Technology

Advancements in fabric filtration technology

Published

7 years ago

February 28, 2018

admin

The article highlights the new emission standards and online reporting protocol for cement plants and captive power plants. It also covers the advancements in filtration technology to reduce dust, SOx, NOx, Mercury, Dioxins and Furans, heavy metals from the Kiln gases and also dust and SO2 from CPP.
Stringent dust emission regulations are introduced in early 1980s where the emission standards were 250mg/Nm3. During this period, most of the cement plants adopted electrostatic precipitators (ESP) for all applications. Subsequently, when the emission standards were reduced to 150mg/Nm3, Cement plants have upgraded the ESP with modern controllers, additional fields, change of electrodes. When dust emission standards have reduced to 50 mg/Nm3, cement kilns have shifted to reverse air baghouses with fibre glass bags and other applications like coal mill, cement mill, raw mill etc., shifted to low temperature bags like polyester/acrylic bags with or without antistatic treatment. However, the clinker cooler and captive plants continued with ESP technology.
In 2014, first time in India, gaseous emission standards (SO2, NOx, VOC, Mercury, NH3, heavy metals, dioxins and furans) for cement kilns and simultaneously dust emissions standards reduced to 30mg/Nm3 instead of 50mg/Nm3, which are on par with the global best practices. Apart from the emission standards, CPCB issued a direction on 5th February 2014 about the online reporting of emissions (both Stack and ambient air) and effluents from 17 categories of industries. Further, CPCB released guidelines for continuous emission monitoring system during July 2017.
The notification calls for online reporting of emissions from all process stacks and ambient air quality stations to SPCB and CPCB on 24 X 7 basis and stringent reporting and compliance standard. In 2015, CPPs emission reduction standard (Dust, Sox, NOx & Mercury) were introduced with varied emissions based on the vintage of the plant and also size of the plant.
Compliance timelines in both the cases i.e., Cement Plants, March 31, 2017 and for CPPs up to December 7, 2017. In both the cases, industry faced many technical as well as financial challenges to complete these projects. Based on the industry request, the Cement plants have been given time line extension up to August 31, 2018 and for the power plants, time line extension is not yet finalised.
The monitoring reporting protocol also is a major challenge in terms of technology option. As per the standard the emissions are measured on a 15 minute average and non-compliance alerts has been given to the companies. By design, emission from ESP varies with the process conditions and also emissions goes up while cleaning system of the electrodes takes place, especially in the outlet field. This becomes a big challenge when complying with the 15 minute duration constant emission from any ESP. Global compliance standards takes 1 day average or 3 day emissions average or 30 days rolling average to issue compliance alert and also to action of noncompliance. Indian standard on monitoring reporting protocol is the toughest standard at this moment.
The reporting issues posed biggest challenge for the technology selection for the control equipment. From early 1980s, there is a rapid advancement in terms of fabric filtration technology and currently newer fabrics and membranes have been developed to reduce the emissions to below 5 mg/Nm3 with a lower pressure drop and guaranteed longer life of up to 6 to 8 years. Apart from dust, the current advanced filter media is capable of reducing heavy metals, Dioxins, Furans, Mercury removal. Latest environmental regulations
Cement Plant: MoEF&CC has issued notification on revised emission norms to cement plants on August 25, 2014 against various parameters such as PM, SO2 & NOX emissions with varied compliance timelines for various parameters from January 1, 2016 to June 1, 2016. Final compliance timelines extension is further extended August 31, 2018.Filtration technologies adopted by cement
Indian cement industry is very progressive and is continuously adapting to the latest technologies to make the Cement Industry more efficient and green with less environment footprint. In the same spirit, Cement Industry is first one to adopt filtration technologies like Pulse Jet Bag House (PJBH), reverse air bag house and hybrid filters for controlling of dust emissions from stack.
Advent of new fabrics which can withstand higher temperatures and tough working conditions, controls and advance electrical systems provided the opportunity to reduce the dust emissions to very low levels. Cement Industry embraced these technologies that helped industry today in achieving consistent and lower stack emissions of 30 mg/Nm3.
To meet the online reporting requirements, cement plants have installed Continuous Emission Monitoring Systems (CEMS) and continuous ambient air quality monitoring stations (CAAQMS). Among various Industrial sectors, Cement Industry is the first one to move ahead with on line reporting of their dust emissions performance. This has demonstrated the willingness of Cement Industry to be more transparent in disclosure of their dust emissions performance.Advancement in filtration technologies in fabric filters
There are several conditions like change in process/raw material, wrong selection of fabric, and other design issues, abrupt changes in process operational parameters, poor diagnosis including lack of automation, improper maintenance, operational incompetency etc. resulting in poor performance of bag filters.
To address these issues, various advancements took placed in fabric filter technology and details of these developments are as given below:

Advancements in filter fabrics w.r.t., temperature with stand ability, chemical resistance, etc., giving an opportunity to select application specific fabric
Higher fabric area weight (density) fabrics
Economic viability of Polytetrafluoroethylene (PTFE) lamination technology
Low pressure filtration
Technological innovation in Pulse valves
Pulse valve failure detection system
Automation in back leak detection through Invention of bag leak detection systems along with latest controls
Remote diagnostics
Computational Flow Dynamics (CFD) studies of the bag house to correct the flow distribution and prevent the bag failure
Constant Pressure drop based bag cleaning system
Tall bags of 10-15 metres
Mandatory precoating of bags
Operating bag house at least 20 deg C above Water / acid dew point temperature
Residual analysis
Mandatorily adopting all seasons weather enclosure

Advancements in filter fabrics: Greater advancement took place in Filter fabrics w.r.t., temperature and tough working conditions with stand ability, filtration efficiency improvement etc., giving an opportunity for fabric manufacturers to develop various fabrics with different surface finishes and characteristics. Notable advancements in this direction are advent of Polyimide (P 84) fibres and micro denier fibres. Fabrics made out of polyimide fibres are having temperature with stand ability of approximately 260 degree and being a felt fabric can withstand rough handling and working conditions. This has helped Cement Industry to consider these fabrics in place of glass with/without PTFE membrane which are very fragile and delicate fabrics for Kiln application which has resulted improved operational efficiency of Kiln Bag Houses.
Similarly, PANOX and PYRON fibersare Oxidised Polyacrylonitrilefibers do not burn nor melt nor char. These fibres in blend with Nomex can bring in extra heat protection in Clinker cooler bag filter application.
Advent of micro denier fibres which are light in weight and high bulk, water repellent helped in developing fabrics which are more efficient with respect to filtration efficiency and more durable. The most common types of microfibres are made from polyesters, polyamides (e.g., nylon, Kevlar, Nomex), or a conjugation of polyester, polyamide, and polypropylene. This has resulted in achieving better permeability with better dust dislodgement characteristics, thereby enhancing the bag filters / bag houses performance.
Apart from dust filtrations, recent trends are towards use of Catalyst powder along with PTFE Powder during the manufacture of the felt. The resultant bag with membrane lamination can be effective in controlling the particulate emissions besides controlling Dioxins and Furans. This is also self-regenerated catalyst and is effective at temperature above 200 degree C.Fabrics with high fabric area weight (density): With the advent of finer fibres like micro denier fibres gave an opportunity to develop higher density fabrics with same / lower thickness than the traditional fabrics. Currently fabrics are available with 600 to 750 grams / sq m fabric density with the similar thickness, flexural characteristics as against traditional fabrics with density of 500 grams / sq m. These high density fabrics are more robust are able to give higher bag life even in touch working conditions.
Economic viability of PTFE membrane technology: Both the PTFE membrane manufacturing and lamination technologies have become more commercially viable.
This has resulted in industry adopting fabrics with PTFE lamination which helps in better permeability, dust dislodging, less pressure drop, lower energy consumption and improved productivity. Industry is looking at this technology wherein reduction in pressure drop and increased productivity up to 10-15 per cent can be tapped from the existing filter.Low pressure filtration: One of the latest technological advancements in bag filters/bag house are low pressure filtration which uses filter bags cleaning pressure of 0.8 bar as against 4 to 6 bar pressure used in traditional Pulse jet bag houses / bag filters. This low pressure filtration is achieved by using physical flow model study / Computational Flow Distribution studies to achieve optimum gas flow distribution, energy efficient roots blowers, specially designed cages and filter bags, advanced pulse valves etc., This helps bag houses in achieving low energy consumption, lower outlet emissions, extended bag life & overall reduced operational cost.Technological advancement in pulse valves: Greater Technological advancements took place in pulse valves, which resulted in enhancing pulse valves performance wrt, its ability to take higher flow / valve, Longer life, ability to have consistent performance due to pressure variations and contamination, very fast and repeatable response time for quick and accurate purges, reliable performance in harsh environment conditions, self-cleaning ability, less consumption of air, faster response time for more efficient duty cycles and higher impact force when blowing. This has resulted in improving operational efficiency and lower energy consumption both in existing and new filters.
Pulse valve failure detection system: These systems will identify the operational failures with Solenoid valves and convey the same to the plant personnel to enable them to replace/repair the solenoid valves immediately. This protect the filter bags from negative impacts like dust build up, blinding etc., due to non-pulsing which in turn increases the Pressure drop and higher power consumption.
