Technology

Optimising Plant Performance

Published

8 years ago

July 4, 2016

admin

The Rietveld method of quantitative analysis of amorphous materials has gained importance in the light of the BIS issuing specifications for composite cement.
Nowadays, many industries are looking for possibilities to reduce CO2 emissions, energy consumption and increase the reuse of waste materials, These demands are enforced by various regulations and international agreements, and in the long term, they will cause cost reductions. In the cement industry, this can be achieved by using modern techniques in production and by an optimisation of the burning process, by fuel substitutions, alternative clinker compositions or by the production of blended cements with different additives. A variety of completely or partly amorphous materials are used as additives, like slag, fly ash, silica, pozzolana and others. Controlling these additives quantitatively is essential in order to guarantee the cement norms.

Since the mineralogy strongly influences the reactivity of the cement as well as the physical properties of the hydrated product, the need for a direct mineralogical assessment by X-ray diffraction is more important than ever before. X-ray diffraction (phase analysis) opens enormous possibilities for process and quality control. Moreover, the recent development of ultra-high-speed X-ray detectors and of the software for quantitative X-ray diffraction analysis allows truly interactive process control. The quantitative Rietveld analysis is an important tool to control raw materials as well as industrial products, hence offering significant benefits in terms of cement production. Cluster analysis in combination with Automatic Program Selection increases the reliability of quantification results.

The examples presented in this paper will show how X-ray diffraction is being used to quantify blended cements with a complex mineralogy containing crystalline and amorphous phases.

Production and quality control using XRD
Nowadays X-ray fluorescence (XRD) and X-ray diffraction (XRF) analyses are standard tools for process and quality control in cement plants. XRD analysis in combination with Rietveld refinement is a reliable, precise and very reproducible way to quantify the relative phase abundances in building materials. The whole process from sample preparation, through measurement to Rietveld evaluation can be implemented in existing laboratory automation systems and takes approximately 10 minutes. Due to the completely automated operating principle, no additional staff are required and the results are user-independent. The Rietveld method is now being applied in industrial laboratories and also in various cement plants as the standard method for quantitative analyses of raw materials, Portland cement clinkers, Portland cements (OPC) and all types of blended cements.

For clinker, the Rietveld method is the only option to determine the phase content in an accurate and fast way, because the Bogue calculation is usually not correct due to the incorporation of higher amounts of minor and trace elements in the clinker phases, especially when alternative fuels are used. The quantitative mineralogical composition of the cement is directly linked to the hardening behavior and the compressive strength after 28 days. Blended cements are classified under different norms. In order to fulfill these norms and to guarantee the quality of the product, it is necessary to determine the exact amount of added blending materials which is only possible by Rietveld quantification.

Figure 1: Contribution of crystalline and amorphous phases to
an XRD pattern

Figure 2: Rietveld quantification of a pure fly ash, containing
mullite, quartz and around 45 per cent amorphous material..

Figure 3: Rietveld quantification of a fly ash
cement with separate

Figure 4: Cluster analysis of different slag cements with low
(blue), medium (grey) and high (green) amounts of slag
quantification of the fly ash components, including amorphous content

Application of Rietveld analysis for blended cements
The Rietveld analysis uses the whole XRD pattern for quantification and not only single peaks like the classical free lime determination. All peaks from the pattern are used for the refinement and the crystalline compounds are normalised to 100 wt.-%. The Rietveld analysis requires information on the structure data of all crystalline phases in the material and other crystallographic parameters. The quantification of amorphous material requires special procedures. Amorphous material doesn?t give clear diffraction peaks; the pattern may just show a higher background or a hump in a certain region. This hump is not always discernible, especially for low concentrations of the amorphous phases. The background noise strongly influences the quantification results for the amorphous material. Figure 1 illustrates the contribution of crystalline and amorphous phases to a XRD pattern.

Different approaches to determine the amorphous content are described in the literature. The addition of an internal standard is a common method for the determination of the amorphous content.

A defined amount of a standard (like corundum or rutile) is added to the material, and the amorphous content can be calculated from the obtained standard amount from the Rietveld quantification. Influences on the quantification resulting from mixing of the sample with the standard, from possible amorphous content in the standard (Whitfield & Mitchell, 2003) or from crystallographic parameters (De La Torre et al., 2001) were studied. Westphal et al. (2009) showed that the calculation of the amorphous content via Rietveld analysis using an internal standard follows a nonlinear function. For an industrial application, especially for automated systems, the internal standard method is not suitable.

Figure 5: Cluster analysis of different limestones rich in quartz, dolomite
or mica. Outlier in red was a damaged sample.
Figure 6: Working scheme of the Automatic Program Selection
based on Cluster Analysis.

For industrial applications, other methods for quantification of the amorphous material were developed. One possibility is the external standard method. In this case a crystalline standard material is prepared only once and measured separately on a weekly basis. Via mathematical procedures the data obtained from this scan are used for the determination of the amorphous content in the cement. The advantage of this method is that no mixing of standard material and cement sample is necessary. Another possibility is to calculate the area or the intensity of the amorphous contribution to the powder diffraction pattern. This approach is known as the ?HKL? method. The amorphous part is considered as an additional phase and included in the Rietveld calculation. The final result including all crystalline and amorphous phases is again normalised to 100 wt.-%.

Table 1 shows typical ranges of reproducibility and repeatability for different slag cements containing slag from 8 wt.% to 65 wt.%. Table 2 shows typical ranges of reproducibility and repeatability for different fly ash cements with fly ash contents from 10 wt.% to 30 wt.%. For the reproducibility sets of 10 separately prepared samples of the same material were measured. The variation of the results is mainly caused by sample inhomogenities and preparation effects. For the repeatability values one prepared sample was measured 10 times.

