Concrete

A Taxonomical Approach to Gravimetric Dosing

Published

5 years ago

July 1, 2021

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The process of metering of mass flows consists of a standard conveying system (e.g. a belt or screw conveyor) and the determination of the actual flow by means of an integrated weighing system. As an example the typical belt scale is shown in Figure 5, where a belt conveyor transports material with a certain speed v [m/s] to a single weighing roller (marked in green), which determines the actual belt load m_belt [kg].

Figure 5- Example for a metering device (here: belt scale)

From the measured belt load m_belt it is possible to compute the actual mass per length unit (?m/?l [kg/m]), which can be used to determine the actual mass flow [kg/h] as follows:

The standard metering device contains no control circuit at all, since it is only computing the actual mass flow but there is no feedback between this information and the actual speed of the conveyor. DI MATTEO offers such metering devices either as belts or as screw conveyors. An ODM-Screw MASTER screw scale (as shown in Figure 6) has the advantage that the system is completely closed and dust-proof and represents therefore in many cases the preferable solution.

3.3 Open-loop dosing

Open-loop dosing is also often called volumetric dosing, since the main principle behind it is the operation of a certain conveyor with a certain pre-defined speed for each possible mass flow setpoint. Thus, the actual weighing of the real material weight is neglected and instead it is assumed, that for the generation of a constant mass flow [kg/h] it is sufficient to generate a constant volume flow [m?/h]. This assumption is of course only valid, if it can be guaranteed that the bulk density ? [kg/m?] of the conveyed material is constant. Since there is no information of the actual mass flow from a gravimetric measurement unit, it is necessary to define a calibration curve or generalised mathematical relation in order to define the dependency between the actual speed of the conveyor v [m/s] and the mass flow. In most cases volumetric dosing is realised by a screw conveyor, since the usage of a through or tubular screw conveyor guarantees a quite stable volumetric feeding behaviour for different speeds if compared to e.g. a belt.

However, especially for materials with time-varying properties and volatile humidity or density, e.g. for the accurate dosing of alternative fuels, a closed loop dosing method is not applicable.

3.4 Closed-loop dosing ??ODM-GraviSCALE and ODM-WeighTUBE^?

The most sophisticated and accurate solution for the proportioning of bulk materials is closed-loop dosing, which is often also referred to as gravimetric dosing, since the actual mass flow [kg/h] is determined by means of an integrated weighing unit.

The most prominent example for such a system is the ODM-GraviSCALE belt weigh feeder, as shown in Figure 7 ??(b). The working principle for the determination of the actual massflow is similar to the one shown in Equation (II), which means that the actual conveying speed v [m/s], as measured e.g. by an incremental encoder, and the actual material load m [kg] are evaluated continuously. As illustrated in Figure 7 ??(a), the closed-loop principle can be interpreted in such a way, that there is a direct feedback from the calculated mass flow to the variable speed drive unit. If there is a deviation between the actual mass flow and the desired setpoint, the actual conveying speed can be therefore continuously adapted. Thus, a high precision of the dosing operation is guaranteed and typically the maximum deviation from the setpoint lies below .

However, the operation of belt weigh feeders in practical applications is characterised by two main aspects: First of all, it needs to be said that belts are by nature non-closed systems. This leads to non-negligible dust emissions and spillage of material, which affects as a logical consequence subsequently the weighing units and their accuracy. DI MATTEO designed the ODM-GraviSCALE in such a way to avoid those effects as much as possible, which is achieved by a smart casing, sealing and scraping concept.

On the other hand and as it was already stated above, all existing dosing methodologies are suffering immensely from possible time-variant material properties of the conveyed bulk. This leads in practical applications to a non-negligible drift in the dosing accuracy over time. Thus, belt weigh feeders need to be recalibrated on a regular basis (e.g. once a month) in order to guarantee a long-term stability of the feeding process. This re-calibration needs to be done manually by service technicians in a time-consuming process, during that the machine has to remain offline.

These two aspects led in the past to the development of a completely novel closed-loop dosing system: the tubular weigh feeder ODM-WeighTUBE^?, which is described in detail within the next section.

