Technology

Low carbon technology roadmap of the Indian cement industry

Published

8 years ago

July 4, 2016

admin

Reducing the clinker factor in the final cement reduces CO2 both from the calcination of carbonates and from combustion of coal, but the fuel substitution rate has to go up. Facilitation is required to allow cement kilns to utilise large quantum of wastes as AFRs. Ulhas Parlikar of Geocycle India elaborates on what can happen with appropriate policy framework.

India is the second largest producer of cement next to China. The Indian cement industry is consolidated, organised and mature. The top 20 cement companies account for almost 70 per cent of the total cement production of the country (IBEF, 2014). Actual production of 250 Mt cement in 2013, meant that the industry consumed approximately 300 Mt of virgin raw material, 24 Mt of coal (MoC, 2015), 20 billion kWh electricity and emitted nearly 175 MtCO2. Due to reducing coal linkages over the years, the Indian cement industry imports over 30% of its total coal requirement, adding to the cost of producing cement.

The Indian industry?s average thermal energy consumption is estimated to be about 725 kcal/kg clinker and the average electrical energy use is about 80 kWh/t cement, much lower than the global average of 934 kcal/kg clinker and 107 kWh/t cement. The best levels achieved by the Indian cement industry, at about 680 kcal/kg clinker and 66 kWh/t cement, are comparable with the best achieved levels in the world (WBCSD CSI, 2013). The cement industry is currently using 45 Mt of fly ash from coal-based power stations and around 10 Mt of blast furnace slag from the production of pig iron (WBCSD, 2013).

The mineral waste fractions are substituting the Portland cement clinker by grinding it together in the cement mill (or separate pulverisation prior to blending). Reducing the clinker factor in the final cement reduces the CO2 both from the calcination of carbonates and from combustion of coal.

However, the Thermal Substitution Rate (TSR) or Fuel Substitution of the Indian cement industry with the utilisation of wastes from agricultural, industrial and municipal sources as alternative fuels and raw materials (AFRs) is only in the range of 1 – 2 per cent.

Waste generation scenario and cement kiln option for its gainful disposal
India generates large quantum of wastes from agricultural, Industrial and municipal sources and currently the entire waste is disposed without any recovery process. Several countries globally have utilised cement kilns as an effective option for their country?s industrial, municipal and hazardous waste disposal. This creates a win-win situation for both the local administration and the cement plants: the administration utilises the infrastructure already available at cement kilns, thereby spending less on waste management, and the cement kilns are paid by the polluter for safe waste disposal, as well as having their fuel requirements partly met.

The Cement Vision of India 2025 prepared by AT Kearney/CII has projected that the TSR of the Indian cement industry would be about 12% by 2025 and the study of the Low-Carbon Technology Roadmap for the Indian cement industry prepared by the International Energy Association, in collaboration with WBCSD, has projected the same to be 19% in 2030 and 25% in 2050.

Opportunity for resource conservation and GHG mitigation through co-processing
If the Indian cement industry is also able to move towards large-scale use of AFRs and is able to achieve the TSR as envisaged in the low carbon technology roadmap, there will be a substantial contribution that the cement industry will be able to make towards resource conservation and GHG mitigation.

The projected output of this exercise is presented in the Table-1
It can be observed that if wastes are utilised as AFRs, there is potential to conserve coal of about 11 to 16 Mio TPA in the year 2030 and about 17 to 30 Mio TPA of coal in the year 2050. In 2020 and 2030, for every Mt of cement produced, 7 000 tonnes and 25 000 tonnes of AFs need to be co-processed, respectively. This means that we will be saving an amount of coal that we are consuming at present. This also helps in mitigating an amount of GHG emissions that we are letting into the environment. India?s industrial waste is growing in volume. Out of current generation of 4 Mt of landfillable and incinerable wastes, 2.5 Mt (60%) is awaiting disposal. Studies conducted by the Ministry of New and Renewable Energy (MNRE) have estimated surplus biomass availability at about 120-150 Mt per annum covering agricultural and forestry residues. As per the Planning Commission task force report on waste to energy, of the 62 Mt of MSW generated in urban India, 12 Mt is a combustible fraction, which can be potentially converted to RDF, thereby replacing 8 Mt of coal.

Current regulatory processes are not aligned to tap this opportunity
The cement industry prefers uniform emission standards for co-processing rather than case-by-case permits. In India, it normally takes more than a year for a waste stream to get regular permits for co-processing. This is because the law and guideline mandates trial runs to be conducted for each new waste streams, requiring approvals for trial and regular usage from both state and central pollution control boards. For some special and difficult to treat hazardous wastes (pesticides, PCB, CFC, etc.), however, it is important and necessary to carry out trial burns to ensure compliance to environment and occupational health and safety.