Automation in back leak detection through Invention of bag leak detection systems along with latest controls: The integrated Bag cleaning mechanism monitors the dust emission on continuous basis. In case of spike in dust emission due to broken bags, the associated solenoid is automatically disabled to avoid flexing of damaged bag, thereby avoiding the enlargement of hole. The controls have features to continuously adjust pulse off time to maintain differential pressure at single set point within a narrow band ? 2.5mmW.C. The solenoid activation pulse output can sense the short or open solenoid with instant failure detection and row identification. The system can also identify leaking or ruptured, stuck open or closed diaphragm with instant failure detection and row identificationRemote diagnostics: Latest automation provides an opportunity for us to have all the bag house operational data like Differential Pressure, Temperature, Pulsing cycle, Dampers position, dust build-up in hoppers, healthiness of dust handling systems, filter bags, solenoid valves, outlet emissions, etc., and fine tune various parameters from the plant control room / local control panel. This helps us in ensuring the operation of bag house at the optimum level to enhance its performance with respect to bag life, differential pressure, energy consumption, etc. and maintaining consistent outlet emissions.
Computational Flow Dynamics (CFD) studies of the baghouse to correct the flow distribution and prevent the bag failure: CFD is a branch of Fluid Dynamics that uses numerical analysis and data analysis and data structures to solve and analyse the problems that involve fluid flows. CFD helps in designing the Air Pollution control systems with better efficiency, minimise cost of product development and design the systems in much smarter method. Modern CFD programs permit the simulation and analysis of flows on the computer. The computer-supported analysis enables examination of the dynamics of flowing media and provides a computer model which represents the examined conditions of an installation. The special strength of CFD simulations lies in the fact that ‘trial and error’ experiments, which are practicable in reality only with great effort, can be limited by CFD to the most likely solutions of the problem and with a minimum of effort.
CFD speeds up project work in conceiving and realising industrial dust removal installation, but it also serves as a tool for basic advancements. With a suitable choice of the simulation model, optimisation possibilities close to the installation can be found. The key to efficiently solving tasks is the networking of the CFD program with the CAD system. Nevertheless a simulation program is only as good as the user who serves it. The model construction, the simulation realisation and evaluation need
a lot of experience. Typical CFD outcomes are as given below:
Constant pressure drop based bag cleaning system: Current bag cleaning systems are automated to maintain constant pressure drop across the bag house. This helps in operating the bag house with consistent performance with respect to pressure drop, energy consumption.Usage of taller bags of 10-15 m long: Advanced pulse valves along with latest ventures are facilitating in effective cleaning of longer bags up to 10 – 15 meters long. This helps in having new bag houses with lesser foot print, converting ESPs to bag houses / hybrid filters.Mandatory pre-coating of bags: Dust with finer particles of 0.5 microns or smaller can leak right through pores of a new bag working their way deep into the media to the point of blinding, or clogging, the filter and slowing or stopping airflow through the bag house / bag filter, which in turn affect the performance of bag house and lead to higher power consumption. Pre-coating can reduce or prevent the permanent failure of new filter bags. Built up of pre-coating material as initial dust cake on the media, prevents dust particles from flowing into and blinding the media. Pre-coating ensures that air flows freely through the dust collector, improving filtering performance while extending the bag life. Pre-coating of new filters provides other benefits like improving the dust collector’s initial filtration efficiency at start-up, ease of cleaning, better dust cake release etc.
Operating bag house at least 20 deg C above water / acid dew point temperature: It is mandatory to operate the bag house at least 20 degree C above water / acid dew point temperature to avoid condensation of water / acids on the filter fabric which in turn will damage the filter bags and leading to higher pressure drop, higher energy consumption and higher emissions (if the bags are damaged due to acid attach). Residual bag life analysis: To ensure consistent performance of the bag house, it is essential to periodically check the filter bags for residual life and to replace the bags before the failure happens. This will help in preventing the higher emissions from the bags and to ensure consistent performance of the bag house.Mandatorily adopting all seasons weather enclosure: Bag houses / Bag filters are prone to water seepage through the top doors, top roof during the rainy season which will impact the performance of bag house by blinding the bags due to water condensation. Hence it mandatory to provide weather enclosure on all the existing/new baghouses to prevent moisture ingress and to ensure consistent performance of the bag house.Conversion of RABH to PJBH/additional module: When the plant capacity is enhanced, few of the options available for accommodating the higher gas volume is either converting reverse air baghouse to pulse jet baghouse or addition of module which will facilitate in creating more filtration area and thus accommodating the additional gas volume.
Current constraints and design challenges for bag filter suppliers
In spite of technological advancements in fabrics and bag house technology, still the bag filter / bag house suppliers continue to face few challenges as given below:

Online maintenance of the filter
Emissions exceeding beyond the permissible limits
Ability to install new filter with least shutdown time
Minimising the ID fan energy consumption and compressed air consumption
Consistent longer bag life
Ability to install fabric filter in ESP Casing
Ease of bag house maintenance / bags replacement
Fabrics which can withstand consistent operating temperatures > 260-280 deg C
Catalytic filter media
Expenses Cages

Advancements in ESPs
In spite of the advancements in Fabric Filters, Electrostatic Precipitators are still preferred over Fabric Filters especially for high temperature applications like Clinker Cooler and treatment of flue gas in Power Plant. One of the main drawbacks of ESP is that it is highly influenced by the process parameters. Small changes in the operation conditions – flue gas temperature, dust/flue gas characteristics have enormous impact on the ESP efficiencies.
Majority of recent advancements in ESPs are as given below:

Smart Controllers for conventional transformer rectifier (TR sets)
Three Phase transformers
High frequency transformers

Smart Controllers for conventional TR sets: Optimum power to the ESP is a key in achieving the maximum dust collection in the different fields of the ESP. Adapting smartly to changing process conditions, reducing the impact of sparking in the field as well as back corona occurrence thereby improving the energising level helps in reducing emissions to desired levels. Fast response to sparking condition thereby always maintaining peak power levels is an inherent feature of these controllers.
Manufacturers are developing better products and software for combating back corona especially in Indian coal scenario. Advanced Algorithms for automatic detection / control of back corona with very high pulse blocking ratios has been effective in mitigating impact of back corona. Reliability has been another issue which has been addressed with the selection of superior components. With ESPs designed with 3-4 electrical fields, failure of one controller can impact collection area of around 25 to 33 per cent. Sectionalisation of mechanical field by splitting into two fields (either across gas flow or in direction of gas flow) to increase number of electrical fields, can result in substantial improvement in the ESP performance.Three Phase Transformer: Recent trends for improvement in power levels have been the increasing up-gradation of existing transformers (single phase 415 V) with Three Phase transformers. Sparking in the field is predominantly due to the peak KV reaching spark over level across the collecting and discharge electrodes. With conventional TR sets, the average KV is 60 to 90 per cent of the peak KV. With conversion to Three Phase transformers, the average KV can be more than 90 per cent of the peak voltage thereby drastically increasing the energisation levels of the ESP, thereby reducing emission levels. Equipment suppliers are willing to offer 20 to 30 per cent reduction in emission for up-gradation with three phase transformersHigh Frequency Transformers (HFTR): In conventional TR sets, the power level to the TR set and thereby to the ESP is controlled by the firing angle of the Thyristor (SCR) – point in the AC power cycle where the voltage is applied to TR set. Once the Thyristor start conducting, it can be stopped only during cross over to the reverse cycle. This limits the point at which the conduction of the SCRs can be stopped, rather there is no control. With the advent of IGBT’s the start / stop of the conduction of the device can be controlled. It is possible to provide more precise control of the ESP parameters such as the output voltages and currents. It is also possible to make a rapid increase or decrease in voltage and to provide a very fast response to load changes.
