Technology
Environmentally Sustainable Mining Practices In India
Published
6 years agoon
By
admin
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:
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
Concrete
Redefining Efficiency with Digitalisation
Published
3 days agoon
February 20, 2026By
admin
Professor Procyon Mukherjee discusses how as the cement industry accelerates its shift towards digitalisation, data-driven technologies are becoming the mainstay of sustainability and control across the value chain.
The cement industry, long perceived as traditional and resistant to change, is undergoing a profound transformation driven by digital technologies. As global infrastructure demand grows alongside increasing pressure to decarbonise and improve productivity, cement manufacturers are adopting data-centric tools to enhance performance across the value chain. Nowhere is this shift more impactful than in grinding, which is the energy-intensive final stage of cement production, and in the materials that make grinding more efficient: grinding media and grinding aids.
The imperative for digitalisation
Cement production accounts for roughly 7 per cent to 8 per cent of global CO2 emissions, largely due to the energy intensity of clinker production and grinding processes. Digital solutions, such as AI-driven process controls and digital twins, are helping plants improve stability, cut fuel use and reduce emissions while maintaining consistent product quality. In one deployment alongside ABB’s process controls at a Heidelberg plant in Czechia, AI tools cut fuel use by 4 per cent and emissions by 2 per cent, while also improving operational stability.
Digitalisation in cement manufacturing encompasses a suite of technologies, broadly termed as Industrial Internet of Things (IIoT), AI and machine learning, predictive analytics, cloud-based platforms, advanced process control and digital twins, each playing a role in optimising various stages of production from quarrying to despatch.
Grinding: The crucible of efficiency and cost
Of all the stages in cement production, grinding is among the most energy-intensive, historically consuming large amounts of electricity and representing a significant portion of plant operating costs. As a result, optimising grinding operations has become central to digital transformation strategies.
Modern digital systems are transforming grinding mills from mechanical workhorses into intelligent, interconnected assets. Sensors throughout the mill measure parameters such as mill load, vibration, mill speed, particle size distribution, and power consumption. This real-time data, fed into machine learning and advanced process control (APC) systems, can dynamically adjust operating conditions to maintain optimal throughput and energy usage.
For example, advanced grinding systems now predict inefficient conditions, such as impending mill overload, by continuously analysing acoustic and vibration signatures. The system can then proactively adjust clinker feed rates and grinding media distribution to sustain optimal conditions, reducing energy consumption and improving consistency.
Digital twins: Seeing grinding in the virtual world
One of the most transformative digital tools applied in cement grinding is the digital twin, which a real-time virtual replica of physical equipment and processes. By integrating sensor data and
process models, digital twins enable engineers to simulate process variations and run ‘what-if’
scenarios without disrupting actual production. These simulations support decisions on variables such as grinding media charge, mill speed and classifier settings, allowing optimisation of energy use and product fineness.
Digital twins have been used to optimise kilns and grinding circuits in plants worldwide, reducing unplanned downtime and allowing predictive maintenance to extend the life of expensive grinding assets.
Grinding media and grinding aids in a digital era
While digital technologies improve control and prediction, materials science innovations in grinding media and grinding aids have become equally crucial for achieving performance gains.
Grinding media, which comprise the balls or cylinders inside mills, directly influence the efficiency of clinker comminution. Traditionally composed of high-chrome cast iron or forged steel, grinding media account for nearly a quarter of global grinding media consumption by application, with efficiency improvements translating directly to lower energy intensity.
Recent advancements include ceramic and hybrid media that combine hardness and toughness to reduce wear and energy losses. For example, manufacturers such as Sanxin New Materials in China and Tosoh Corporation in Japan have developed sub-nano and zirconia media with exceptional wear resistance. Other innovations include smart media embedded with sensors to monitor wear, temperature, and impact forces in real time, enabling predictive maintenance and optimal media replacement scheduling. These digitally-enabled media solutions can increase grinding efficiency by as much as 15 per cent.
Complementing grinding media are grinding aids, which are chemical additives that improve mill throughput and reduce energy consumption by altering the surface properties of particles, trapping air, and preventing re-agglomeration. Technology leaders like SIKA AG and GCP Applied Technologies have invested in tailored grinding aids compatible with AI-driven dosing platforms that automatically adjust additive concentrations based on real-time mill conditions. Trials in South America reported throughput improvements nearing 19 per cent when integrating such digital assistive dosing with process control systems.
The integration of grinding media data and digital dosing of grinding aids moves the mill closer to a self-optimising system, where AI not only predicts media wear or energy losses but prescribes optimal interventions through automated dosing and operational adjustments.