1. ODM-WeighTUBE^?– A Novel Gravimetric Closed-Loop Dosing Unit

The initial base for the development of the ODM-GravitAS control system was the introduction of the innovative ODM-WeighTUBE^? platform in 2010. Even if the first installations of the novel dosing system were mainly focused on plants for problematic bulk material, such as residue derived fuels (RDF), shredded tires or polyethylene granulate material, actually roundabout one hundred units of the ODM-WeighTUBE^?are successfully integrated around the world and have been also used for more conventional bulk materials, such as raw meal, fly ash, iron core or clinker. This can be interpreted as a great success, especially for a relatively conservative industrial branch, such as the cement industry. Figure 8 provides an overview of the ODM-WeighTUBE^? RWS series, in the German production facility of Di Matteo. Up to know, there are three different models of the WeighTUBE^? available (RWS 500, RWS 400, RWS 250) depending on the type of bulk material and the intended dosing range.

FIG 8

The general dosing principles is similar to the classical closed-loop scheme, as it was introduced for the ODM-GraviSCALE belt weigh feeder. The same idea is transferred to a screw conveyor, as shown in Figure 9. The WeighTUBE consists of a tubular screw conveyor, which is continuously discharging material from an intermediate buffer. The material is conveyed to the tube section, which is placed on a set of load cells and decoupled from the main frame of the machine by flexible connections. Therefore it is possible to measure the actual material weight within the tube (tube weight) m_tube [kg]. Furthermore, the actual conveying speed of the screw v_screw [m/s] is continuously acquired. Similar to the principle shown in Figure 7 ??(a), both physical values are processed in order to calculate the actual mass flow [kg/h]. By taken into consideration the desired mass flow (setpoint) it is possible to determine the actual deviation e [kg/h], which is fed to the continuous dosing controller (CDC), which calculates the necessary adaption of the screw speed in order to minimize the deviation under all circumstances and at any given time. All software elements are implemented within the ODM-GravitAS control system, which was developed by DI MATTEO as a unified platform for all weighing and dosing applications (see [4]).

FIG 9

Furthermore, the ODM-GravitAS control system implements an automatic calibration routine, which provides the possibility to estimate properties of the dosed bulk material and automatically adapt the controller parameters in such a way that the dosing accuracy remains stable over time. The actual process operation is not influenced by the execution of the automatic calibration routine, so that the available machine time can be increased.

During the automatic calibration routine the intermediate buffer hopper of the ODM-WeighTUBE is filled to a certain maximum in a first stage of operation. Within the second phase the buffer hopper is emptied by normal dosing operation (and parallel stopped feed of material to the buffer) up to a predefined minimum buffer weight. From the resulting difference in mass ( ) and the corresponding expired time ( ), the actual control parameters of the continuous dosing controller are automatically adapted. To avoid possible undesired influences, all controller parameters are checked for plausibility based on a probabilistic analysis of former calibration cycles, before they become active in the system. A typical calibration process, with its three phases, is shown in the following figure, where the actual buffer weight m_plant [kg] is visualised over time.

The decreasing buffer weight in phase II of the calibration process follows an almost exact linear pattern, which can be interpreted as a manifestation of the highly constant material throughput of the device. A possible deviation between the actual and the desired mass flow during this phase is evaluated for the probabilistic adaption of the controller parameter.

The possibility for a continuous on-the-fly auto-tuning of the controller depending on the given material properties is a very important element for long-time stability and accuracy of the gravimetric dosing. In particular, if the decreasing quality of alternative fuels derived from industrial waste (see [3]) is taken into account. By the combination of the ODM-WeighTUBE^? platform with the GravitAS control system a high dosing precision of <?1% related to the nominal throughput can be guaranteed.

1. Summary and Conclusion

This article introduced a framework for the systematic classification of dosing and metering equipment for cement plants and relative industries. The defined taxonomy allows a better understanding of the exact nature of a certain type of equipment and can be used as a guideline during the design and implementation of system setups.

Each class of system was defined in detail by using the complete variety of dosing and weighing equipment as offered by DI MATTEO, from static silo scales and weighing hoppers to the latest developments in closed-loop high-precision dosing (e.g. ODM-GraviSCALE belt weigh feeder).

Another important aspect for the selection of adequate dosing equipment is the typical ??tatus-quo decision-making trap??as described in [5]. It mainly states, that the logical consequence of most buying decisions in larger organisations is just the preservation of the current technological state. This is especially observable in relative conservative industries, such as cement manufacturing, since in most cases those systems are unintentionally preferred, that are already known. This has severe consequences on the competitive situation of many organisations, because it might happen that technological developments are adopted too late or even completely neglected.

