physical layout, production capacity, and operational challenges of each facility are unique, and we ensure our solutions address these specific needs.
Moreover, our ongoing research and development efforts focus on enhancing reliability, improving heat recovery, and lowering energy consumption. By integrating the latest technological advancements, we make sure our coolers set new benchmarks in performance and sustainability.

Do you offer customised solutions for each cement plant, and how does the increasing use of alternative fuels (AFR) impact your clinker cooling solutions?
Absolutely, customisation is at the core of what we do at IKN. In the case of retrofits, every cooler is custom-designed to fit the specific layout and operational needs of the existing cement plant. For new installations, we collaborate closely with our clients to design coolers that are precisely sized and configured to meet their requirements.
Regarding alternative fuels (AFR), their increasing use in cement plants presents unique challenges. AFR often results in the production of finer clinker, which can be more difficult to handle during the cooling process. To address this, we optimise the operating parameters of our coolers, such as airflow density and cooler speed, to ensure they perform effectively with the type of clinker being produced. This adaptability ensures that our coolers remain efficient and reliable, even in plants using diverse and non-traditional fuels.

What challenges do you face in providing clinker cooling solutions, both from your operations and from the cement industry’s perspective?
Challenges are inevitable in any advanced technological field, and clinker cooling is no exception. One of the primary challenges we face is adapting to the changing demands of our customers. For example, frequent shifts in fuel types or the introduction of AFR can disrupt the cooling process. These changes often result in variations in clinker properties, requiring us to make adjustments to maintain optimal performance. Additionally, the grid surfaces in coolers may face increased wear and tear due to these changes. At IKN, we address such challenges by reinforcing the grid surfaces and fine-tuning our systems to handle these dynamic conditions.
From an industry perspective, there is an increasing emphasis on efficiency, sustainability, and cost reduction. Meeting these expectations while maintaining high performance is challenging, but it is a challenge we embrace through innovation, research, and collaboration with our clients.

What are your views on the net zero mission, and how is IKN contributing toward this goal?
The net zero mission is a vital initiative for energy-intensive industries such as cement, steel, and power. It requires a collective effort across the supply chain to achieve meaningful progress.
At IKN, we are committed to supporting this global goal. One of our key contributions is the development of oxy-fuel plants, which are designed to significantly reduce carbon emissions during production. We are also exploring innovative cooling methods, such as the use of nitrogen or other media, to further enhance sustainability. Currently, we have two oxy-fuel projects underway in Germany. These plants not only demonstrate our commitment to the net zero mission but also serve as examples of how advanced technology can drive sustainability in the cement industry. By focusing on durability, efficiency, and innovation, we help our clients reduce their environmental footprint while maintaining high operational standards.

– Kanika Mathur

Concrete

Smart Cement Plants

Published

6 months ago

August 23, 2024

Roshna

By integrating advanced technologies like IoT and AI, cement plants are transforming into highly efficient and interconnected systems. ICR explores how these innovations enable real-time monitoring and predictive maintenance, significantly reducing downtime and operational costs.

The cement industry, traditionally known for its reliance on heavy machinery and manual processes, is undergoing a significant digital transformation. This shift is driven by advancements in technology that promise to enhance efficiency, reduce costs, and improve overall production quality. Key trends include the adoption of the Internet of Things (IoT), which enables real-time monitoring and control of production processes through interconnected devices. Artificial Intelligence (AI) and Machine Learning (ML) are being utilised to optimise operations, predict maintenance needs, and minimise downtime by analysing vast amounts of data. Additionally, the integration of Big Data analytics allows for more informed decision-making by providing insights into production trends and potential areas for improvement.
“One of the key advantages of integrating data across our systems is the ability to have a more transparent, agile, and integrated supply and logistics chain. With the implementation of Oracle Logistics Management Solution, we have been able to overcome challenges related to consignment locations and truck movements, providing real-time visibility into our operations. This has also led to operational efficiency improvements and the ability to predict consignment delivery times, which we share with our customers, enhancing their experience” says Arun Shukla, President and Director, JK Lakshmi Cement.
According to BlueWeave Consultancy, during the forecast period between 2023 and 2029, the size of India cement market is projected to grow at a CAGR of 9.05 per cent reaching a value of US$ 49.24 billion by 2029. Major growth drivers for the India cement market include the growing need from construction and infrastructure sectors and rising governmental initiatives and investments in expansive infrastructure ventures encompassing highways, railways, airports, and public edifices.

