Concrete

Process Control Solutions for the Future

Published

3 years ago

March 15, 2023

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From the increased use of modern techniques of control to advanced software solutions, technology is accelerating cement processes in myriad ways. ICR looks at the economic impact of AI and automation on the cement sector.

The history of cement production dates back to 12,000 years ago. The earliest archaeological discovery of a consolidated whitewashed floor made from burned limestone and clay is found in modern-day Turkey. Around 800 BC, the Phoenicians had the knowledge that a mixture of burnt lime and volcanic ash, today called ‘pozzolana’, could be used to produce hydraulic lime, which was not only stronger than anything previously used, but also hardened under water. The Romans perfected it later with their process called, ‘opus caementicium,’ a type of concrete made of lime with aggregates of sand and crushed rock. No wonder the Colosseum and Pantheon in Rome, and the Hagia Sophia in Istanbul, all stand perfectly fine today.
But modern production of cement is million times bigger in scale and must be controlled to derive the benefits of cost, throughput and quality, sometimes several objective functions must be optimised to give the overall gain in terms of profit maximisation. The technology itself progressed in leaps and bounds to make allowance for both throughput increase and cost while the quality improved from one milestone to the next. The first cement standard for Portland cement was approved in Germany in 1878, defining the first test methods and minimum properties, with many other countries following suit.
Cement production and applications surged globally at the turn of the century. Since the 1900s, rotary kilns have replaced the original vertical shaft kilns, as they use radiative heat transfer, more efficient at higher temperatures. achieving a uniform clinkering temperature and producing stronger cement. Gypsum is now also added to the resulting mixture to control setting and ball mills are used to grind clinkers.
Other developments in the last century include calcium aluminate cements for better sulphate resistance, the blending of Rosendale (a natural hydraulic cement produced in New York) and Portland cements to make a durable and fast-setting cement in the USA, and the increased usage of cementitious materials to store nuclear waste. New technologies and innovations are constantly emerging to improve the sustainability, strength and applications of cement and concrete. Some advanced products incorporate fibres and special aggregates to create roof tiles and countertops, for example, whilst offsite manufacture is also gaining prominence with the rise of digitalisation and AI, which could reduce waste and improve efficiency and on-site working conditions. Cements and concretes are also being developed, which can absorb CO2 over their lifetimes, reducing the carbon footprint of the building material.
The focus of the current times is manifold – on the one hand cement process and technology experts have the job cut out to create sustainable solutions and on the other, the process control techniques have improved to embrace new digitisation techniques to better improve the following processes:

Quarrying and preparation
Close circuit blending systems that create the ideally suited raw mix
Clinker kilning
Cement grinding

The systems of the cement production control these operations to produce maximal quantity of the cement with prescribed quality and minimal cost. The quality also depends on many variables. The appropriate rate of the basic components determining the setting time, strength, heat of hydration, expansion, etc. is the most important. The free lime content (FLC) also influences the quality similarly to the size distribution and the relative surface area. A great many open and closed loop controls can be found in the cement production, however, the proper control of the operations-triplet proportioning-burning-grinding can ensure to reach the overall control aim, the other controls are auxiliary ones. The synthesis of this would aim at thermal efficiency parameters with use of different fuel mixes, alternate fuels included and the raw mix must be so blended such that a range of objective functions can be met that include Lumping, Burnability, High Heat of Hydration, Fast Setting, One Day, 3 Day, 7 Day, 28 Day Strength, etc.
The burnability parameters include lime saturation factor, silica ratio, af ratio, content of coarse quartz, content of coarse calcite, while the compositional parameters like content of C3S, MgO, C3A and presence of alkali. Silica ratio and other aspects could together influence the attainment of the quality objectives like fast setting or efficiency objectives like high heat of hydration. This is where control systems step in to play a decisive role to make adjustments in a number of parameters, while the production process remains continuous. Achieving stability of the process, where coal feed, kiln feed, raw mix, all have a myriad of parameters to be weighed against the objectives of productivity, efficiency and quality.

The AI to Z of Technology
Artificial intelligence (AI) today provides valuable decision support and control techniques in these uncertain environments. Two common techniques used in this field are artificial neural networks and fuzzy logic. Fuzzy logic is especially useful for processes that are difficult to control by conventional or discrete methods due to the lack of knowledge of quantitative relations between the inputs and outputs. Controls based on fuzzy logic employ a close-to-human language to describe the input-output relationships of the controlled process. The controller converts an expert knowledge-based control strategy into an automatic control strategy imposed on the process. Most control environments have steadily moved towards adoption of AI and fuzzy logic techniques as dynamic environments are impossible to model with any other tools and techniques unless we want to avoid the inter-play and friction of some of the control parameters.
Use of modern techniques of control have shown productivity gains (t/h) of 3 per cent and energy gains (Kcal/t) of 5 per cent compared to expert operators using controls. In cement milling, the productivity increased by 3.1 per cent and the energy savings were 2.9 per cent. In clinkerisation, there were increases from 1 to 3 per cent in the daily production, reductions from 2 to 4 per cent in energy consumption, reductions from 12 to 16 per cent in the variability of clinker quality requirements, and reduction of up to 10 per cent in the variability of the lifetime of the liner. In other clinker kilns, there were from 4 to 5 per cent reduction in fuel consumption, from 80 to 90 per cent decrease in variability and increase from 7 to 8 per cent in productivity.
Now the focus in controls have shifted to use of algorithms and software that would step in to make allowance on the selection of specific objective functions like quantity over efficiency or efficiency over quality or vice versa, as the optimisation objectives could vary. The forward progress also shows far greater focus on use of alternate fuels that actually changes the dynamics by a considerable extent. For CO2 abatement measures and carbon sequestration processes, the use of controls are moving to the next level of automation as more complexity is getting introduced. Electronics and electrical systems are now inseparable from the field of software and algorithms that embrace AI to create the right blend of self-controls and automation that limits human interventions as the complexities of the dynamic environment makes it impossible for humans to interact any more.
Software solutions together with drone systems and automation allow the process to be self-serving in delivering multi-objectives within the framework of optimisation; the caution however is that the final decision on the choices must include proper testing (in a test environment) before selection of the type of the AI based system as the number of options are on the increase and competing systems all vouch for the similar end-results.
Software progress should not be limited to cement production systems alone, but cement distribution and logistics as well. With tracking and tracing systems in place it is easy to match planning with execution where one can make a simulation of movements of cement deliveries across the demands of micro, mini and regional markets to arrive at the best overall distribution to attain the goals of sales and profitability; this need not be based on rule of thumb which has nothing to do with the realities on the ground where the situation is far too dynamic throughout the day. Merging planning algorithms with track and trace systems has everything ready to be used, only the lack of intent seems ominous for some. The leaders however have progressed considerably in this regard.

-Procyon Mukherjee

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Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

Published

6 days ago

February 5, 2026

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FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

Concrete

Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

Published

1 week ago

February 2, 2026

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Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

Published

2 weeks ago

January 31, 2026

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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