However, the usage of AFs within the clinkering process is always associated by a more complex combustion behaviour, due to its volatile bulk material characteristics, such as humidity and bulk density (see [6]). Furthermore each fuel type has its own unique combustion characteristics that cement plant operators must adapt to in order to guarantee a successful kiln operation. In addition the presence of halogens (e.g. chlorine) found in biomass such as what straw and rice husks may be problematic for the kiln operation, while petroleum-based wastes are prone to cause sulphur and NO_x emissions.

The more varying the characteristics of the fuel are the more important becomes a stable dosing of these fuels into the burning process. Every additional inaccuracy within the dosing itself would automatically lead to an increased uncertainty while handling those fuels. A simple example proves the importance of a stable feeding: Under the assumption that biomass (e.g. rice husks) shall be used as AF and the associated typical lower heat value varies between 10 and 20 GJ/T. Thus, if the dosing device would work with a maximum deviation of 5%, the actual deviation within the massflow accumulates with the deviation in heat value naturally given in the fuel itself. This would make it quite difficult to control the thermal process.

This article introduced the ODM-WeighTUBE^? as the latest development in gravimetric long-term stable high accurate dosing of bulk materials, which has proven its capability to solve many problems and drawbacks of classical proportioning equipment in numerous different application fields. This can be considered to be a possibility to break the wall of the status-quo and guarantee long-term reliability and fast return-on-investment.

References

[1] Aufderheide, D., DI Matteo, L.: Dynamic Dosing. In World Cement 12 (2014), pp. 63-68, Palladian Publications, Farnham – ISSN 0263-6050

[2] Aufderheide, D., DI Matteo, L.: Full Modular Control System for Gravimetric Dosing Applications. In ZKG 11 (2014), pp. 44-49, Bauverlag, G?tersloh – ISSN 0949-0205

[3] Vetter, G (Ed.). (2002): Handbuch Dosieren. Vulkan Verlag GmbH, Essen ??ISBN 380-272-1993

[4] Aufderheide, D., DI Matteo, L.: ODM-GravitAS for DI MATTEO WeighTUBE feeders ??A Full Modular Control System for Gravimetric Dosing Applications. In Global Cement Magazine 2 (2015), Pro Global Media Ltd., Epsom – ISSN 1473-7940

[5] Emiliani, M.L.: Executive Decision-Making Traps and B2B online reverse auctions. In Supply Chain Managament: An International Journal 1 (11) (2006), pp. 6-9

[6] Aufderheide, D., Di Matteo, L.: Remote and preventative maintenance. In International Cement Review 4 (2016), pp. 60 ??66, Tradeship Publications ??ISSN 0959-6038

Prof. Dr. Dominik Aufderheide

About the authors

Prof. Dr. Dominik Aufderheide is a professor for industrial metrology at the South Westphalia University of of Applied Sciences in Soest, Germany. He had served for many years as the Head of the Automation and Research department at the DI MATTEO Group, Germany. He holds a PhD in Electrical Engineering from the University of Bolton in the UK. He has been an active researcher in the field of process technology, automation and sensor technology for more than a decade and participates actively in the development of new technologies within the field of co-processing of alternative fuels within the cement industry.

Dr. Luigi Di Matteo

Dr. Luigi Di Matteo is the CEO of the DI MATTEO Group, Germany. He received his doctorate degree from the Technical University of Braunschweig, Germany. His contributions to the field of conveying and process technology, especially for problematic bulk materials, have become a key element for utilizing alternative fuels within the clinkering process.

Concrete

Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict

Crisil Sees Margins Easing Despite Steady Demand

Published

3 weeks ago

July 29, 2026

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Crisil said operating margins of Indian cement manufacturers are expected to decline by Rs 50-75 per tonne (t) this fiscal to Rs 925-950 per t due to higher input costs triggered by the West Asia conflict. The analysis covered 18 cement companies accounting for nearly 90 per cent of India’s domestic cement capacity and noted margins had improved sharply to around Rs 1,000 per t in fiscal 2026.