Importance of Digitalisation
Digitalisation in cement manufacturing is crucial for several reasons:

Enhanced efficiency: Digital tools streamline production processes, reducing waste and improving the precision of operations. This leads to higher output and better resource utilisation.
Predictive maintenance: By leveraging AI and IoT, cement plants can predict equipment failures before they occur, minimising unplanned downtime and extending the lifespan of machinery.
Energy optimisation: Digital technologies enable the monitoring and optimisation of energy consumption, leading to significant cost savings and a reduced carbon footprint.

This aligns with global sustainability goals and regulatory requirements.

Quality control: Advanced sensors and data analytics ensure consistent product quality by closely monitoring and adjusting the production parameters in real time.
Safety improvements: Automation and robotics reduce the need for human intervention in hazardous environments, enhancing worker safety and reducing the risk of accidents.
Competitive advantage: Companies that embrace digitalisation can respond more quickly to market changes, innovate faster, and provide better customer service, giving them a competitive edge in the industry.
Digital transformation is reshaping the cement industry by driving efficiency, enhancing product quality, and promoting sustainability. As the industry continues to evolve, the adoption of digital technologies will be essential for maintaining competitiveness and achieving long-term success.

Key technologies driving digitalisation
The digital transformation of the cement industry is powered by a suite of advanced technologies that enhance efficiency, improve product quality, and drive sustainability. Here are some of the key technologies making a significant impact:
IoT refers to a network of interconnected devices that communicate and exchange data in real time. In the cement industry, IoT applications are revolutionising operations by enabling real-time monitoring and control of production processes. Sensors embedded in equipment collect data on various parameters such as temperature, pressure, and vibration. This data is then transmitted to a central system where it is analysed to optimise performance. For instance, IoT-enabled predictive maintenance systems can detect anomalies and predict equipment failures before they occur, minimising downtime and reducing maintenance costs. Additionally, IoT helps in energy management by monitoring consumption patterns and identifying opportunities for energy savings.
AI and ML in process optimisation are pivotal in enhancing process optimisation in the cement industry. AI algorithms analyse vast amounts of data generated from production processes to identify patterns and insights that human operators might overlook. ML models continuously learn from this data, improving their accuracy and effectiveness over time. These technologies enable real-time adjustments to production parameters, ensuring optimal performance and product quality. For example, AI-driven systems can automatically adjust the
mix of raw materials to produce cement with consistent properties, reducing waste and improving efficiency. AI and ML also play a crucial role in predictive maintenance, forecasting potential issues based on historical data and preventing costly equipment failures.
Tushar Kulkarni, Head – Solutions, Innomotics India, says, “Adoption of artificial intelligence (AI) will significantly help cement plants in their efforts towards innovation, efficiency and sustainability goals through improved process optimisation and increased productivity.”
“The Innomotics Digi-Suite (AI-based) is positioned to support the cement industry in this endeavour. Built on microservices architecture, Digi-Suite offers flexible self-learning AI based solutions which can be customised or tailor-made in accordance with plant / customer requirements. It enables customers to implement their digitalisation strategies in a stepwise manner and scale it up to an entire plant or multiple plants. Through this platform, customers can monitor and manage processes centrally. This approach provides guidance for company-wide process standardisation, knowledge sharing and optimum utilisation of expert resources,” he adds.
Big Data analytics involves processing and analysing large volumes of data to extract meaningful insights. In the cement industry, Big Data analytics is used for predictive maintenance and strategic decision-making. By analysing data from various sources such as sensors, machinery logs, and production records, companies can predict equipment failures and schedule maintenance activities proactively. This approach minimises unplanned downtime and extends the lifespan of critical assets. Furthermore, Big Data analytics helps in optimising supply chain management, inventory control, and production planning by providing actionable insights into trends and patterns. Decision-makers can leverage these insights to make informed choices that enhance operational efficiency and competitiveness.
Arun Attri, Chief Information Officer, Wonder Cement, says, “The advantages of data integration are substantial. By leveraging integrated data,
we build a single source of truth, we can identify patterns, optimise processes, and implement strategic initiatives that drive overall business growth. This approach not only enhances operational efficiency but also strengthens our relationships with all stakeholders by providing a clear and consistent view of our operations.”
“By establishing a single source of truth, we ensure that all stakeholders, both internal and external, have access to consistent and accurate data. This unified data repository enhances visibility into our operations, improves decision-making, and enables comprehensive analyses. For internal stakeholders, such as our production, quality and maintenance teams, this means having reliable data to optimise processes and schedule maintenance effectively. For external stakeholders, including suppliers and customers, it ensures transparency and trust, as they can rely on the accuracy of the information provided,” he adds.
Cloud computing offers a scalable and flexible solution for data storage and access, playing a vital role in the digitalisation of the cement industry. By storing data in the cloud, companies can easily access and share information across different locations and departments. Cloud-based platforms facilitate real-time collaboration and data sharing, enabling seamless integration of various digital tools and systems. Additionally, cloud computing provides robust data security and backup solutions, ensuring that critical information is protected and can be recovered in case of data loss. The scalability of cloud services allows cement manufacturers to handle the increasing volume of data generated by IoT devices and other digital technologies, supporting their growth and innovation initiatives.

