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Environmentally Sustainable Mining Practices In India

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Sustainability has assumed considerable importance in developed countries which are extensively involved in mining practices, like Australia, Canada, USA, South Africa and Papua New Guinea etc. They take comprehensive view of sustainable development in mining which includes important dimensions such as local stakeholder engagement, socio-economic development in mining project areas and transparency in communication with the stakeholders, along with environment. These developed nations undertake mining activities with all compliances to regulatory requirements and environmental laws leads to lessen the impact of mining and strictly implement it. These compliances include provisions for mine closure and associated reclamation and rehabilitation of mined land.

In India, major mining companies have taken steps for socio-economic development projects in their mining areas. The Indian mineral industry comprises of large and small mines that are covered under public, private and informal sectors, covering most minerals being extracted. The public sector continues to play a dominant role in production of various major minerals (like coal, lignite, petroleum, iron and steel, bauxite and aluminium) where as a large number of small mines (including quarries for extracting minor minerals) operated by private players in most states. These present difficult challenges for sustainable development as their financial, technical and managerial limitations restrict their ability to take effective corrective measures against the negative impacts of mining.

Major mining companies uses advanced technology, adopt comprehensive environment protection measures, sensitise their personnel on sustainability issues and progressively try to improve their environmental performance. There are other large, medium and even small companies whose environment obligation consists in strictly conforming to the prescribed legal provisions. Major threats for adopting sustainable mining practices are illegal workings, where legal compliances are not observed to the fullest extent. It is reported that the illegal mining of sand is largely responsible for the environmental degradation especially the river beds of all major rivers including Ganga and Jamuna. There are only little checks for controlling illegal and rampant mining, whereas the political interference has turned the situation grim. Even legal mines flout norms and damage the environment considerably.

Concerns for environmentally sustainable mining
Today, the sustainable mining is the key to the security of raw materials and energy for many countries in the world. The sustainable development of mining of mineral resources is a major concern for today’s global world, addressed to mining companies, people of science associated with mining and many other institutions and organisations. Public awareness that the mineral resources are non-renewable assets, is, unfortunately, small and therefore improvements or changes to the situation in this area is another key concerns, it should be followed by concrete actions.

Modern mining, which is considered for negatively affecting the environment, and also causes discomfort for people living in mining areas or their immediate surroundings, must have the public acceptance for its activities. Thus, the real concern about the environment is becoming an important factor for obtaining such public acceptance. Mining in the twenty-first century, while striving for sustainable development, must provide employees with a safe working environment, therefore the problems regarding safety, due to its complexity, is a major challenge for mine operators. The trend of increasing the depth of mines, observed in the world, means that work safety is, and will continue to be a key area of concern for the sustainable development of the mining industry.

The complexity of the problems for the sustainable development of mining and the resulting diversity on a global scale point at the need for the continuous exchange of experience in the field of knowledge, methods, technologies and other solutions. They should provide a sustainable and socially acceptable development and continued operation of mining, invariably needed by people, to provide necessary mineral resources.

Objectives and Effects of sustainable mining practices –
There are several objectives of sustainable mining practices, which are interrelated and success will involve the issues most frequently linked to another. They can be summarised as follows:

  • Healthy Life : Eradicate poverty and hunger,
  • Universalize access to basic services : Includes water, sanitation and sustainable energy
  • Support the generation of development opportunities : Inclusive education and decent work
  • Foster innovation and resilient infrastructure : Converting surrounding communities and cities able to produce and consume sustainably
  • Reduce inequality in the world : especially that concerning gender
  • Care for the environment : combating climate change and protecting the oceans and land ecosystems
  • Promote collaboration: between different social bodies to create an environment of peace and sustainable development.
  • On the other hand, the after effects of sustainable mining practices can be summarised in the figure below
  • Implementation of Sustainable Mining Practices –
    Two major methods of implementing sustainable mining practices are – 1) Good governance from Global, Central & State Government bodies resulting in effective laws and regulations for implementation –

    Every now and then, the various Government bodies, judiciary systems of India has shown their concerns over bad mining practices and not following sustainable approach. Also efforts are being made by them to implement these mining practices for betterment for eco-system.