Crisil noted that the reduction would be driven mainly by higher power and fuel costs, which account for about 30 per cent of total costs, as petcoke and imported coal prices have surged amid geopolitical uncertainties. Freight costs, which account for about a quarter of total costs, are also expected to remain elevated because of higher diesel prices. The impact on profitability is likely to be more pronounced in the first half of the fiscal year before easing commodity prices moderate cost pressures later.

The rating agency said steady domestic demand and strong balance sheets should keep credit profiles stable despite the moderation in margins. Green energy currently accounts for 35-40 per cent of the sector’s total electricity consumption and is expected to partly cushion higher energy costs. Operating cash flows are likely to remain resilient, supported by projected 6-7 per cent growth in cement demand this fiscal.

Crisil highlighted that demand growth will be driven primarily by infrastructure spending, which meets about one-third of sector consumption, and by a nearly 18 per cent higher budgetary allocation for core ministries that should support project execution. Weaker rural housing demand amid pressure on agricultural incomes from a possible below-average monsoon may be offset by improved urban housing demand supported by favourable home-loan rates and a strong pipeline of Pradhan Mantri Awas Yojana-Urban projects. Ongoing capacity additions will keep capital expenditure elevated and may lift net debt to EBITDA to between 1.2 and 1.4 times from around 1.0 time last fiscal, though ratios are expected to remain healthy.

Concrete

UltraTech Board Approves Rs 50 bn Fundraise Via NCDs

Company to issue half a million debentures for expansion plan

Published

3 weeks ago

July 28, 2026

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UltraTech Cement’s board of directors has approved raising Rs 5,000 crore (Rs 50 bn) through non?convertible debentures issued in rupees.

The finance committee cleared a proposal to issue up to 500,000 fully paid, unsecured, listed, rated, redeemable, rupee?denominated, non?convertible, non?cumulative debentures of Rs 1 lakh each (Rs 0.1 mn each), aggregating to the Rs 5,000 crore programme.

As of June 2026 the firm reported net debt of Rs 15,875 crore (Rs 158.75 bn) and said its capacity expansion projects under execution are backed by capital expenditure of about Rs 17,000 crore (Rs 170 bn) over the next two to two?and?a?half years.

UltraTech spent Rs 9,500 crore (Rs 95 bn) on capital expenditure in financial year 2026 and in April the group crossed 200.1 mn tonnes per annum of domestic grey cement capacity and 205.5 mn tonnes per annum of global capacity.

The chief financial officer indicated the company would take consolidated capacity beyond 242 mn tonnes per annum, with grey cement capacity reaching 212.7 mn tonnes per annum by the end of financial year 2027. He noted the net debt?to?earnings before interest, taxes, depreciation and amortisation ratio stood at 0.87 times as of June 2026 and the company was confident of ending financial year 2027 with the ratio below one time.

In the first quarter of financial year 2026?27 UltraTech’s net profit attributable to owners rose 16.8 per cent year?on?year to Rs 2,599.3 crore (Rs 25.993 bn) and revenue from operations increased 15.9 per cent to Rs 24,648.20 crore (Rs 246.482 bn). The board approval is expected to complement internal cash flows as the company advances its expansion programme.

Concrete

Reimagining the Future

Published

4 weeks ago

July 21, 2026

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From LC3 and AI-driven kilns to RDF gasification, ICR explores the full breadth of technological innovation reshaping India’s cement industry. Low-carbon materials, digital manufacturing, alternative fuels and breakthrough concrete science are collectively advancing the sector’s transition from high-emission commodity producer toward a net-zero, infrastructure-ready future.

Innovation has become the defining force shaping the future of the cement industry. As the world’s second-largest cement producer, India is witnessing rising demand driven by infrastructure development, urbanisation, affordable housing, and industrial growth. At the same time, the International Energy Agency (IEA) estimates that cement production accounts for nearly 7 per cent to 8 per cent of global CO2 emissions, with clinker manufacturing contributing the largest share, making innovation an operational necessity. The industry is therefore investing heavily in low-carbon cement technologies, artificial intelligence (AI), digital manufacturing, alternative fuels, renewable energy and carbon capture, utilisation and storage (CCUS). Innovations such as limestone calcined
clay cement (LC3), supplementary cementitious materials (SCMs), AI-driven process optimisation and automated quality control are enabling manufacturers to produce more sustainable, efficient, and high-performance cement.
According to the Global Cement and Concrete Association (GCCA), achieving net-zero emissions will require a combination of material innovation, digital transformation, circular economy practices and collaborative research, making innovation central to the industry’s long-term competitiveness and India’s sustainable infrastructure growth.