Global case studies in digital adoption
Several cement companies around the world exemplify digital transformation in practice.
Heidelberg Materials has deployed digital twin technologies across global plants, achieving up to 15 per cent increases in production efficiency and 20 per cent reductions in energy consumption by leveraging real-time analytics and predictive algorithms.
Holcim’s Siggenthal plant in Switzerland piloted AI controllers that autonomously adjusted kiln operations, boosting throughput while reducing specific energy consumption and emissions.
Cemex, through its AI and predictive maintenance initiatives, improved kiln availability and reduced maintenance costs by predicting failures before they occurred. Global efforts also include AI process optimisation initiatives to reduce energy consumption and environmental impact.
Challenges and the road ahead
Despite these advances, digitalisation in cement grinding faces challenges. Legacy equipment may lack sensor readiness, requiring retrofits and edge-cloud connectivity upgrades. Data governance and integration across plants and systems remains a barrier for many mid-tier producers. Yet, digital transformation statistics show momentum: more than half of cement companies have implemented IoT sensors for equipment monitoring, and digital twin adoption is growing rapidly as part of broader Industry 4.0 strategies.
Furthermore, as digital systems mature, they increasingly support sustainability goals: reduced energy use, optimised media consumption and lower greenhouse gas emissions. By embedding intelligence into grinding circuits and material inputs like grinding aids, cement manufacturers can strike a balance between efficiency and environmental stewardship.
Conclusion
Digitalisation is not merely an add-on to cement manufacturing. It is reshaping the competitive and sustainability landscape of an industry often perceived as inertia-bound. With grinding representing a nexus of energy intensity and cost, digital technologies from sensor networks and predictive analytics to digital twins offer new levers of control. When paired with innovations in grinding media and grinding aids, particularly those with embedded digital capabilities, plants can achieve unprecedented gains in efficiency, predictability and performance.
For global cement producers aiming to reduce costs and carbon footprints simultaneously, the future belongs to those who harness digital intelligence not just to monitor operations, but to optimise and evolve them continuously.
About the author:
Professor Procyon Mukherjee, ex-CPO Lafarge-Holcim India, ex-President Hindalco, ex-VP Supply Chain Novelis Europe, has been an industry leader in logistics, procurement, operations and supply chain management. His career spans 38 years starting from Philips, Alcan Inc (Indian Aluminum Company), Hindalco, Novelis and Holcim. He authored the book, ‘The Search for Value in Supply Chains’. He serves now as Visiting Professor in SP Jain Global, SIOM and as the Adjunct Professor at SBUP. He advises leading Global Firms including Consulting firms on SCM and Industrial Leadership and is a subject matter expert in aluminum and cement. An Alumnus of IIM Calcutta and Jadavpur University, he has completed the LH Senior Leadership Programme at IVEY Academy at Western University, Canada.
Concrete
Digital Pathways for Sustainable Manufacturing
Published
3 days agoon
February 20, 2026By
admin
Dr Y Chandri Naidu, Chief Technology Officer, Nextcem Consulting highlights how digital technologies are enabling Indian cement plants to improve efficiency, reduce emissions, and transition toward sustainable, low-carbon manufacturing.
Cement manufacturing is inherently resource- and energy-intensive due to high-temperature clinkerisation and extensive material handling and grinding operations. In India, where cement demand continues to grow in line with infrastructure development, producers must balance capacity expansion with sustainability commitments. Energy costs constitute a major share of operating expenditure, while process-related carbon dioxide emissions from limestone calcination remain unavoidable.
Traditional optimisation approaches, which are largely dependent on operator experience, static control logic and offline laboratory analysis, have reached their practical limits. This is especially evident when higher levels of alternative fuel and raw materials (AFR) are introduced or when raw material variability increases.
Digital technologies provide a systematic pathway to manage this complexity by enabling
real-time monitoring, predictive optimisation and integrated decision-making across cement manufacturing operations.
Digital cement manufacturing is enabled through a layered architecture integrating operational technology (OT) and information technology (IT). At the base are plant instrumentation, analysers, and automation systems, which generate continuous process data. This data is contextualised and analysed using advanced analytics and AI platforms, enabling predictive and prescriptive insights for operators and management.
Digital optimisation of energy efficiency
- Thermal energy optimisation
The kiln and calciner system accounts for approximately 60 per cent to 65 per cent of total energy consumption in an integrated cement plant. Digital optimisation focuses on reducing specific thermal energy consumption (STEC) while maintaining clinker quality and operational stability.