Digital twin technology
Digital twin technology involves creating a virtual replica of a physical asset, process, or system. This digital counterpart is continuously updated with real-time data from sensors and other sources, mirroring the physical entity’s performance, behaviour and condition. In the cement industry, digital twins
offer numerous benefits. They enable real-time monitoring and analysis, allowing operators to visualise and understand complex processes in detail. This enhanced visibility helps in optimising production, improving efficiency, and reducing downtime. Digital twins also facilitate predictive maintenance by simulating various scenarios and identifying potential issues before they occur, thereby extending the lifespan of equipment and minimising maintenance costs. Moreover, they support data-driven decision-making by providing comprehensive insights into operations, leading to better resource management and increased productivity.
Tarun Mishra, Founder and CEO, Covacsis, explains, “Different plant data reside within the walls of individual plants. Comparing micro economic performance across plants is impossible. Covacsis’ IPF is designed to aggregate multiple plant’s data at unified enterprise datalike (historian) which then further used for relative baselining and relative performance analysis across same and similar asset base or product or processes.”
“Data plays the most important role in any algorithm. Big data and fast data are only adding to the logistics performance of any algorithm and platform. Covacsis is a decade old and most mature platform in the world. Covacsis’ SaaS infrastructure is already handling more than 350 billion of cement process and operation data on a daily basis with a compounding daily growth rate of 1 per cent. This provides a significant advantage to Covacsis towards building algorithms and ensuring the value efficacy of these algorithms for the industry,” he elaborates.
The implementation of digital twins in cement plants involves several steps. First, detailed models of the plant’s equipment, processes, and systems are created using data from various sources such as sensors, historical records, and engineering specifications. These models are then integrated into a digital platform that continuously collects and analyses real-time data from the physical plant. For instance, a digital twin of a cement kiln can monitor temperature, pressure, and other critical parameters, allowing operators to optimise the combustion process and improve energy efficiency.
Similarly, digital twins of grinding mills can help in adjusting operational parameters to achieve optimal particle size distribution and improve cement quality. The integration of digital twins with other digital technologies such as IoT, AI and Big Data analytics enhances their capabilities, providing a comprehensive and dynamic view of the entire production process. As a result, cement plants can achieve significant improvements in operational efficiency, product quality and sustainability.

Automation in cement production
Automation plays a pivotal role in enhancing productivity within the cement industry by streamlining operations and reducing the reliance on manual labor. Automated systems and machinery can perform repetitive and complex tasks with higher precision and consistency than human workers. This leads to significant improvements in operational efficiency and throughput. For instance, automated material handling systems can manage the movement and storage of raw materials and finished products more effectively, minimising delays and reducing handling costs.
Automated process control systems enable real-time monitoring and adjustments of production parameters, ensuring optimal performance and reducing waste. Additionally, automation helps in maintaining consistent product quality by minimising human errors and variations in the manufacturing process. Overall, the integration of automation technologies results in faster production cycles, lower operational costs, and increased competitiveness in the market.
The introduction of automation in the cement industry has a profound impact on workforce skills and safety. As automation takes over routine and hazardous tasks, the demand for manual labour decreases, and the focus shifts to more technical and supervisory roles. Workers are required to develop new skills in operating and maintaining automated systems, as well as in data analysis and problem-solving. This shift necessitates continuous training and upskilling to ensure the workforce can effectively manage and leverage advanced technologies.
On the safety front, automation significantly enhances worker safety by reducing their exposure to dangerous environments and tasks. Automated systems can handle heavy lifting, high-temperature processes, and exposure to harmful dust and chemicals, thereby minimising the risk of accidents and occupational health issues. As a result, automation not only boosts productivity but also contributes to a safer and more skilled workforce, fostering a more sustainable and resilient industry.