Next-generation cement
The future of cement lies in reducing its dependence on clinker-the most carbon-intensive component of cement-through the adoption of low-carbon materials and advanced blended cement technologies. Products such as Portland Pozzolana Cement (PPC), Portland Slag Cement (PSC), Portland Composite Cement (PCC), and LC3 are driving this shift by replacing clinker with SCMs like fly ash, GGBS, calcined clay and limestone.
According to GCCA, SCMs can replace 30 to 50 per cent of clinker, with some applications exceeding 70 per cent, significantly reducing carbon emissions without compromising strength or durability. These blended cements also improve concrete performance by enhancing durability, reducing permeability, and increasing resistance to chloride and sulphate attacks. As the availability of traditional SCMs declines with the decarbonisation of the power and steel sectors, the industry is increasingly exploring alternative materials and next-generation cement formulations to support long-term sustainability.
Shrivats Singhania, Deputy Managing Director, JK Lakshmi Cement, says, “Innovation is enabling the cement industry to address one of its most important challenges – producing more with fewer resources and lower emissions. Across the value chain, manufacturers are deploying technologies that simultaneously improve operational efficiency and advance sustainability goals. For example, greater adoption of alternative fuels, waste heat recovery systems, renewable energy, and digital process controls is helping reduce energy consumption and optimise resource utilisation. Data-driven manufacturing allows plants to monitor operations in real time, improve equipment reliability, minimise downtime, and reduce wastage, resulting in both environmental and economic benefits.”
“Meaningful progress is also being achieved through material innovation. The growing use of blended cements and next-generation products such as LC3 reduces dependence on clinker, the most carbon-intensive component of cement production, thereby lowering embodied carbon without compromising performance,” he adds.
Among emerging technologies, LC3 has gained global recognition as one of the most promising low-carbon cement innovations. In a standard formulation, LC3 comprises approximately 50 per cent clinker, 30 per cent calcined clay, 15 per cent limestone, and 5 per cent gypsum. LC3 can reduce CO2 emissions by up to 40 per cent compared with Ordinary Portland Cement (OPC) while delivering comparable strength and enhanced durability. Its reliance on abundant, locally available raw materials, rather than industrial by-products, makes it highly scalable and well suited to countries like India.
According to the LC3 Project, nearly 75 per cent of cement plants worldwide could adopt LC3 using existing manufacturing infrastructure, potentially reducing global CO2 emissions by over 400 million tonnes annually, if adopted at scale globally. India’s introduction of BIS standard IS 18189:2023 for LC3, coupled with its adoption in projects such as the Noida International Airport, marks a step toward commercial implementation. As demand for sustainable construction grows, LC3 is poised to become a cornerstone of low-carbon infrastructure development.

Making of a smart cement plant
The modern cement plant is rapidly evolving into a digitally connected, AI-enabled manufacturing ecosystem where data drives every aspect of production – from raw material proportioning and kiln operations to quality control, maintenance and energy management.
According to IEA, digital technologies can improve energy efficiency in heavy industries by 10 per cent to 20 per cent. Advanced process control systems in cement plants have demonstrated the potential to reduce thermal energy consumption by 3 to 5 per cent, lower electricity consumption by 2 to 10 per cent, and improve kiln throughput and clinker quality. AI-powered predictive maintenance further helps reduce unplanned equipment downtime by 30 to 50 per cent and extend equipment life by continuously analysing sensor data to detect failures before
they occur.
Jignesh Kundaria, Director and CEO, Fornnax Technology, says, “AFR is no longer viewed solely as a sustainability initiative. It has become a strategic business priority for cement manufacturers. Rising fuel costs, stricter environmental regulations, and growing pressure to reduce dependence on conventional fuels are accelerating AFR adoption across the industry. However, the success of an AFR project depends heavily on how effectively waste is processed before it reaches the kiln. Poor preprocessing can negatively impact kiln performance, fuel efficiency, and emission control systems. Inconsistent fuel
quality often forces operators to make frequent adjustments, reducing throughput and increasing energy consumption.”
Dr Kapil Kukreja, General Manager, NCCBM, says, “Variations in composition, particle size, and calorific value can lead to inconsistent combustion behaviour resulting in fluctuating heat release patterns. These fluctuations can affect process stability, temperature control and clinker quality. Additionally, incomplete combustion of RDF particles can result in increased emissions, higher unburnt carbon content, and operational difficulties within the calciner system. Higher ash and inert content of RDF can dilute the clinker quality and reduce calciner efficiency.”
Meanwhile, digital twins are allowing manufacturers to simulate entire production processes, optimise kiln performance, evaluate process changes virtually, and reduce operational risks before implementation. Automated Laboratory Information Management Systems (LIMS), coupled with online and offline XRF and XRD analysers, are delivering real-time monitoring of clinker chemistry and mineralogy, ensuring tighter quality control, lower clinker variability and more consistent cement performance.
Dr Prateek Sharma, Group Project Manager, NCCBM, explains, “Chlorides and alkalis present in RDF can lead to excess buildup and blockages in the kiln and calciner increasing the downtime of cement plants. Hence, issues with direct utilisation of RDF establishes the need for fuel conditioning and alternative utilisation approaches that can maximise the energy potential of RDF while minimising adverse impacts on plant operation. RDF gasification emerges as an efficient tool for converting solid RDF into syngas which can be used as a fuel with improved characteristics.”
Digitalisation and intelligent manufacturing will be among the most critical enablers of achieving the cement industry’s net-zero ambitions by improving operational efficiency while simultaneously reducing energy consumption and greenhouse gas emissions, confirms a GCCA report.