    At global level, the heads of 193 UN member states prepared a set of 17 Sustainable Development Goals (SDGs), which is for global development framework available for the society and generations. Mining companies have the potential to become leading partners in achieving the SDGs. Through their direct operations, mining companies can generate profits, employment, and economic growth in low-income countries. And through partnerships with government and civil society, they can ensure that benefits of mining extend beyond the life of the mine itself, so that the mining industry has a positive impact on the natural environment, climate change, and social capital.

    At the same time, mining companies will be called on to extract with responsibility, produce with less waste, use safer processes, incorporate new sustainable technologies, promote the improved wellbeing of local communities, curb emissions, and improve environmental stewardship. Mining companies committed to the SDGs will benefit from improved relationships with governments and communities and better access to financial resources; those that fail to engage meaningfully with the SDGs will put their operations at risk in the short and long term.

    Based on interviews with over 60 global experts from industry, civil society, governments, academia, and financial institutions, the report identifies where sustainable mining practices can enhance the positive impacts it has and mitigate the negative impacts across the 17 SDGs (see figure below).

    A Planning Commission report from 2012 titled "Sustainable Development, Emerging issues in India’s mineral sector" observed that in the mineral-rich states of Odisha, Goa, Karnataka and Jharkhand, mining has brought about economic development. At the same time, it has caused significant environmental damages and negatively impacted communities in project areas. To that extent the mining and environmental laws and regulations have not been very effective.

    As per the report published by NITI Ayog in 2017 on "Socio Economic Impact Study of Mining and Mining Polices on the Livelihoods of Local Population" has mentioned that mining is considered as one of the necessary evils of the modern world, which provides the materials required to sustain quality of life. While improving the quality of life and giving an impetus to economic development, it has also brought in its wake, a notable impact on the environment as well as socio-economic conditions of local people (Vagholikar and Moghe, 2003).The proposed mining areas and activities have been severely criticized by environmentalists and social activists, on the subjects of potential loss of forests and displacement of villages as the mines increase in number and size of operations. Insufficient attention to managing impacts on the environment and the socio-economic fabric observed in the past, has reflected adversely on public support for reform and private investment needed for accelerating growth in the state.

    The most important environmental requirement for a mining project is a comprehensive environment assessment (EIA) programme, which was started in 1994. However, laws and regulatory instruments work unsatisfactorily due to weak enforcement and inadequate coordination among government agencies. Although mining companies tend to meet the legal requirement of preparing a mine closure plan, the implementation falls short. Local communities are not consulted in the preparation and implementation of mine closure plans.

    The New Mineral Policy, 2019 has also been focused on main theme of mining being environmentally sustainable, we are going to explore those very efforts, which will answer the very question, and could mining activities ever become environmentally sustainable for both environment and our health?

    The answer is, it very much possible to make mining more environmentally sustainable, there are few practices being followed across international mines, which can be implemented at Indian Mines to minimise environment pollution. All we have to do is to develop and integrate these practices that reduce environmental effects resulting from mining operations. Sustainable mining practices is basically mining practices that meets the present demand without compromising the future generation’s needs. In the process, the advent of new mining methods, tools, regulation and legislation, significant efforts are helpful to make mining more environmentally friendly.

    2) Self-regulating mining enterprises which are economically viable, financially profitable and technically efficient i.e. innovative mining practices and use of technologies –

    There are prime responsibility of mining companies towards the implementation of the principles of sustainability for mining. It has applications for all stages of the mine life cycle, i.e., starting from exploration, mine planning, development, mineral extraction to mine closure, post-closure reclamation and rehabilitation. These principles include elements such as intra and inter-generational equity, the precautionary principle, scientific mining, management of environmental and socio-economic impacts, creation of substitute capital in the form of social and physical infrastructure and most importantly stakeholder engagement..