Energy efficiency and sustainability
Digital tools are revolutionising the way energy consumption is monitored and optimised in the cement industry. Advanced sensors and IoT devices continuously collect data on energy usage across different stages of the manufacturing process. This real-time data is analysed using AI and machine learning algorithms to identify patterns, inefficiencies, and opportunities for energy savings. Energy management systems (EMS) integrate these digital tools to provide a comprehensive overview of energy consumption, allowing operators to make informed decisions to reduce energy waste. For instance, predictive analytics can forecast energy demands and optimise the operation of high-energy equipment, such as kilns and grinders, to align with periods of lower energy costs. Additionally, automated control systems can adjust operational parameters to maintain optimal energy efficiency, thereby reducing the overall energy footprint of the plant.
McKinsey & Company for the cement industry analyse that pursuing digitisation and sustainability levers are key to significantly boosting productivity and efficiency of a typical cement plant. The result is a margin gain of $4 to $9 per tonne of cement, which would shift a traditional plant to the top quartile of the cost curve for plants with similar technologies.
Digital technologies are also instrumental in driving sustainable practices within the cement industry. By providing precise control over production processes, digital tools help in minimising raw material wastage and reducing emissions. For example, advanced process control (APC) systems optimise the combustion process in kilns, leading to more efficient fuel use and lower carbon dioxide emissions. Digital twins, which create virtual replicas of physical assets, enable detailed simulations and scenario analyses, allowing companies to explore and implement more sustainable production methods. Furthermore, the integration of renewable energy sources,
such as solar and wind power, is facilitated by digital technologies that manage and balance energy loads effectively.
Digital platforms also support the implementation of circular economy practices, such as the use of alternative fuels and raw materials, by tracking and optimising their utilisation throughout the production cycle. Overall, digital technologies empower the cement industry to achieve significant advancements in energy efficiency and sustainability, contributing to environmental conservation and compliance with global sustainability standards.

Future of digitalisation
The cement industry is on the brink of a significant transformation driven by emerging technologies. Innovations such as artificial intelligence (AI), machine learning (ML), advanced robotics, and blockchain are poised to revolutionise various aspects of cement production and supply chain management. AI and ML will enable more sophisticated predictive maintenance and process optimisation, reducing downtime and increasing efficiency. Advanced robotics will automate more complex and hazardous tasks, further enhancing productivity and worker safety. Blockchain technology offers potential benefits in enhancing transparency and traceability in the supply chain, ensuring the integrity of product quality and compliance with environmental regulations. These emerging technologies will collectively contribute to a more efficient, reliable, and sustainable cement industry.
Smart cement plants represent the future of the industry, where digital technologies are fully integrated to create highly automated and interconnected production environments. In these plants, IoT devices, digital twins and AI-driven systems will work together seamlessly to monitor, control and optimise every aspect of the manufacturing process. Real-time data from sensors will feed into advanced analytics platforms, enabling instant adjustments to maintain optimal performance. Digital twins will allow operators to simulate and test changes in a virtual environment before implementing them in the physical plant, minimising risks and enhancing decision-making. Furthermore, smart cement plants will incorporate renewable energy sources and energy storage solutions, supported by intelligent energy management systems that ensure efficient and sustainable operations.
Over the next decade, the digital transformation of the cement industry is expected to accelerate, driven by continuous advancements in technology and increasing demands for sustainability. We can anticipate widespread adoption of AI and ML for real-time process optimisation and predictive maintenance, leading to significant reductions in operational costs and emissions. The use of digital twins will become standard practice, enabling more precise and flexible production planning and execution.
Enhanced connectivity and data sharing across the supply chain will improve efficiency, transparency, and collaboration among stakeholders. Additionally, the integration of renewable energy and advanced energy storage solutions will become more prevalent, supported by digital platforms that optimise energy usage and reduce environmental impact. As the industry embraces these digital innovations, we will see a new era of smart, sustainable, and highly efficient cement manufacturing, positioning it to meet the challenges and opportunities of the future.

Conclusion
The digital transformation of the cement industry is poised to revolutionise traditional manufacturing processes, driving significant advancements in efficiency, sustainability, and competitiveness. Emerging technologies such as IoT, AI, ML advanced robotics, and blockchain are not only optimising energy consumption and improving operational efficiency but are also paving the way for more sustainable practices. The evolution towards smart cement plants, where digital tools are fully integrated, is set to redefine production environments with enhanced automation, real-time monitoring and advanced analytics.
Over the next decade, we can expect these technologies to become standard practice, leading to substantial reductions in costs and emissions, improved supply chain transparency, and greater adoption of renewable energy sources. As the industry embraces digitalisation, it will be better equipped to meet future challenges and seize new opportunities, ultimately contributing to a more sustainable and resilient
global economy.

– Kanika Mathur