Some blended cements have a very complex composition containing more than 20 crystalline phases and one or more amorphous components, introduced by the addition of materials like fly ash or other compounds. Fly ashes used in the cement industry contain usually 30 – 70 per cent amorphous material and as main crystalline phases quartz and mullite. Different feldspars, magnetite, hematite, anhydrite or other phases may also occur.

A Rietveld refinement of an example of a fly ash containing quartz, mullite and amorphous material is shown in Figure 2.

The described quantification methods including amorphous contents can easily be integrated into automation systems. The output file can be defined according to the needs, either all crystalline phases are shown separately (as depicted in Figure 3), or a total value for the amount of slag, fly ash, pozzolana or other added material is given.

A Rietveld refinement of a cement sample containing 20 per cent fly ash is shown in Figure 3.

Cluster Analysis
Statistical analysis techniques are necessary for the data interpretation.
Cluster analysis is a useful tool, as it greatly simplifies the analysis of large amounts of data. This application can be used for simple pass/fail analyses of raw materials, characterisation of blended cements, and automatic selection of control files for Rietveld analysis (APS).

Powder diffraction scans or other data sets are sorted automatically into separate clusters, with closely related scans in a cluster. The most representative as well as the most different scans or data sets can be identified. Outliers are clearly visible as they do not fit into any of the defined classes. Outliers represent deviations or problems in the production process, like changes in the composition, instabilities in a kiln or others. They can be also a result of problems with the sample itself, resulting from sample preparation or transport, like uneven surface or a broken sample. An example of cluster analysis of different slag cements is shown in Figure 4. In Figure 5 an example for an outlier produced by a damaged sample is given.

Automatic Process Control (APS)
The quality of the control files for the Rietveld quantification is decisive for the accuracy of the results and therefore also for the whole process control. A control file can work over a large range of compositions, e.g. from very low to very high amounts of slag in a cement, with good results. For smaller ranges, the control files can be designed with an optimised accuracy. Separate control files are also recommended if different fly ash types are used. Special designed refinement strategies, different background treatment and an optimised fitting for other parameters can be implemented to achieve higher accuracy for the quantification. The selection of a control file can be done automated by cluster analysis. After a measurement, the scan is compared with a pool of scans, the master scans. These scans define separate clusters, representing clinkers or cements with different compositions, like slag cements with low, mid, and high amounts of slag. The variability of each cluster, represented by the diameter of the spheres in the PCA (Principal Component Analysis) plot, is defined by the allowed range of composition for each material. Every measured scan is classified into an existing cluster, if it is within the allowed range, or rated as an outlier.

To each cluster, an optimised control file for the automated quantification is assigned. Each scan can then be processed by a special control file designed for this material. The results of the quantification can be handled by a LIMS (Laboratory Information Management Solution) system. Outliers have to be treated in a special way. The scan can be processed with the control file of the nearest cluster, accompanied by a warning message, that the quantification is of limited reliability. In any way, human interaction is necessary or recommended. The process scheme of the Automatic Program Selection is shown in Figure 6.

Conclusion
Phase analysis by X-ray diffraction opens enormous possibilities for process and quality control in the cement industry especially for blended cements. Moreover, the development of fast X-ray detectors allows fast quantitative X-ray diffraction analysis and truly interactive process control. The Rietveld method allows precise and reproducible quantitative analysis of all types of blended cements. It can be performed in an automated, stable and accurate way. Using an external standard or HKL fit, the determination of the amorphous content can be done directly on the cement sample. The result output includes the quantitative analysis of the crystalline and amorphous phases as well as the total amount of added cementitious material. Nowadays the Rietveld method is being applied in many cement plants worldwide as the standard method for quantitative phase analyses of all types of blended cements. The integration of the cluster analysis into the Rietveld quantification allows fully automated selection of an optimised control file for each material. This increases the accuracy of the quantification and allows an easy identification of outliers.

References
1.Rietveld, H. M. (1969): A profile refinement method for nuclear and magnetic structures, J. Appl. Cryst. 2, 65-71
2. Young, R. A. (1993): The Rietveld Method, Oxford University Press
3.De La Torre, A. G., Bruque, S., and Aranda, M. A. G. (2001): Rietveld quantitative amorphous content analysis, J. Appl. Crystallogr. 34, 196-202.
4.Westphal, T., F?llmann, T., and P?llmann, H. (2003): Rietveld quantification of amorphous portions with an internal standard-mathematical consequences of the experimental approach, Powder Diffr. 24, 239-243
5.Walenta, G., Gimenez, M., and F?llmann, T. (2008): Quantitative analyses of blended cements in industrial applications.- International Cement Review, July 2008, 67-71
6.Whitfield, P. S. and Mitchell, L. D. (2003): Quantitative Rietveld analysis of The amorphous content in cements and clinkers, J. Mater. Sci. 38, 4415-4421.
7.Westphal, T., F?llmann, T.: Quantifying Amorphous Portions in Blended Cements – A Comparative Study.
8.F?llmann, T., Meier, R., and Witzke, T.(2012): Use of X-ray techniques to optimize the efficiency of cement and concrete characterization.
Fuellmann, T., Witzke, T., van Weeren, H. PANalytical B.V., Lelyweg 1, 7602 EA Almelo, The Netherlands

Concrete

Smart Cement Plants

Published

4 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

4 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

6 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”.