From research to reality
While the cement industry has made remarkable progress in developing breakthrough technologies, the transition from laboratory research to large-scale commercial deployment remains one of its greatest challenges. The successful adoption of innovations such as LC3), CCUS, advanced alternative fuels, green hydrogen and novel SCMs depend not only on technical feasibility but also on economic viability, regulatory support, raw material availability, and market acceptance.
Veerendra Jamdade, CEO and Founder, Vritti Solutions, states, “The cement industry has a market that is constantly in flux, due to factors such as infrastructure investment, seasonality of demand, fuel costs, building activity by region and general economic cycles; therefore, having accurate forecasts is very important in this type of market. Traditional ERP systems are primarily data repositories with limited analytic functionality; thus, they capture transactional and operational information but generally lack advanced analytical capabilities for converting captured data into actionable information. This
affects everything from demand forecasting and inventory planning through procurement and production scheduling.”
According to IEA, technologies that are still at the demonstration or early commercial stage-including CCUS and next-generation low-carbon binders-are expected to contribute nearly 40 per cent of the emissions reductions required for the global cement sector to achieve net-zero emissions by 2050, underscoring the importance of accelerating their scale-up. This requires robust R&D ecosystems, stronger collaboration between cement manufacturers, research institutions, technology providers,
equipment suppliers, and policymakers, as well as supportive standards and financial incentives to reduce investment risks.
Ashutosh Pandita, Director – Head, Cement Business, TKIL Industries, elaborates, “The cement industry’s most transformative innovation today is the increased use of alternative fuels and raw materials (AFR), supported by advanced feeding systems and process technologies that are driving both operational efficiency and decarbonisation. Looking ahead, oxyfuel combustion and carbon capture technologies remain underappreciated but hold immense potential for enabling deep reductions in carbon emissions and accelerating the industry’s journey towards net-zero production. By 2030, cement manufacturing is expected to become significantly more sustainable, energy-efficient, and technology-driven, with widespread adoption of AFR, low-clinker cement technologies, greater digitalisation and automation, and the early commercial deployment of carbon capture solutions, all supported by stronger industry collaboration and a shared commitment to achieving long-term sustainability goals.”
In India, organisations such as the National Council for Cement and Building Materials (NCCBM), leading academic institutions, and major cement companies are working together to develop and validate emerging technologies, while the introduction of standards such as IS 18189:2023 for Limestone Calcined Clay Cement (LC3) marks a significant step towards commercial adoption. However, challenges such as high capital investment, long validation cycles, limited infrastructure for technologies like CCUS, fluctuating availability of alternative raw materials, and customer acceptance continue to slow implementation. Bridging the gap between research and commercial reality will therefore require sustained investment in innovation, knowledge-sharing, pilot projects, policy support, and industry-wide collaboration to ensure that promising technologies evolve into scalable, economically viable solutions capable of transforming the future of cement manufacturing.

