Economy & Market

Revival of small scale cement manufacturing

Published

7 years ago

January 7, 2019

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The availability of most of the AFR is limited or scattered which may not be economically viable for use in most of the large cement plants because of logistics, quantity, preparation and technical issues, says Dr KN Bhattacharjee.

The availability of most of the AFR is limited or scattered, which may not be economically viable for use in most of the large cement plants because of logistics, quantity, preparation and technical issues. This is a great roadblock for the effective use of AFR. However if an industry can find means to utilise its own by-product or waste in its own premises or nearby then it will be a win- win situation for all. Cement manufacturing process is a very appropriate process to recycle many industrial and agricultural wastes. The black meal process of vertical shaft kiln technology is a proven technology in China and India and can serve as a very good outlet for consuming AFR in the vicinity of industries generating the waste in small quantities.

This will also help in reducing environmental pollution. The author has carried out numerous plant scale trials with various industrial and agricultural wastes in VSK plants in India with reasonable success and feels that it may be worthwhile to go backward technology-wise to improve India’s usage of AFR. With the recognition of performance-based cements in most of the standards of world, composite cements are to gain ground and many alternate materials mainly industrial wastes can find profitable use again in small-sized cement plants.

The vertical shaft kiln (VSK) technology is an old technology of Portland Cement manufacture and even the modern versions have almost phased out from India mainly because of economics of scale and taxation issues. In China, still 30 per cent of its cement production comes from shaft kiln plants. The VSK process technology is still a workable proposition for use of wastes available in limited quantities. Also by virtue of the simple process a plethora of process issues associated with modern pre-heater, pre-calciner rotary kiln system are eradicated while using AFR. Plant scale trials with many wastes have shown improvement in VSK clinker quality and better productivity from the kilns. Also it is possible to add many wastes in small quantities directly to VSK clinker to produce high performing composite cements. Although the plan sounds to be reverse engineering but sometimes an old concept can regain its past glory due to changing national needs and environmental issues.

The modern vertical shaft kiln technology is technically sound and institutes like National Council of Cement and Building Materials (NCCBM) and the then Regional Research Laboratory (RRL), Jorhat had done a commendable work in modernising the technology in India. Also the village-based Saboo technology created a stir in India in the 80s when they brought cement manufacturing under the umbrella of small scale industry. During that period, the objective was to increase production as India was cement deficit and VSK technology was a partial answer to quickly bridge the gap between demand and supply. In the hilly terrain of North East, it is still a viable proposition to use scattered small limestone deposits in the midst of logistical challenges.

The advantages and disadvantages of black meal process of vertical shaft kiln technology:

Advantages:

Small scale cement production and still suitable in hilly terrains having limestone deposits for local distribution of cement.
Energy efficient process: Specific heat consumption is in the range 600 to 650 Kcal/kg of clinker. Specific power consumption is in the range 0f 60 to 70 Kwh/tonne OPC although authentic figures are not available. Since drying, pre-heating, calcining, burning and cooling are integrated in the same vessel, heat losses due to convection and radiation is much reduced.
Porous VSK clinker is much easier to grind thus cement grinding power requirement is less.
Very low refractory consumption as kiln is stationery and low abrasion as material flow is vertically downward with slow speed.
Vast scope of using AFR available in smaller quantities is the major advantage. Some alternate waste materials can act as flux or mineraliser. Mineralising ions can increase the rate of reaction in burning zone leading to complete burning in burning zone.
Thus the technology offers avenue not only in the use of wastes but also utilise the waste in improving burnability by stabilising phases at lower temperatures.
recirculation of obnoxious gases and materials which ensures smooth operation and higher productivity.
Due a constant bed of wet green nodules above the calcining zone the green nodules bed acts as an effective filter to arrest all dust particles. No additional gas cleaning device is required.
Since fuel is inter-ground with raw materials elaborate arrangement of fuel preparation and firing is eliminated
Very effective and controlled flow of material through flat grate using variable frequency drive (VFD). This helps to position the burning zone constantly at the same level.
Relatively simple machines to operate and maintain.
Gestation period of starting a new plant is very low.
No highly skilled manpower is required and local folk/plant staff can be easily trained for operations.
Possible to manufacture a variety of clinkers and thereafter produce various kinds of low cost Portland cements.
Very little chance of cold air in-leakages. Diversion of combustion air during clinker discharge has been ably dealt by either triple air locking arrangement or material block tube in the modern VSKs.
Since each nodule has its independent fuel system significantly higher temperatures are not achieved leading to no issues of NOx.