    In some cases, mining operations have been executed without concerning for the "carrying capacity"of the environment and other infrastructural limitations of the surroundings of the mine site. This has put unavoidable pressure on the environment and caused inconvenience to the people living alongside mining areas. Illegal mining in many cases has similar effect while additionally causing loss of public revenues. The mineral extraction and processing release several toxic materials, contaminating the soil and water which leads to deforestation and ground water degradation. Mineral extraction has also disproportionately affected health of forest ecosystems and the surrounding environment and furthermore the tribes as well as the forest dwelling populations are also adversely affected. However, the mining and mineral sectors are perceived to have failed to alleviate poverty for these vulnerable populations around the forest areas. Thus, the impacts of mining and mines upon natural ecosystems, biodiversity and tribal livelihoods have become a key environmental concern and source of conflict and socioeconomic tension.

    Most of work done by mining industry to protect environment and address social concerns has not been received due attention of the Government, media and society. In spite of the fact that, their efforts of sustainable mining practices and operations, few NGOs and environmental protection agencies tries to malign all efforts based on stray incidents. With increasing stringent guidelines by the Governments to regulate mining and its impact, the mining industry has been relentlessly striving for not only achieving expectation of regulatory agencies, but also to exceed these and set international benchmarks. Mining companies are striving hard to contribute towards sustainable development of the country

    To make mining environmentally friendly, few steps are suggested below, they are in regular discussion on various forums around the world. In India, mining companies can adopt these steps to achieve the goals of New Mineral Policy: –

    Reclaimingof Materials used in worked out Mines and properly closing of the area-
    This step involves usage of material from the old worked out mines, which affects the environment in a variety of ways, especially in its natural decaying, rotting and eroding processes, withal it can also lead to illegal or unregulated mining activity. This specially occurs in underground mines where support systems, cables, pipes etc, are left out with significant amount of ore, it decays and pollutes environment in a serious way. However, when these areas are adequately excavated, mining companies would find some materials that could be reused productively. In Opencast also, several waste materials like cables, pipes, etc, are left as is post mining and it is buried in mine overburden materials.

    Every mining company has to research on these unused resources and materials throughout the mining process, to try and conserve its current "non-renewable" materials. Each company can form small decommissioning groups which study systems and the complete mining processing facilities and plants; this process will allow the pipelines to be drained, equipment and parts of the mine to be cleaned and sold off, the buildings can be repurposed or demolished, warehouse materials recovered and wasted disposed of. These groups then clean and sell off any remaining operational equipment and provided they are still structurally sound, repurpose the premises.

    The main objective in reclaiming process is to return the site and the land which surrounds it back to reusable standards, ensuring that any landforms and structures are stable, and the watercourses need to be evaluated in order to regain water quality within the affected area.

    This step needs the effective supervision during the process of mining and closure, its successful impacts on the environment could well be diluted through the re-use of materials that would have previously been left to decay.

    Closing illegal and unregulated mines
    In India, we find several illegal and unregulated mine which is operational. The New Mineral Policy 2019 has tried to curb these types of illegal mine workings. In context with enforcing regulations and maintaining steadfast legislation regarding the behaviour and processes of the mines,strict and swift closing of illegal or unregulated mining activity will set an environmental precedent within the industry.

    For example, before 2010, most mines in China were completely unregulated which were affecting surrounding areas gravely. Details are mentioned in coming pages of this article, where effective steps taken by Chinese Government has helped in reducing the damage and provide a sustainable mining areas. Effective closing and reclamation of old mined out areas will significantly help in sustainable mining practices in and around the mineralised belts.

    Accurate measurements and declaration of waste mining which creates pollution –
    Mining companies always try to save face when it comes to the environmental conservation and try to hide the facts of actual pollution and maintain secrecy in reporting the toxic mining wastes produced by mining operations. These companies usually keep the public in the dark giving an accurate report of what’s being dumped into the environment and the various by not pollutants created by them.