Advanced Process Control (APC) stabilises critical parameters such as burning zone temperature, oxygen concentration, kiln feed rate and calciner residence time. By minimising process variability, APC reduces the need for conservative over-firing. Artificial intelligence further enhances optimisation by learning nonlinear relationships between raw mix chemistry, AFR characteristics, flame dynamics and heat consumption.
Digital twins of kiln systems allow engineers to simulate operational scenarios such as increased AFR substitution, altered burner momentum or changes in raw mix burnability without operational risk. Indian cement plants adopting these solutions typically report STEC reductions in the range of 2 per cent to 5 per cent. - Electrical energy optimisation
Electrical energy consumption in cement plants is dominated by grinding systems, fans and material transport equipment. Machine learning–based optimisation continuously adjusts mill parameters such as separator speed, grinding pressure and feed rate to minimise specific power consumption while maintaining product fineness.
Predictive maintenance analytics identify inefficiencies caused by wear, fouling or imbalance in fans and motors. Plants implementing plant-wide electrical energy optimisation typically achieve
3 per cent to 7 per cent reduction in specific power consumption, contributing to both cost savings and indirect CO2 reduction.
Digital enablement of AFR
AFR challenges in the Indian context: Indian cement plants increasingly utilise biomass, refuse-derived fuel (RDF), plastic waste and industrial by-products. However, variability in calorific value, moisture, particle size, chlorine and sulphur content introduces combustion instability, build-up formation and emission risks.
Digital AFR management: Digital platforms integrate real-time AFR quality data from online analysers with historical kiln performance data. Machine learning models predict combustion behaviour, flame stability and emission trends for different AFR combinations. Based on these predictions, fuel feed distribution, primary and secondary air ratios, and burner momentum are dynamically adjusted to ensure stable kiln operation. Digitally enabled AFR management in cement plants will result in increased thermal substitution rates by 5-15 percentage points, reduced fossil fuel dependency, and improved kiln stability.
Digital resource and raw material optimisation
Raw mix control: Raw material variability directly affects kiln operation and clinker quality. AI-driven raw mix optimisation systems continuously adjust feed proportions to maintain target chemical parameters such as Lime Saturation Factor (LSF), Silica Modulus (SM), and Alumina Modulus (AM). This reduces corrective material usage and improves kiln thermal efficiency.
Clinker factor reduction: Reducing clinker factor through supplementary cementitious materials (SCMs) such as fly ash, slag and calcined clay is a key decarbonisation lever. Digital models simulate blended cement performance, enabling optimisation of SCM proportions while maintaining strength and durability requirements.
Challenges and strategies for digital adoption
Key challenges in Indian cement plants include data quality limitations due to legacy instrumentation, resistance to algorithm-based decision-making, integration complexity across multiple OEM systems, and site-specific variability in raw materials and fuels.
Successful digital transformation requires strengthening the data foundation, prioritising high-impact use cases such as kiln APC and energy optimisation, adopting a human-in-the-loop approach, and deploying modular, scalable digital platforms with cybersecurity by design.
Future Outlook
Future digital cement plants will evolve toward autonomous optimisation, real-time carbon intensity tracking, and integration with emerging decarbonisation technologies such as carbon capture, utilisation and storage (CCUS). Digital platforms will also support ESG reporting and regulatory compliance.
Digital pathways offer a practical and scalable solution for sustainable cement manufacturing in India. By optimising energy consumption, enabling higher AFR substitution and improving resource efficiency, digital technologies deliver measurable environmental and economic benefits. With appropriate data infrastructure, organisational alignment and phased implementation, digital transformation will remain central to the Indian cement industry’s low-carbon transition.
About the author:
Dr Y Chandri Naidu is a cement industry professional with 30+ years of experience in process optimisation, quality control and quality assistance, energy conservation and sustainable manufacturing, across leading organisations including NCB, Ramco, Prism, Ultratech, HIL, NCL and Vedanta. He is known for guiding teams, developing innovative plant solutions and promoting environmentally responsible cement production. He is also passionate about mentoring professionals and advancing durable, resource efficient technologies for future of construction materials.

Concrete
Turning Downtime into Actionable Intelligence
Published
4 days agoon
February 19, 2026By
admin
Stoppage Insights instantly identifies root causes and maps their full operational impact.