Disadvantages:

Viability can be at stake due to taxation policies and lower scale of operation. However if Government gives tax rebates on use of AFR the plants can be viable. Also it is possible to reduce cost of production by using low cost or free of cost non- conventional materials and waste fuels available locally. Maybe the savings can be shared with customers.
Quality issues: Many believe that VSK clinker cannot be at par with modern rotary plant clinker. In this respect a few conflicting issues are prevalent. It is true that using the same raw materials and fuel the modern rotary clinker will be better performing especially the later age compressive strengths and soundness of cements produced. However the soft burnt nature of the VSK clinker opens up possibilities of addressing customer requirements of good early age compressive strength and early setting in the case of PPC and PSC. The author has found that early age compressive strengths and setting can be matched with modern plants while making PPC with a maximum of 30 per cent fly ash absorption. The Black meal process is capable of producing sound clinkers with less than 1.5 per cent free lime and 45 per cent C3S component. The author’s experience in few VSK plants in Jodhpur-Rajasthan region supports this viewpoint. Experiences with various limestone in Northern India and Bhutan reveals that the technology cannot tolerate high magnesia limestone primarily due to the absence of rapid cooling arrangement but adding certain industrial wastes with mineralising minor constituents gives amazing results in reducing or mitigating this deleterious effect.
Consistency of clinker: Consistency does get affected if the raw mix is not well homogenised and nodulisation is not controlled. However these can be easily solved by using good homogenisation and blending techniques. Nodulisation can be automated to yield nodules of good strength. In some cases nodule strength can be improved by double nodulisation. Various industrial wastes like bagasse from sugar industry have been found to improve nodule strength together with bonus addition of heat value. Waste oils can be added at this stage to give very good results.
Heat difference between the central and peripheral charge especially in the large dia kilns of 100 TPD per day can be a matter of concern in some cases depending of raw materials and fuels used. The 50 tonne/day Saboo shaft kiln design was found to very efficient in this respect. Crust formations were found to be minimal. Dustry clinker due to beta to gamma conversion of C2S is prevalent in few cases but can be eliminated by stabilisation of phases even with the inherent disadvantage of rapid or quench cooling.

Plant scale trials using various alternate materials and fuels:

Use of pond ash, bottom ash and boiler fired rice husk ash in a 50 TPD VSK plant in Kanpur Dehat, Uttar Pradesh: Both bottom and pond ash were procured from Panki Thermal power plant and were used as components of raw mix separately as a source of Silica and Alumina by partial replacement of plastic clay by 15 to 20 per cent. There was drop in free lime from 2.2 per cent to 1.8 per cent and the dust content in clinker reduced drastically. There was increase of 1.5 to 2.0 MPa in 3 days and 3 MPa in 28days compressive strength of 43 grade OPC. The pond and bottom ash had substantial carbon particles (LOI- 15 to 20 per cent) which added some heat value and perhaps the reactivity of the raw mix increased by the presence of some amount of reactive alumino-silicates. Indirect effects noticed was smooth kiln operations with a slight increase of production from the 50 TPD VSK. Pond ash which is generally wet can be added directly during nodulisation if a dosing arrangement is designed to avoid the drying operation. Boiler fired Rice Husk was tried in the same plant which gave very good results in improving clinker quality. The material was black in colour with LOI around 10 per cent indicating unburnt carbon which must have supplemented the heat input. It was possible to add rice husk as it is but plant scale trial was not attempted with the apprehension that the husk fibres may not give a homozenised mix in the existing raw grinding arrangement.
Use of Phosphorus furnace slag, alkali bypass dust and bag house dust from a Calcium Carbide plant: All these materials were tried with a contention to capitalise mineralising effect from the wastes due to some minor constituents or the presence of reactive silica or Alumina. Even granulated blast furnace slag (GBFS) was also tried. Improvements in kiln productivity and quality was noticed of clinker in most of the cases. In VSK operation any measure which goes to ensure completion of the reactions in the short burning zone will definitely go in improving clinker quality and smooth kiln operations. Appropriate raw mix fineness with correct proportioning of waste materials and fuels, homogenisation hold the key to success.
Additions of alternate waste materials with VSK clinker to make composite cements The future of cement making is composite cements. This not will helps to use some industrial or agricultural wastes in the final product but also help to improve performance of cements and reduce the carbon footprint. In many cases it can lead to low cost cements together with better performance.