    New mineral Policy instructs to frame rules to recognise the actual pollution generated by mining companies; accordingly, a suitable step shall be taken to panelise these companies or to reduce pollution as much as possible, with suitable remedial measures to be suggested. Of course, strict penalties for violating companies have to be decided by State and Central Governments.

    Use reusable waste to build and reuse/recycle of material –
    At present ubiquitous, mining companies are discovering efficient ways to capitalize wholly on materials in order to provide sustainable goods and services. On the other hand, the society at large, wants to utilise less wood, metal, stone, plastic and other materials by adopting efficient practices.

    One simple way is to start using reusable materials effectively while building new constructions and infrastructure affecting the surrounding environment of any mining. Recycling the metals from accumulated scrap and waste in landfills may be in some cases more economical than to mine ore deposits. For example, in 2008, the world steel industry produced over 1.3 billion tonnes of steel. It used 1.48 billion tons of raw materials, or 470 million tonnes less than, would have been needed to make the same volume of steel in the 1970s. Concerning aluminium, it is estimated that since 1880, approximately 900 million tons of aluminium were produced of which nearly 75% is still in use today. The demand for aluminium continues to skyrocket and recycling aluminium saves more than 90% of the energy required to producing new metal, thus rendering recycling very attractive. This scales down the amount of wasteful use on public and private level. Accordingly, mining companies can start use of durable goods that can be easily re-usable, re-manufactured, or recycled, undertaking environmentally sustainable practices will reduce its inimical impact. There are success stories in these re-usable material applications.

    This creative and increasing trend of scrap mining, or utilizing ever-reusable resource for other mining initiatives, saves from the environmental hazards. It is necessary to find out each and every detail of each piece which is being used and generated in a mining site, which will help the mining industry to take suitable steps towards re-use, for becoming a more sustainable industry. For similar examples, we can use recycling of copper waste, which takes seven times less energy than processing of copper ore, and recycling steel which uses three-and-a-half times less energy than processing of iron ore. These small steps will help us immensely in determining not only the longevity of a sustainable mining practices and also have its positive environmental impact.

    This article has been reproduced from CEMENT, ENERGY AND ENVIRONMENT, a Bi-Annual journal of Cement Manufacturers Association of India in its July-Dec’2019 Issue. Part II of the same will be published in the next month.

    About the author – "Author BHANU PRAKASH BHATNAGAR is B.E. Mining Engg. (Gold Medal), FCC, MBA, working as Head Mining, Adani Cementation Ltd, Ahmedabad. He is having more than 27 years" experience in Overall Mine management including Acquisition of mineral resources through Auction Process, New Mine Development, Production Planning, Mine Operations and Quality Management for Large Opencast Limestone Mines. He had previously worked with cement companies like ACC-Holcim, Reliance Cement Ltd and overseas mining experience."

    Part I
    Come up with better regulations and legislation

    As observed by the Honourable Supreme Court in its judgement on mining in 2017, the present mining legislation that we have today is far from being effective or productive. Mining continues to affect the environment because companies never cease to take advantage and continue polluting environment by waste discharges. Regulation obviously differs from country to country, with some countries more advanced in terms of their legislation than others. However, the need for improvement is always there in this industry, which inevitably causes some environmental damage.

    We have to learn a lot from other countries like, for example In Canada, where mines like the Island Copper Mine on Vancouver Island stands as a highly regulated mine site that is operational from 1971 to 1995 when it was closed for resource depletion.

    It was forced by regulatory agencies and control of the government that a detailed mine closure plan was developed to comfortably close the mine in order to protect the few resources which remained, and the Mine enacted the contaminated sites regulation process which was awarded the Certificate of Conditional Compliance.

    This step involves the effective framing of the mineral policy and as we found that the new Mineral Policy 2019 advocates for the stringent laws for environmentally sustainable mining practices.