In India itself, co-processing technology has also been used to destroy hazardous chemicals. A trial conducted at ACC-Kymore cement works, in SINTEF?s and CPCB?s supervision, demonstrated destruction and removal efficiency (DRE) of 99.9999% for concentrated CFC (chlorofluorocarbons) gases at high feeding rate in an Indian cement kiln. This shows the potential of the technology with regard to safe and sound destruction of hazardous chemicals in existing infrastructure.

The major categories of wastes that can be used by the cement industry as alternative fuels and raw materials are hazardous wastes, non-hazardous wastes, Refuse Derived Fuel (RDF), Municipal Solid Waste (MSW), shredded tyres and biomass. The major constraints in implementing large-scale co-processing of these kinds of wastes in the Indian cement industry along with the support required are elaborated in detail in the low carbon technology roadmap document.

The major constraint is the current regulatory framework that is built on the principle of disposal rather than the principle of sustainability. A permitting system resembling international best practice will probably stimulate broader interest. A revision and update of the existing guidelines and permitting requirements (addressing issues such as interstate transportation, emission limits, standard approach for utilisation of alternative sources of de-carbonated materials and mineralizers, etc.,) is regarded to be of crucial importance in order to stimulate increased co-processing practice.

Desired changes in the Indian regulatory framework
The desired changes are provided below.
I.Hazardous wastes
1)Amendment in Hazardous Waste (Management, Handling & Transboundary Movement) Rules, 2008 to:
1.Recognise co-processing in cement kiln as a preferred technology for disposal because it is a resource recovery option over landfill and incineration operation. (By this provision, the wastes that can be co-processed will not get disposed through landfill and incineration process. In fact, restrictions or limits on landfill (or inclusion of externality charges or future liability costs to landfill charges) will give impetus to co-processing initiative in India).

2.Authorise cement plants to receive, store, pre-process and co-process wastes based on the availability of required infrastructure to handle and store hazardous wastes as specified in the HWM Rules and based on prescribed emission standards.

The current waste by waste permitting process through co-processing trial is not a relevant process of approval for co-processing for following reasons: (a)The concern of the impact of the chemical constituents present in the waste on the emissions/ product quality.

(b)There are more than 20,000 waste streams that are co-processed globally. In the past 10 years, we have been able to complete trial of less than 100 waste streams. By the waste by waste trial approval process, we will never be able to move ahead.

(c)Even if a waste stream is approved for co-processing through trial, its waste characteristics are never constant. They vary from batch to batch and from time to time.

(d)While undertaking the co-processing of approved waste streams, they get blended to a new chemical composition which is completely different from all individual ones.

(e)The very purpose of implementing waste stream approval based on trial gets completely defeated.

Hence, the trial based waste by waste permitting process is not relevant at all.

Based on experience gained in India and international best practices, the desired regulatory process of approval needs to be based on (i) emission standards for cement kilns conducting co-processing, (ii) adequate infrastructure to safely handle and store wastes, (iii) appropriate laboratory facility to achieve desired input control, (iv) proper systems to monitor & control the input rates and (v) well established operational procedures for health and safety. These processes will secure the same level of environmental protection at Indian cement plants as the current EU and US regulations.

3.Allow interstate movement of hazardous wastes for cement kiln co-processing with letter of intimation to concerned SPCBs.

With this provision, waste can be moved at economically attractive distances across the states.

The pricing of waste management services is a key factor, both to ensure waste minimisation at source (to reduce disposal costs for waste generators) as well as to ensure low cost to cement manufacturers (encouraging them to install the infrastructure needed for proper handling, storage and firing at their premises) for increased TSR. The ?polluter-pays? principle should be the basis for the economic and financial analysis of waste utilisation.

II.Non-hazardous waste
To allow cement kilns, that are complying with the prescribed emission standards for co-processing, to co-process of all kinds of non-hazardous wastes in cement kilns through intimation to SPCBs.

III.RDF from MSW
To implement amendment in draft Municipal Solid Wastes (Management and Handling) Rules, 2015 to ensure that the segregated combustible fraction is not allowed to be landfilled but is converted into Refused Derived Fuel (RDF) that is suitable for use as alternate fuel in cement plants and other suitable thermal processes. Also, to institute fiscal measures that will facilitate building large number of pre-processing facilities to convert wastes into AFRs and MSW into RDF.

IV.Shredded Tyres
Shredded tyres are used extensively in the cement industry as a supplementary fuel and MoEFFCC/CPCB may want to consider ways to increase the availability in India.