Significant improvement was observed when 5 per cent bag house dust from a calcium carbide plant was added in a quaternary mix of 60 per cent Granulated Blast Furnace slag (GBFS) and 3 per cent gypsum using VSK clinker. Initial setting time was reduced from 180 minutes to 40 minutes when compared with plain control sample of PSC. There was an improvement of 2 MPa at 3 days and 28 days compressive strength was more or less the same. Quaternary blends using Alkali bypass dust and 60 to 70 per cent GBFS , gypsum and VSK clinker also performed well in terms of faster setting and improvement of early age compressive strength. Similar results were obtained while using brick kiln ash and calcined clay Pozzolana in dosages of 15 to 20 per cent while making PPC mixes using VSK clinker.

Thus VSK clinker can act as a performance enhancer for early setting and early age compressive strength in presence of high dosage GBFS containing PSC cements and fly ash/CCP based Pozzolanic cements. Hydration studies have revealed that the soft burnt VSK clinker releases soft burnt lime at a faster rate in the early ages leading to higher quantity hydration products both with GBFS and Pozzolana.

Conclusion
The author was associated with VSK plants for six years while doing his Ph.D. His doctoral work is mainly associated with hydration studies of composite cements and VSK clinker doped with ions coming from various industrial and agricultural wastes. He feels that the black meal process using modern vertical shaft kiln technology can be a viable proposition to use localised waste materials available in limited quantities. The process simplicity of the Black Meal process opens up immense potential for use of wastes (both agricultural and Industrial) with improved cement performance in many cases. Waste generating plants can have captive VSK plants or sub let this activity to local entrepreneurs. All performance enhancements have been validated by actual hydration studies which is available with the author for anyone who is interested. This has been a part of the author’s doctoral work. The author feels that for India till we incorporate large scale AFR facilities catering to large cement plants the VSK plants can be revived mainly for use of localised AFR as the project cost and gestation period from concept to commissioning is very low.

Acknowledgement
The author is grateful to AKS University administration for allowing to publish this paper.

About the author
Prof (Dr) KN Bhattacharjee has 37 years experience in the global cement industry. He has worked with all process technologies of cement manufacture and has done considerable work on use of AFR in mini-cement plants. His Ph.D thesis is in applied cement chemistry and his findings helped many mini-cement plants in India to improve their profitability during the late 80s. He has publications in reputed international and national journals like Cement and Concrete Research, ZKG International, Silicate Industrials, Transactions of Indian Ceramic Society, etc. After his retirement in 2016 from Dangote-Africa, he is teaching cement technology to B.Tech students in AKS University, Satna. Dr KNB has worked with ACC in India, two plants in Oman, Lafarge Canada and Dangote, Africa.

Economy & Market

SEW-EURODRIVE India Opens Drive Technology Centre in Chennai

Published

2 weeks ago

March 25, 2026

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The new facility strengthens SEW-EURODRIVE India’s manufacturing, assembly and service capabilities

SEW-EURODRIVE India has inaugurated a new Drive Technology Centre (DTC) in Chennai, marking a significant expansion of its manufacturing and service infrastructure in South India. The facility is positioned to enhance the company’s responsiveness and long-term support capabilities for customers across southern and eastern regions of the country.

Built across 12.27 acres, the facility includes a 21,350-square-metre assembly and service setup designed to support future industrial growth, evolving application requirements and capacity expansion. The centre reflects the company’s long-term strategy in India, combining global engineering practices with local manufacturing and service capabilities.

The new facility has been developed in line with green building standards and incorporates sustainable features such as natural daylight utilisation, solar power generation and rainwater harvesting systems. The company has also implemented energy-efficient construction and advanced climate control systems that help reduce shopfloor temperatures by up to 3°C, improving production stability, product quality and working conditions.

A key highlight of the centre is the 15,000-square-metre assembly shop, which features digitisation-ready assembly cells based on a single-piece flow manufacturing concept. The facility also houses SEW-EURODRIVE India’s first semi-automated painting booth, aimed at ensuring uniform surface finish and improving production throughput.

With the commissioning of the Chennai Drive Technology Centre, SEW-EURODRIVE India continues to strengthen its manufacturing footprint and reinforces its long-term commitment to supporting industrial growth and automation development in India.