    Effective implementation of this policy will not only protect environmental and public health, but also improve the lifespan of the mining industry and provide sustainable mining. The new Mineral Policy elaborates that extraction of mineral impacts other natural resources like land, water, air and forest. It is necessary to take a comprehensive view to facilitate the choice or order of land use keeping in view of the needs of development as well as needs of protecting the forests, environment and ecology and to conserve biodiversity of areas to be mined.

    Responsible and Regulated mining near surrounding habitations of Silver Mine at Peru.
    The New Mineral Policy has also emphasised on the effective Mine Closure where once the resources in mine are completely exhausted there is need for scientific mine closure which will not only restore ecology and regenerate bio-diversity but also take into account the socio-economic aspects of such closure. Government has a role in ensuring that post production mine decommissioning and land reclamation are an integral part of mine development process. Consistent approaches are adopted for efficient and effective mine reclamation and rehabilitation.

    Investing in Research and Development of Environmentally sustainable Mining Technology –
    Mining industry is always in need of proper research and development in order to make sure the industry is ready for today’s ever-changing commitment to sustainability and turning the world into a more "environmentally sustainable" place.

    New Mineral Policy has emphasised on "Scientific Methods of Mining" which state that the mine development and mineral conservation, as governed by the Rules and Regulations, will be on sound scientific basis, with the regulatory agencies like IBM and State Directorates, closely interacting with R&D organisation and scientific and professional bodies. This is to ensure the proper mining practices being followed by mining companies. Policy advocates for R&D effort shall be made to improve efficiency in process, operation and also the recovery of by-products and reduction in specification and consumption norms. R&D efforts shall be directed to find new and alternative uses for minerals whose traditional demand is on the wane.

    In this regard, as per the latest News published by NCCBM (NCB News, Sept 2019), the NCCBM has achieved great success with recent research and development with Investigation of standardization of new clinker for blended cement. The objective of the study was to investigate effects of high MgO clinker on performance characteristics of resultant OPC, PPC and PSC. The project was undertaken on accelerated mode and the report to be submitted to BIS is under preparation. The main agenda was to promote utilization of low-grade limestone containing higher MgO with good result. This will certainly result in increase of mine life.

    Reduce resources inputs for effective mining practices –
    The mining industry consumes large amount of water and land in their operations. One solution to becoming more environmentally sustainable is to reduce the input of the mine. By diverting surface water and pumping groundwater, mines can reduce both the quantity and quality of water available downstream for aquatic ecosystems and other use.

    With regard to energy, a mining company can look into alternative energy sources such as solar or wind power. By reducing the energy usage, a mine can reduce greenhouse gases and extend the life of fossil fuel reserves. Mining companies will also be able to reduce the cost to produce the product and thus reduce the cost of the commodity itself. The New Mineral policy advocates for minimising the inputs for mining processes.

    Improving the efficiency of mining processes –
    This step is very much in discussion globally for closely monitoring the standard mining supply chain, mining industry/companies will be forced to confront ways in which a company can improve its efficiency where its lacking in terms of sustainability and green mining initiatives, improving the efficiency of this process can help trim down environmental impact. This also allows companies to regulate processes which may be inadequate in terms of environmental friendliness.

    This needs a proper supervision of the mining and ancillary process that will allow mining companies to change elements/activities that are inefficient or that use too many natural resources. Conducting a material flows analysis will effectively track the physical flows of natural resources through extraction, production, fabrication, use, recycling and final disposal. This will develop new ways of thinking, new metrics, business process re-engineering and new management/supervisory tools that will help cushion the transition into more efficient and less environmental toxic patterns of resource used in modern societies. This process change will allow supervisors to develop new processes that are more efficient and sustainable than previous ones. Across the world, organizations like The World Resources Institute (WRI) are currently conducting research on most frequently used resources and materials, in order to better understand how the industry can conserve its non-renewable materials. The WRI has been working towards developing a database, and can now indicate the flow of materials through industrial economies. Material flows analyses, as mentioned above, will track the physical flows of natural resources in every step of mining process, accounting for both the gains and losses occurring throughout the supply chain.

