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

The primary high-power applications are fans and mills

Published

2 days ago

October 10, 2025

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Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

Concrete

We conduct regular internal energy audits

Published

2 days ago

October 10, 2025

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Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

Concrete

Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

The airport is set to become Asia’s largest air connectivity hub.

Published

2 days ago

October 10, 2025

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Enlight Metals has supplied 3,200 metric tonne of steel for the newly inaugurated Navi Mumbai International Airport, marking a major contribution to one of India’s largest infrastructure projects and reinforcing the company’s commitment to supporting national development.

The Navi Mumbai International Airport, developed under a Public-Private Partnership led by the Adani Group, was inaugurated today by Prime Minister Narendra Modi. The airport is set to become Asia’s largest air connectivity hub, enhancing regional connectivity, boosting economic growth, and expanding trade opportunities. Prime Minister Modi described the project as a “glimpse of Viksit Bharat,” highlighting its transformative impact on infrastructure and development in the region.

“The supply of 3,200 metric tonne of steel for this key project aligns with our focus on supporting critical infrastructure development through reliable and timely metal sourcing. Enlight Metals is committed to enhancing transparency and efficiency in the steel supply chain, contributing to projects integral to India’s growth objectives,” said Vedant Goel, Director, Enlight Metals.

Enlight Metals has implemented technology-driven solutions to strengthen supply chain efficiency, ensuring consistent availability of construction materials for large-scale projects nationwide. Its contribution to the Navi Mumbai International Airport underscores the company’s growing role in supporting India’s infrastructure development initiatives.

This milestone reflects Enlight Metals’ ongoing engagement in delivering quality materials and timely services for major national projects, further cementing its position as a reliable partner in India’s infrastructure sector