Concrete

Material Flow Efficiency

Published

3 weeks ago

March 18, 2026

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We explore how material handling systems are becoming strategic assets in cement plants, enabling efficient movement of raw materials, clinker and finished cement. Advanced conveying, automation and digital technologies are improving plant productivity while supporting energy efficiency and sustainability goals.

Material handling systems form the operational backbone of cement plants, enabling the efficient movement of raw materials, clinker and finished cement across complex production networks. With India’s cement industry producing over 391 million tonnes of cement in FY2024 and possessing an installed capacity of around 668 mtpa, according to the CRISIL Research Industry Report, 2025, efficient material logistics have become critical to maintaining plant productivity and cost competitiveness. At the same time, cement production is highly energy intensive and contributes around 7 per cent to
8 per cent of global CO2 emissions, making efficient material flow and logistics optimisation essential for reducing operational inefficiencies and emissions states the International Energy Agency Cement Technology Roadmap, 2023. As plants scale capacity and integrate digital technologies, modern material handling systems, ranging from automated conveyors to intelligent stockyards, are increasingly recognised as strategic assets that influence plant stability, energy efficiency and environmental performance.

Strategic role of material handling
Material handling is no longer viewed as a secondary utility within cement plants; it is now recognised as a strategic system that directly influences production efficiency and process stability.
Cement manufacturing involves the continuous movement of large volumes of limestone, clay, additives, clinker and finished cement across multiple production stages. Even minor disruptions in conveying systems or storage infrastructure can lead to kiln feed fluctuations, production delays and significant financial losses. According to Indian Cement Industry Operational Benchmarking Study, 2024, unplanned downtime in large integrated cement plants can cost between Rs.15–20 lakh per hour, highlighting the economic importance of reliable material handling systems.
Modern cement plants are therefore investing in advanced mechanical handling systems designed for high throughput and operational reliability. Large integrated plants can process over 10,000 tonnes per day of clinker, requiring highly efficient conveying systems and automated stockyards to maintain continuous material flow, suggests the International Cement Review Industry Analysis, 2024. Efficient material handling also reduces spillage, minimises dust emissions and improves workplace safety. As cement plants become larger and more technologically advanced, the role of material handling is evolving from simple transport infrastructure to a critical operational system that supports both productivity and sustainability.

From quarry to plant
The transport of raw materials from quarry to processing plant represents one of the most energy-intensive stages of cement production. Traditionally, limestone and other raw materials were transported using diesel-powered trucks, which resulted in high fuel consumption, dust generation and increased operational costs. However, modern plants are increasingly adopting long-distance belt conveyors and pipe conveyors as a more efficient alternative. These systems allow continuous material transport over distances of 10–15 kilometres, significantly reducing fuel consumption and operating costs while improving environmental performance, states the FLSmidth Cement Industry Technology Report, 2024.
Milind Khangan, Marketing Manager, Vertex Market Research & Consulting, says, “Efficient and enclosed handling of fine materials such as cement, fly ash and slag requires modern pneumatic conveying systems. By optimising the air-to-material ratio, these systems can reduce energy consumption by 10 per cent to 15 per cent while ensuring smooth material flow. Closed-loop conveying further minimises dust loading and improves the performance of bag filters, supporting cleaner plant operations. In addition, flow-regulated conveying lines help prevent clogging and maintain reliable dispatch performance. Overall, automation in pneumatic conveying delivers immediate operational benefits, including improved equipment uptime, lower energy use, reduced material spillage and more stable kiln and mill performance.”
Pipe conveyor systems are particularly gaining traction because they provide a completely enclosed transport system that prevents material spillage and dust emissions. According to global cement engineering studies, conveyor-based transport can reduce energy consumption by up to 30 per cent compared to truck haulage, while also improving operational reliability. Several cement plants in India have already implemented such systems to stabilise quarry-to-plant logistics while reducing carbon emissions associated with diesel transport.