V.Biomass
Co-processing of biomass leads to complete energy recovery and this process is much more energy efficient, even compared to biomass-based power plants. Incentives should be given for biomass utilisation in cement kilns akin to that given for biomass-based power plants.

International co-operation for assimilating Technology, Skills and Policy (TSP) framework to leap-frog
Co-processing in cement kilns is a widely practiced activity in many countries for management of wastes. The technological infrastructure required for implementing large scale co-processing is well established and operated. The skills are well developed with the operating teams to operate the kilns with large quantum of wastes and produce the right quality cement product. In these countries, the legislative processes are also designed and practiced with preference to recovery technologies such as co-processing. The TSR in these countries is therefore very high.

Our experience in the country of the past 10 years suggests to us that AFR co-processing growth takes place with a reasonable learning curve and support available from the international co-operation helps a lot. The Indian cement industry is already collaborating with several knowledge partners in utilising this lever for using large amount of wastes as AFRs in the cement kilns. Several international cement players that are implementing large scale co-processing in their plants in different countries, such as LafargeHolcim, Hiedelberg, CRH, VICAT, Italicement, etc are already operating in India and several Indian cement players such as Ultratech, Dalmia, etc., are also sourcing international co-operation in bridging the technical and skill gap in implementing large scale utilisation of AFRs.

CPCB has been closely working with the Norwegian research organisation SINTEF for the last few years and has been able to contribute towards building capacity and confidence among various stakeholders on the viability of safe and sound co-processing. We consider that co-operation of Indian policy-making bodies with agencies like SINTEF, who have been working closely with the authorities and industries in such countries, can facilitate quicker assessment of the policy level hurdles encountered in implementing large scale management of wastes as AFRs through co-processing and implementing fitting solutions to deal with them from the policy and operational considerations.

Low carbon technology roadmap
Table-1

Parameter	Unit	Base case	Low demand			High Demand
		2010	2020	2030	2050	2020	2030	2050
Cement Production	Mio TPA	217	416	598	780	492	848	1361
Clinker to Cement Ratio		0.74	0.7	0.64	0.58	0.7	0.64	0.58
Thermal Intensity of clinker production	Kcal / Kg Clinker	725	709	694	680	703	690	678
Alternative Fuel share in total energy used	%	0.6	5	19	25	5	19	25
Coal conserved having CV of 4,500 Kcal/Kg	Mio TPA	0.16	2.3	11.2	17.1	2.7	15.8	29.7
CO₂ emission reduced	Mio TPA	0.19	2.8	13.8	21.0	3.3	19.4	36.5

Concrete

Smart Cement Plants

Published

3 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

Concrete

Advantages of data integration are substantial

Published

3 months ago

August 23, 2024

Roshna

Arun Attri, Chief Information Officer, Wonder Cement, discusses the digital transformation and advanced technologies used to enhance operational efficiency, sustainability and cybersecurity in their cement manufacturing processes.

How has the implementation of IT initiatives transformed your operations and processes in the cement industry?
We operate under the digital vision: To leverage digital to accelerate growth, build relationships and enhance consumer experience.
Our digital transformation initiatives have profoundly reshaped operations and processes at Wonder Cement. By integrating advanced technologies such as IoT, cloud computing and constructing a data lake house for data consolidation as a single source of truth, we have enabled seamless information flow between applications and developed real-time analytics. These advancements have streamlined our production processes, enhanced operational efficiency, and improved decision-making. Additionally, predictive analytics allows us to anticipate market trends and customer needs more accurately.

Can you discuss how your organisation is adopting Industry 4.0 technologies and the benefits you are experiencing?

Embracing Industry 4.0 technologies is truly transforming our operations and improving reliability. Here are the key benefits we are experiencing:

Real-time monitoring: IoT devices provide real-time data on equipment performance, enabling predictive maintenance and reducing downtime.
Process optimisation: AI and machine learning algorithms enhance process optimisation,
leading to increased efficiency and reduced operational costs.
Higher productivity: Improved monitoring and optimisation result in higher productivity and better product quality.
Enhanced sustainability: Better resource utilisation contributes to enhanced sustainability.

What specific automation technologies have you implemented, and how have they improved efficiency and productivity in your cement plants?
Automation technologies have revolutionised efficiency and productivity at our cement plants. Automated quality control systems ensure consistent product quality by continuously monitoring and adjusting production parameters. Robotic process automation (RPA) in administrative functions like inventory management and order processing has drastically reduced manual errors and boosted operational efficiency. These advancements enable us to uphold high standards of precision and reliability, optimise resource utilisation and minimise wastage.