In cement, mining and minerals processing operations, every unplanned stoppage equals lost production and reduced profitability. Yet identifying what caused a stoppage remains frustratingly complex. A single motor failure can trigger cascading interlocks and alarm floods, burying the root cause under layers of secondary events. Operators and maintenance teams waste valuable time tracing event chains when they should be solving problems. Until now.
Our latest innovation to our ECS Process Control Solution(1) eliminates this complexity. Stoppage Insights, available with the combined updates to our ECS/ControlCenter™ (ECS) software and ACESYS programming library, transforms stoppage events into clear, actionable intelligence. The system automatically identifies the root cause of every stoppage – whether triggered by alarms, interlocks, or operator actions – and maps all affected equipment. Operators can click any stopped motor’s faceplate to view what caused the shutdown instantly. The Stoppage UI provides a complete record of all stoppages with drill-down capabilities, replacing manual investigation with immediate answers.
Understanding root cause in Stoppage Insights
In Stoppage Insights, ‘root cause’ refers to the first alarm, interlock, or operator action detected by the control system. While this may not reveal the underlying mechanical, electrical or process failure that a maintenance team may later discover, it provides an actionable starting point for rapid troubleshooting and response. And this is where Stoppage Insights steps ahead of traditional first-out alarm systems (ISA 18.2). In this older type of system, the first alarm is identified in a group. This is useful, but limited, as it doesn’t show the complete cascade of events, distinguish between operator-initiated and alarm-triggered stoppages, or map downstream impacts. In contrast, Stoppage Insights provides complete transparency:
- Comprehensive capture: Records both regular operator stops and alarm-triggered shutdowns.
- Complete impact visibility: Maps all affected equipment automatically.
- Contextual clarity: Eliminates manual tracing through alarm floods, saving critical response time.
David Campain, Global Product Manager for Process Control Systems, says, “Stoppage Insights takes fault analysis to the next level. Operators and maintenance engineers no longer need to trace complex event chains. They see the root cause clearly and can respond quickly.”
Driving results
1.Driving results for operations teams
Stoppage Insights maximises clarity to minimise downtime, enabling operators to:
• Rapidly identify root causes to shorten recovery time.
• View initiating events and all affected units in one intuitive interface.
• Access complete records of both planned and unplanned stoppages
- Driving results for maintenance and reliability teams
Stoppage Insights helps prioritise work based on evidence, not guesswork:
• Access structured stoppage data for reliability programmes.
• Replace manual logging with automated, exportable records for CMMS, ERP or MES.(2)
• Identify recurring issues and target preventive maintenance effectively.
A future-proof and cybersecure foundation
Our Stoppage Insights feature is built on the latest (version 9) update to our ACESYS advanced programming library. This industry-leading solution lies at the heart of the ECS process control system. Its structured approach enables fast engineering and consistent control logic across hardware platforms from Siemens, Schneider, Rockwell, and others.
In addition to powering Stoppage Insights, ACESYS v9 positions the ECS system for open, interoperable architectures and future-proof automation. The same structured data used by Stoppage Insights supports AI-driven process control, providing the foundation for machine learning models and advanced analytics.
The latest releases also respond to the growing risk of cyberattacks on industrial operational technology (OT) infrastructure, delivering robust cybersecurity. The latest ECS software update (version 9.2) is certified to IEC 62443-4-1 international cybersecurity standards, protecting your process operations and reducing system vulnerability.
What’s available now and what’s coming next?
The ECS/ControlCenter 9.2 and ACESYS 9 updates, featuring Stoppage Insights, are available now for:
- Greenfield projects.
- ECS system upgrades.
- Brownfield replacement of competitor systems.
Stoppage Insights will also soon integrate with our ECS/UptimeGo downtime analysis software. Stoppage records, including root cause identification and affected equipment, will flow seamlessly into UptimeGo for advanced analytics, trending and long-term reliability reporting. This integration creates a complete ecosystem for managing and improving plant uptime.
(1) The ECS Process Control Solution for cement, mining and minerals processing combines proven control strategies with modern automation architecture to optimise plant performance, reduce downtime and support operational excellence.
(2) CMMS refers to computerised maintenance management systems; ERP, to enterprise resource planning; and MES to manufacturing execution systems.
Refractory demands in our kiln have changed
Digital supply chain visibility is critical
Redefining Efficiency with Digitalisation
Cement Additives for Improved Grinding Efficiency
Digital Pathways for Sustainable Manufacturing
Refractory demands in our kiln have changed
Digital supply chain visibility is critical
Redefining Efficiency with Digitalisation
Cement Additives for Improved Grinding Efficiency
Digital Pathways for Sustainable Manufacturing
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