Stockyard management and homogenisation
Stockyards play a critical role in maintaining raw material consistency and stabilising kiln feed quality. Modern cement plants use advanced stacker and reclaimer systems to ensure efficient storage and blending of raw materials before they enter the grinding and pyroprocessing stages. Automated stacking methods such as chevron or windrow stacking enable uniform distribution of materials, while bridge-type or portal reclaimers ensure consistent extraction during kiln feed preparation. These systems are essential for maintaining stable chemical composition of raw meal, which directly influences kiln efficiency and clinker quality. The Cement Plant Operations Handbook, 2024 indicates that advanced homogenisation systems can reduce raw mix variability by up to 50 per cent, significantly improving kiln stability and energy efficiency. Integrated stockyard management systems also incorporate sensors for monitoring bulk density, moisture levels and stockpile volumes, enabling real-time control over material blending processes.

Clinker and cement conveying technologies
Once clinker is produced in the kiln, it must be efficiently transported to storage silos and subsequently to grinding and packing units. Modern cement plants rely on high-capacity belt conveyors, bucket elevators and pneumatic conveying systems to manage this stage of material flow. Steel-cord belt bucket elevators are now capable of lifting materials to heights exceeding 120 metres with capacities reaching 1,500 tonnes per hour, making them suitable for large-scale clinker production lines, states the European Cement Engineering Association Technical Paper, 2023.
For fine materials such as cement, fly ash and slag, pneumatic conveying systems provide a reliable and dust-free solution. These systems transport powdered materials using controlled airflow, ensuring enclosed and contamination-free movement between grinding units, silos and packing stations. Optimised pneumatic systems can reduce energy consumption by 10 per cent to 15 per cent compared to older conveying technologies, while also improving plant cleanliness and environmental compliance, according to the Global Cement Technology Review, 2024.

Automation and digitalisation
Digitalisation is transforming material handling systems by introducing real-time monitoring, predictive maintenance and automated control. Advanced sensors and Industrial Internet of Things (IIoT) platforms enable plant operators to track conveyor health, stockpile levels and equipment performance in real time. Predictive maintenance systems analyse vibration patterns, temperature fluctuations and equipment load data to detect potential failures before they occur. According to McKinsey’s Industry 4.0 Manufacturing Report, 2023, for heavy industries, digital monitoring and predictive maintenance technologies can reduce equipment downtime by up to 30 per cent and increase productivity by 10 per cent to 15 per cent. Digital control centres also integrate data from conveyors, stacker reclaimers and dispatch systems, enabling centralised management of material flows from quarry to dispatch.

Handling of AFR
The growing adoption of Alternative Fuels and Raw Materials (AFR) has introduced new challenges and opportunities for material handling systems in cement plants. AFR materials such as refuse-derived fuel (RDF), biomass and industrial waste often have irregular particle sizes, variable moisture content and lower bulk density compared to conventional fuels. As a result, specialised storage, dosing and feeding systems are required to ensure consistent kiln combustion. According to the Cement Sector Decarbonisation Roadmap published by NITI Aayog in 2026, increasing the use of AFR could enable India’s cement sector to achieve thermal substitution rates of around 20 per cent in the coming decades. To support this transition, plants are investing in automated receiving stations, shredding units, drying systems and precision dosing equipment to stabilise AFR supply and combustion performance.

Energy efficiency and dust control
Material handling systems also play a crucial role in improving plant energy efficiency and environmental performance. Modern conveyor systems equipped with variable speed drives and energy-efficient motors can significantly reduce electricity consumption. Permanent magnet motors used in conveyor drives can deliver 8 per cent to 12 per cent energy savings compared to conventional induction motors, improving overall plant energy efficiency according to the IEA Industrial Energy Efficiency Study, 2023. Dust control is another major concern in cement plants, particularly during material transfer and storage operations. Enclosed conveyors, dust extraction systems and advanced bag filters are widely used to minimise particulate emissions and improve workplace safety.

Future trends in material handling
The future of material handling in cement plants will be shaped by automation, digitalisation and sustainability considerations. Emerging technologies such as AI-driven logistics optimisation, autonomous mobile equipment and digital twins are expected to further improve plant efficiency and operational visibility. Digital twin models allow engineers to simulate material flow patterns, optimise stockyard operations and predict equipment performance under different operating conditions. According to the International Energy Agency Digitalisation and Energy Report, 2024, the adoption of advanced digital technologies could improve industrial energy efficiency by up to 20 per cent in heavy industries such as cement manufacturing. As cement plants expand capacity and adopt low-carbon technologies, intelligent material handling systems will play a critical role in maintaining productivity and reducing environmental impact.