Creating a green future
Clinker production will increasingly rely on low-carbon technologies such as LC3, high-volume SCMs, AFR, renewable energy, waste heat recovery, and eventually CCUS, enabling manufacturers to significantly reduce their environmental footprint.
Achieving net-zero concrete by 2050 will require a combination of clinker substitution (around 37 per cent of cumulative CO2 reductions), carbon capture technologies (approximately 36 per cent), and improvements in thermal efficiency, renewable energy, and circular economy practices.
Industry Expert SA Khadilkar comments, “Customer requirements are a key driver of innovation in the cement industry, influencing product development, process improvements, sustainability initiatives, and digital solutions. Innovation is most effective when it addresses real market needs, particularly in areas such as performance, durability, and application-specific requirements. Around a decade ago, ACC and Ambuja Cements (now Adani Cement) recognised this shift and introduced performance-oriented blended cement brands with enhanced durability, reduced water penetration, and OPC-like properties. Their success encouraged other major cement manufacturers to develop specialised cement brands with unique performance characteristics, demonstrating how product innovation has evolved to meet changing customer expectations.”
“Ultimately, customer expectations have transformed innovation from a technology-driven exercise into a market-driven strategy, ensuring that new developments create measurable value across the construction value chain,” he adds.
India is expected to add nearly 500 million square metres of urban built-up area by 2030, driving sustained demand for greener, more durable, and higher-performing construction materials, according to NITI Aayog. Meeting this demand will require cement manufacturers to evolve from commodity producers into integrated providers of sustainable building solutions, supported by data-driven manufacturing, collaborative R&D, customer-centric product innovation, and circular resource management. The cement plant of tomorrow will therefore be defined not only by its production capacity but also by its ability to manufacture smarter, cleaner, and more sustainable construction materials that support India’s ambitious infrastructure and climate goals.

Conclusion
The path ahead is clear in its direction, if not yet in its pace. India’s position as the world’s second-largest cement producer, combined with its infrastructure ambitions and its 2070 net-zero commitment, makes this transition both urgent
and consequential.
What this article has made evident is that no single technology will carry the industry to net zero. LC3 addresses clinker dependency. Digital manufacturing addresses efficiency and waste. Alternative fuels address fossil fuel dependence. CCUS addresses the residual process emissions that no other lever can reach. Each is necessary. None is sufficient alone. The industry’s task is to advance all of them simultaneously, at a pace that matches the scale of the challenge.
The plants that will build tomorrow’s highways, airports and homes will need to do so with a fraction of today’s carbon footprint.

Innovations in cement and concrete

Carbon mineralisation in concrete: A 2026 peer-reviewed study in the Journal of the American Ceramic Society by MIT’s Masic Lab and CarbonCure Technologies used in-situ Raman microspectroscopy to show that CO2 injected during cement mixing triggers a three-stage hydration sequence, producing a more uniform microstructure with approximately 13 per cent higher early strength while permanently sequestering carbon within the concrete matrix.

Source: www.carboncure.com

Zero-clinker geopolymer blocks: Theseus Development manufactures geopolymer blocks using upcycled aluminosilicate waste from quarries and mines through an inorganic polymerisation process, achieving up to 80 per cent lower embodied carbon compared to conventional cement blocks. An interlocking block design reduces mortar requirements, lowering construction costs while eliminating clinker entirely from the production process.

Source: www.rmi.org

3D-printed basalt fibre grids: Austrian startup Fiber Elements, founded in 2023, uses robotically wound continuous basalt fibres arranged into three-dimensional reinforcement grids that replace steel in concrete structures. The resulting composites are three times stronger than steel, weigh two-thirds less, resist corrosion entirely and reduce CO2 emissions by up to 70 per cent compared to conventional steel-reinforced concrete.

Source: www.eitmanufacturing.eu

Self-healing concrete: Dutch company Basilisk leads commercial deployment of bacteria-based self-healing concrete, with licensed production now active in Japan and a highway viaduct pilot planned for 2026. Dormant Bacillus bacteria embedded in the mix activate upon crack formation, metabolising nutrients to precipitate calcium carbonate that autonomously seals fractures. The global self-healing concrete market is projected to grow significantly through 2031, driven by green building mandates and infrastructure agencies targeting lower maintenance costs and extended structural life.

Sources: www.thelegaljournalontechnology.com and www.mordorintelligence.com