    The New Mineral policy mentions that the use of equipment and machinery which will improve the efficiency, productivity and economics of mining operations as well as mineral beneficiation process, safety, health of persons working in mines/beneficiation plant and surrounding area shall be encouraged.

    Re-evaluating Cut-off Grades
    A Raw mill cut-off grade is the level set that is considered to be the lowest quality of already mined ore which is economically feasible to continue processing. Different materials have different properties that determine a feasible cut-off grade. Often these grades are set at over-conservative levels. The easiest way to improve efficiency in mining and to reduce waste products is to decrease the mill cut-off grade of the mine. Re-evaluating these grades at each mine will significantly reduce waste.

    A lower mill cut-off grade may decrease the quality of the material, but certain final uses of the material do not need a very pure compound. Cut-off grades will be determined on a mine-by-mine basis by looking at the precedents for the material in question and taking the future use of the material into consideration.

    For example, the above mentioned recent R&D study done by NCCBM, has very encouraging results in terms of re-evaluating the MgO (Magnesia) content in Limestone for Clinker manufacturing, which earlier assumed to be less than 3.5%. Three types of high MgO clinker samples were obtained and designated as Clinker-1 (MgO~6.2%), Clinker-2 (MgO~6.8%) and Clinker-3 (MgO~7.5%).

    PPC & PSC got succeeded in Clinker-1 & Clinker-2 in all respect, while testing with OPC autoclave expansion was observed. The performance results obtained so far are quite encouraging which will pave the way for utilization of low grade limestone containing high MgO, increased mine life (~15 years) besides improved sustainability during cement manufacture. This will also add to the utilisation of waste material of mine, thus leading to sustainable mining practices.

    Replenishing the environment
    A seemingly simple step, but it is rarely prioritized, replenishing mine sites and mine environment is one of the key factors to not only earning respect and cooperation of those living surrounding the mine site, but it will also ultimately protect the mine’s impact on the environment. Mining companies sometimes overlook the importance of replenishing the environment. This simple act can go a long way towards increasing the environmental sustainability of mining.

    It has simple solutions like replenishing native soils and grasses, cleaning excess waste, proper waste removal, site inspections, replanting trees and natural forestry. By restoring the environment around the mine, the mining companies are contributing to positive environmental change, rather than making the environment more difficult to live in. The entire mine reclamation process should combine removal of hazardous materials, reshaping land, restoring topsoil, and planting native grasses, trees or ground cover natural to the site.

    The New Mineral Policy emphasized that all mining shall be undertaken within the parameters of a comprehensive Sustainable Development Framework which will ensure that environmental, economic and social considerations are integrated effectively in all decisions of mines and mineral issues. The Guiding principal shall be that a miner shall leave the mining area in an ecological shape which is as good as it was before the commencement of mining or better with least impact on flora and fauna of the area.

    Improving environmental performance
    It is well known fact that mining activity impacts the environment in unnatural ways, which not only disrupts its natural decaying process, but also does more damage long-term than natural erosion processes. With exorbitant numbers of materials excavated and used daily, it is important to see that this destruction is actually going towards productive use.

    This step is basically emphasised on adopting new measures useful in mitigating these environmental impacts. Let’s push for a systematic framework that will help us monitor the environmental performance.

    We have to adopt practice of systematically examining environmental impacts and adopting measures to mitigate these impacts, it is possible to make mining less destructive to the environment. Incremental efficiency gains will not do the job.

    Instead, an imaginative remaking of the industrial world-one that aligns economies with the natural environment that supports them is the sustainable way forward. The New Mineral Policy has given thrust on the Sustainable Development

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    Concrete

    Smart Cement Plants

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    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

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    Concrete

    Advantages of data integration are substantial

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    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

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    Concrete

    WCA’s annual conference

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    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”.

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