Conclusion
Material handling systems have evolved from basic transport infrastructure into strategic operational systems that directly influence plant efficiency, reliability and sustainability. From quarry transport and automated stockyards to digital dispatch platforms and advanced conveying technologies, modern material handling solutions enable cement plants to manage large production volumes while maintaining process stability.
As India’s cement industry continues to expand to meet infrastructure and urban development demands, investments in advanced material handling technologies will become increasingly important. By integrating automation, digital monitoring and energy-efficient systems, cement manufacturers can improve operational performance while supporting the industry’s long-term sustainability and decarbonisation goals.

Kanika Mathur

Concrete

Modernise to Optimise

Published

3 weeks ago

March 18, 2026

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Cement plant modernisation is reshaping the industry through upgrades in
kilns, energy systems, digitalisation, AFR integration and advanced material
handling. We explore these technologies that improve efficiency, reduce
emissions, strengthen competitiveness, while preparing the industry for India’s
next phase of infrastructure growth.

India’s cement industry, the world’s second-largest, is undergoing a rapid transformation driven by infrastructure demand, decarbonisation targets and technological advancement. The sector’s installed capacity stood at approximately 668 million tonnes per annum (mtpa) in FY2025 and is projected to reach 915–925 mtap by 2030, supported by large-scale capacity expansions and infrastructure investment cycles, suggests CRISIL Intelligence Industry Report, 2025. At the same time, cement production remains highly energy intensive and contributes about 6 per cent to 7 per cent of India’s total greenhouse gas emissions, making efficiency improvements and modernisation critical for long-term sustainability as stated in CareEdge ESG Research, 2025. As a result, cement manufacturers are investing in advanced kiln technologies, digital monitoring systems, waste heat recovery, alternative fuels, and modern material handling infrastructure to enhance productivity while aligning with global decarbonisation pathways.

Need for modernisation
The need for plant modernisation is closely linked to the sector’s rapid capacity expansion and rising operational complexity. India’s installed cement capacity has grown significantly in the last decade and is expected to exceed 900 mtpa by 2030, driven by demand from housing, infrastructure and urban development projects, as per the CRISIL Intelligence Industry Report, 2025. However, increasing scale also places pressure on energy efficiency, logistics, and production stability. The report also suggests that the cement plants must upgrade equipment and processes to operate at higher utilisation rates, which are projected to reach 75 per cent to 77 per cent by the end of the decade, compared to around 72 per cent to 74 per cent in FY2026.
Environmental imperatives are another major driver of modernisation. Cement manufacturing is responsible for a significant share of industrial emissions because clinker production requires high-temperature processes that depend heavily on fossil fuels. According to CareEdge ESG research, the cement sector contributes 6–7 per cent of India’s total greenhouse gas emissions, with approximately 97 per cent of emissions arising from direct fuel combustion and process emissions in kilns. Consequently, plant modernisation initiatives now focus not only on productivity improvements but also on reducing emissions intensity, energy consumption, and reliance on conventional fuels.
“One of the most impactful upgrades implemented at Shree Cement in the last five years has been the adoption of advanced data management platforms that provide real-time visibility across major process areas. This digital advancement has strengthened plant automation by enabling faster and more accurate responses to process variations while improving the reliability of control loops. Real-time dashboards, integrated analytics and automated alerts now support quicker, data-driven decision-making, helping optimise kiln and mill performance, improve energy control and detect deviations early. By consolidating data from multiple systems into a unified digital environment, the company has enhanced operational consistency, reduced downtime and improved both productivity and compliance. This shift towards intelligent automation and real-time data management has become a key driver of operational excellence and future-ready plant management,” says Satish Maheshwari, Chief Manufacturing Officer, Shree Cement.