The HFTR supply uses an IGBT converter which supplies the primary of transformer with 5 kHz – 20 kHz AC. (Conventional TR set are controlled at mains frequency i.e 50 Hz). Due to these advantages it is possible to suppress the supply quickly in the case of sparking, reducing the spark energy and the quantity of ionised gasses produced by the electric arc. Similarly the recharging is also faster. Reduction in the spark energy is many times compared to conventional SCR solution.Thus HFTR can comfortably operate with 50 to 100 sparks per minute without significant loss of corona power and very close to flash over levels unlike traditional Sets.
The lower quantity of ionised gasses produced by the spark contribute to much shorter de-ionisation intervals, required to quench sparking and evacuate charged particles in order to reinstate the voltage and proceed with the operation.
Since the average and peak KV being very close, they can operate at significantly below flash over levels in case of combustible and explosive applications thereby reducing chances of fire and maintaining the desired efficiency.
As a result, the collection efficiency and energy efficiency of the electrostatic precipitator can be increased many fold by applying high frequency high voltage power supply. Hybrid Dust Collectors: ESP-Bag filter
Another approach quickly gaining widespread usage especially for CPP Boiler is Hybrid Dust Collectors. For a typical four field ESP, the outlet two fields can easily be converted to bag filter by simple modification of the ESP internals. The Coarse particles are easily collected in the inlet fiels and the fine particles which are comparatively difficult to collect in ESP are collected by the filter bags. The cost for new bag house is reduced as in most cases the existing ESP casing / ducting & hopper / dust conveying system is used. Also the operating cost is reduced as the DP is on lower side as dust loading is quite low.
HFTRs and Three Phase work the best in inlet fields. So in Hybrid filters providing HFTR / 3 Phase in the field-1 is a great idea! Benefits a) In case of minor bag failures emissions will not rise alarmingly. b) The requirement of cleaning bag is less since it is exposed to less dust, meaning longer bag life and less compressed air usage.Closed Loop Energy Management System
The importance of closed loop energy management systems with opacity monitors is being looked at seriously. Although the limited electrical fields do not give enough room for energy management, this will slowly become the norm rather than exception.
Another off shoot of new emission norms is that a lot more care is taken in dust and ash conveying, especially false air leakages through them. This not only reduces emissions, but saves power also. Care is also taken to avoid dust build-up in hopper so as to avoid tripping of the fields due to ‘hopper
level high’Conclusion
Environmental Protection and continuous adoption of environment abatement technologies continue to be the primary focused area of Cement Industry to comply with environment regulations and to beyond the regulatory regime. Various technical advancements in filtration technology indicated above are clearly demonstrating their significance for new emission regulations by overcoming constraints like layout constraints, longer shutdown timelines, reduced financial resources requirements, etc. Acknowledgement
We thank Dilip Sakphara – Managing Director and Rushabh Sakhpara – Business Development -MaxTech Industries and Dr VS Rajan – Chief Technical Advisor – Supreme NonWoven Industries Pvt Ltd for providing technical inputs in drafting this article.
The article is authored by: KN Rao, Director – Energy, Environment & Sustainability, ACC Limited

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”.