How are predictive analytics and maintenance technologies being utilised in your operations to minimise downtime and optimise maintenance schedules?
Predictive analytics and maintenance technologies are pivotal in minimising downtime and optimising maintenance schedules at Wonder Cement. By analysing historical data and real-time sensor inputs, we proactively predict and address potential equipment failures. This approach has drastically reduced unplanned downtime, enhanced equipment reliability, and extended machinery lifespan. Our maintenance teams use these insights to schedule activities during planned shutdowns, ensuring minimal production disruption. This proactive strategy has led to substantial cost savings and significantly boosted overall plant efficiency.

What are the challenges and advantages of integrating data across various systems in your cement manufacturing process?
Integrating data across various systems in our cement manufacturing process presents both challenges and advantages. One of the primary challenges is ensuring data consistency and accuracy across different platforms. To address this, we have implemented robust data integration and validation frameworks that facilitate seamless data flow and synchronisation.
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.

How is digitalisation contributing to sustainability efforts and reducing the environmental impact of your cement production?
IT initiatives play a pivotal role in supporting our sustainability efforts and reducing the environmental impact of cement production at Wonder Cement. One of the key contributions of IT is the optimisation of energy consumption. Through advanced energy management systems, we continuously monitor and analyse energy usage across our operations. This allows us to identify areas of inefficiency and implement measures to reduce energy consumption, such as adjusting process parameters and utilising energy-efficient equipment.
Additionally, IT enables us to track and manage emissions more effectively. By integrating emission monitoring systems with our IT infrastructure, we can continuously measure and analyse emission levels, ensuring compliance with environmental regulations and identifying opportunities for reduction. For instance, real-time data on CO2 emissions allows us to adjust our production processes to minimise the carbon footprint.
IT initiatives also facilitate the implementation of circular economy practices. Through sophisticated waste management systems, we can monitor and optimise the use of alternative fuels and raw materials, reducing our reliance on traditional resources and minimising waste generation.

With the increasing digitisation of operations, what steps are you taking to ensure cybersecurity and protect sensitive data?
With the increasing digitisation of operations, ensuring cybersecurity and protecting sensitive data is paramount at Wonder Cement. We have implemented advanced technologies such as artificial intelligence and machine learning (AI/ML) for threat detection and response, and Secure Access Service Edge (SASE) to provide secure and efficient network access. Additionally, our Security Operations Centre (SOC) continuously monitors our digital infrastructure, utilising AI/ML to identify and mitigate potential threats in real-time. Comprehensive cybersecurity measures, including firewalls, intrusion detection systems, and regular security audits, further safeguard our systems. We also conduct regular training sessions for our employees to raise awareness about cybersecurity best practices and potential threats. By prioritising cybersecurity, we ensure the confidentiality, integrity, and availability of our critical data and systems, staying ahead of emerging cyber threats.

What future IT trends do you foresee having the most significant impact on the cement industry, and how is your organisation preparing to embrace these trends?
Looking ahead, we foresee several IT trends that will significantly impact the cement industry. These include the further integration of AI and machine learning for advanced process optimisation, the adoption of blockchain technology for transparent and secure supply chain management, and the expansion of IoT applications for enhanced monitoring and control. Additionally, the use of drones for site inspections, computer vision for quality control, generative AI for innovative design solutions, and robotics and RPA for automating repetitive tasks will bring substantial benefits. At Wonder Cement, we are actively preparing to embrace these trends by investing in research and development, collaborating with technology partners, and continuously upgrading our IT infrastructure. Our proactive approach ensures that we remain at the forefront of technological advancements, driving innovation and maintaining our competitive edge.

– Kanika Mathur

Concrete

WCA’s annual conference

Published

5 months ago

June 13, 2024

Roshna

At the World Cement Association’s annual conference the WCA Director, Emir Adiguzel addressed the global cement industry to outline the challenges and opportunities facing the global cement industry.

The conference held in Nanjing, had industry leaders, innovators and stakeholders in attendance to discuss the future of cement production and sustainability. The WCAA director emphasised on the cement industry’s stern commitment to sustainability; spoke about the global cement demand and market dynamics, projecting a period of stagnation from 2024-2030 with growth expected only in the Middle east, India and Africa; about the challenges and opportunities in carbon capture technology hat show promise but will need further development and substantial investment as well as about the strategic initiatives and collaboration within the industry in improving sustainability and operational performance.

Adiguzel concluded his address by highlighting the crucial point where the global cement industry stands by saying “Collaboration within the World Cement Association is essential for sharing knowledge and aligning on long-term objectives. Ensuring the industry’s resilience and adaptation to evolving market dynamics is crucial for the survival of independent cement producers”.