Kiln and pyroprocessing upgradation
The kiln remains the technological heart of cement manufacturing, and modernisation efforts often begin with upgrades to pyroprocessing systems. Many older plants in India operate with four- or five-stage preheaters, while modern plants increasingly adopt six-stage preheater and pre-calciner systems that significantly improve heat efficiency and clinker output. These systems enhance heat transfer, reduce fuel consumption, and stabilise kiln operations under high throughput conditions.
Professor Procyon Mukherjee suggests, “Cement manufacturing is, at its core, a thermal process. The rotary kiln and calciner together account for energy consumption and emissions. The theoretical thermal requirement for clinker production is around 1700–1800 MJ per tonne, yet real-world plants often operate far above this benchmark due to inefficiencies in combustion, heat recovery and material flow. Modernisation, therefore, must begin with the
kiln system, and not peripheral automation or
isolated upgrades. The shift from wet to dry process kilns, combined with multi-stage preheaters and precalciners, has already delivered step-change improvements, making dry kilns nearly 50 per cent more energy efficient.”
Recent investment programmes across the industry have included kiln cooler upgrades, advanced burners, and improved refractory materials designed to increase operational reliability and reduce specific heat consumption. Such upgrades are essential because cement production remains highly energy intensive, and continuous efficiency improvements are required to meet global decarbonisation targets. According to the International Energy Agency (IEA) Cement Tracking Report, 2023, the cement sector must achieve annual emissions intensity reductions of around 4 per cent through 2030 to align with global net-zero scenarios.

Energy efficiency and WHRS
Energy efficiency remains one of the most important areas of modernisation in cement manufacturing, given the sector’s heavy reliance on thermal and electrical energy. Modern plants deploy advanced process controls, efficient grinding systems, and improved combustion technologies to reduce specific energy consumption. The adoption of energy-efficient technologies is particularly important in India, where energy costs account for a large share of production expenses. As demand grows and plants expand capacity, improving energy performance becomes essential to maintain competitiveness.
Waste Heat Recovery Systems (WHRS) have emerged as a key solution for improving plant energy efficiency. During cement production, large volumes of high-temperature gases are released from kilns and coolers. WHRS technology captures this waste heat and converts it into electricity, thereby reducing reliance on external power sources. According to energy benchmarking studies for the Indian cement industry, installed waste heat recovery capacity in the sector has reached approximately 840 MW, with an additional potential of around 500 MW states the Green Business Centre, Energy Benchmarking Report, 2023. Several leading producers have already implemented large WHRS installations; for example, UltraTech Cement has deployed systems with around 121 MW of waste heat recovery capacity, reducing carbon emissions by nearly 0.5 million tonnes annually according to the Energy Alternatives India Case Study, 2024.

Integration of AFR
The integration of Alternative Fuels and Raw Materials (AFR) is another critical dimension of cement plant modernisation. AFR refers to the use of industrial waste, biomass, refuse-derived fuel (RDF), and other non-fossil materials as substitutes for conventional fuels such as coal and petcoke. Increasing the use of AFR helps reduce fossil fuel consumption while simultaneously addressing waste management challenges. According to the NITI Aayog Decarbonisation Roadmap, 2026, scaling the use of RDF and other alternative fuels could enable the sector to achieve thermal substitution rates of around 20 per cent in the coming decades.
However, integrating AFR requires significant plant modifications and operational adjustments. Waste-derived fuels often have inconsistent calorific values, higher moisture content, and heterogeneous physical properties compared to traditional fuels. As a result, modern plants invest in advanced fuel preparation systems, dedicated feeding equipment, and automated dosing technologies to ensure stable kiln operation. These upgrades allow plants to maintain consistent clinker quality while increasing the share of alternative fuels in their energy mix.

Digitalisation and smart plant operations
Digitalisation is rapidly transforming cement plant operations by enabling data-driven decision-making and predictive maintenance. Industry 4.0 technologies such as IoT sensors, artificial intelligence (AI), and advanced analytics are now used to monitor equipment performance, optimise process parameters, and anticipate maintenance requirements. These digital tools enable plant operators to detect early signs of equipment failure, minimise unplanned downtime, and improve operational efficiency. Predictive maintenance systems, for example, analyse vibration, temperature, and acoustic signals from rotating equipment to identify potential faults
before they escalate into major breakdowns. Digital twins and integrated control systems further allow operators to simulate plant performance under different scenarios and optimise production strategies. Such technologies are becoming increasingly important as cement plants operate at larger scales and higher levels of process complexity.
Maheshwari also adds, “Plant modernisation is also increasingly central to the global competitiveness of Indian cement manufacturers. As cost pressures rise across energy, logistics and regulatory compliance, modern plants offer the structural efficiency required to operate reliably and competitively over the long term. Technologies such as AI-driven Advanced Process Control (APC) integrated with real-time data systems are emerging as essential investments for the future. These platforms use predictive algorithms, machine learning and live process inputs to optimise kiln, mill and utility operations with greater precision than traditional control systems. By continuously analysing variations in feed chemistry, temperature profiles, energy demand and equipment behaviour, APC enables stable operations, lower specific energy consumption, reduced emissions and improved product consistency. As regulatory expectations tighten and plants pursue higher efficiency with lower carbon intensity, AI-enabled APC will play a crucial role in strengthening automation, enhancing decision-making and ensuring long-term operational resilience.”

Modern material handling and logistics
Material handling systems play a critical role in ensuring smooth plant operations and efficient logistics. Modern cement plants rely on advanced conveying systems, automated stockyards, and digital dispatch platforms to manage the movement of raw materials, clinker, and finished cement. Long-distance belt conveyors and pipe conveyors are increasingly replacing truck-based transport between quarries and plants, reducing fuel consumption, dust emissions, and operational costs. Automated stacker-reclaimers ensure consistent blending of raw materials,
which improves kiln stability and clinker quality. Meanwhile, advanced packing and dispatch systems equipped with high-speed rotary packers and robotic palletisers enhance throughput and reduce manual labour. These technologies allow cement plants to optimise logistics efficiency while supporting higher production capacities.

Emission control and environmental compliance
Environmental compliance has become a central focus of cement plant modernisation as regulators and investors place greater emphasis on sustainability performance. Modern plants deploy advanced emission control technologies such as high-efficiency bag filters, electrostatic precipitators, and selective non-catalytic reduction systems to reduce particulate matter and nitrogen oxide emissions.
Sine Bogh Skaarup, Vice President, Head of Green Innovation and R&D, Fuller Technologies says, “One of our key focus areas is decarbonisation. We help cement producers reduce CO2 and overall carbon emissions. We offer alternative fuel solutions and calcined clay technologies to enable the production of LC3 cement, which play a significant role in decarbonising the cement industry. By combining alternative fuels and calcined clay solutions, CO2 emissions can be reduced by up to 50 per cent, making this a highly impactful approach for sustainable cement production.”
Continuous emission monitoring systems are increasingly used to track environmental performance in real time and ensure compliance with regulatory standards. In addition to air pollution control, cement companies are also investing in water recycling systems, renewable energy integration, and carbon reduction initiatives. These measures are essential for aligning the sector with national climate goals and improving the environmental footprint of
cement manufacturing.

Economic benefits and future outlook
Beyond environmental and operational advantages, cement plant modernisation also delivers significant economic benefits. Energy efficiency improvements, digital process optimisation, and advanced material handling systems reduce operating costs and improve asset utilisation. Waste heat recovery and alternative fuels help lower fuel expenditure and reduce exposure to volatile fossil fuel markets. As the industry expands capacity to meet growing demand, modernised plants are better positioned to achieve higher productivity and maintain profitability. The long-term outlook for the sector remains positive, with India expected to continue large-scale infrastructure investments in roads, housing, railways, and urban development.
Milan R Trivedi, Vice President – Projects, Prod & QC, MR, Shree Digvijay Cement, says, “The main focus in case of modernisation projects drives through the investment decision, which is mainly based on IRR and impact on overall efficiency improvement, cost optimisation and improvement in reliability. However, there are certain modernisation, which has high impact on environmental impact, statutory requirements, etc. has higher priority irrespective of ROI or payback period.”
“The energy efficiency and reliability investment projects generally provide fast return on investment whereas strategic, digitalisation and environmental investment projects provide long term and compounded benefits. Typical modernisation investment projects are decided with IRR of about > 20 per cent, payback period of typically 2-3 years for fast-track projects,” he adds.
In this context, modernisation will remain a key strategic priority for cement manufacturers seeking to maintain competitiveness in an increasingly sustainability-focused market.

Conclusion
The modernisation of cement plants is no longer a purely technical upgrade but a strategic transformation that reshapes how the industry operates. As India’s cement sector expands capacity toward the next growth cycle, improvements in energy efficiency, digitalisation, alternative fuels and advanced logistics will determine the competitiveness of individual plants. Modern technologies allow producers to operate at higher productivity levels while simultaneously reducing energy consumption and emissions intensity.
Looking ahead, the pace of technological adoption will play a decisive role in shaping the future of
the cement industry. Companies that successfully integrate modern equipment, digital systems, and sustainable production practices will be better positioned to meet rising infrastructure demand while aligning with global climate commitments. In this evolving landscape, plant modernisation stands as the cornerstone of both operational excellence and environmental responsibility.