Concrete

Making Cement with Surrogates

Published

3 years ago

June 12, 2023

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The cement sector, specifically the one in India, shoulders the responsibility of paving the way for the use of alternative fuels and raw materials (AFR) as it continues to take sturdy strides towards decarbonisation. ICR explores the various facets and technological innovations involved in the use of AFR.

India is the world’s second-largest cement manufacturer. It makes up more than 8 per cent of the installed capacity worldwide. The cement industry is anticipated to gain the most from India’s potential for expansion in the infrastructure and building sectors. Furthermore, cement consumption in India has been steadily increasing as a result of the increased need for rural housing. One of the key factors driving demand for cement is the industrial sector’s rapid expansion. As a result, there is a great chance that the long-term need for the cement sector will rise. The creation of 98 smart cities is only one of the current efforts that are anticipated to have a big impact on the industry.
According to the IMARC Group, the India cement market size reached 3,644.5 MT in 2022. The market is expected to reach 4,832.6 MT by 2028, exhibiting a growth rate (CAGR) of 4.94 per cent during 2023-2028.
The India cement market is primarily driven by the significant rise in construction activities due to the rapid population expansion and a surge in the need for residential spaces. The development of mega infrastructure projects in the country, such as airports and roads, is also bolstering the growth of the market. Furthermore, with the growing environmental concerns, there has been a rise in the demand for green buildings. This has led to an increase in the sales of sustainable and green cement as it minimises the CO2 emissions generated during the production process. Moreover, rapid urbanisation and industrialisation, along with the rising purchasing power of consumers, are some of the other factors catalysing the market growth across the country.
The rising demand for cement impacts the use of raw materials and fuels in its production process and can have consequences for natural resources.
As the production of cement requires significant amounts of raw materials, primarily limestone and clay and its demand is increasing with the times, there is greater pressure on the extraction of these materials from quarries. This can lead to habitat destruction, deforestation, and disruption of ecosystems. Overexploitation of natural
resources can also deplete these non-renewable materials, potentially leading to long-term environmental impacts.
Similarly, the cement manufacturing process is energy-intensive, requiring high temperatures for the kiln operation. Traditionally, fossil fuels such as coal, oil, and natural gas have been used as the primary sources of energy in cement kilns. The rising demand for cement increases the consumption of these fossil fuels, leading to higher greenhouse gas emissions and contributing to climate change.
The extraction of raw materials and the burning of fossil fuels in cement production have associated environmental impacts which include air pollution, release of greenhouse gases (such as carbon dioxide and nitrogen oxides), and potential water contamination due to mining activities. The cumulative effect of these impacts can contribute to climate change, air pollution and ecosystem degradation.

THE PROCESS OF CEMENT MAKING
All over the world, cement is one of the most important building materials. The process starts with extracting raw materials, crushing and transporting them to the manufacturing facility. The most important raw materials for making cement are limestone, clay and marl. These are extracted from quarries by blasting or by ripping using heavy machinery. Wheel loaders and dumper trucks transport the raw materials to the crushing installations. There the rock is broken down to roughly the size used in road metaling. It is then blended and homogenised, dried, and grinded.
The prepared raw material is then burned at approx. 1,450°C in a kiln. In this process, a chemical conversion takes place where carbon dioxide is emitted, and the product is the clinker. Once the burnt clinker is cooled down, it is stored in clinker silos. From there the clinker is conveyed to ball mills or roller presses, in which it is ground down to very fine cement, with the addition of gypsum and anhydrite, as well as other additives, depending on the use to which the cement is to be put. The finished cement is stored in separate silos, depending on type and strength class.
The fuel used to heat the kiln is mainly coal which is a naturally occurring resource that is getting extinct by the day and also emits carbon. Similarly, limestone in the chemical process produces a large amount of carbon dioxide. This leads to the need of alternative raw materials and fuels in the cement manufacturing process.

SUSTAINABILITY IN CEMENT MAKING
To mitigate the impacts like depleting fossil fuels or raw materials for cement and increasing carbon content in the environment, the cement industry has been actively adopting measures to improve resource efficiency, reduce emissions, and promote sustainable practices. This includes the use of alternative fuels (such as biomass and waste-derived fuels) to replace fossil fuels, as well as the utilisation of alternative raw materials (like fly ash and slag)
to reduce the reliance on primary resources. Additionally, the industry is investing in energy-efficient technologies and exploring carbon capture and utilisation/storage (CCUS) methods to minimise environmental consequences.
There are several ways in which the cement manufacturing process can be made more sustainable.
The use of alternative fuels is one of the key strategies to enhance the sustainability of cement manufacturing. By replacing traditional fossil fuels with renewable or waste-derived fuels, such as biomass, agricultural waste, municipal solid waste, and sewage sludge, the carbon footprint of cement production can be significantly reduced. Co-processing waste materials as fuels not only diverts waste from landfills but also provides a sustainable energy source.
Integrating alternative raw materials in cement production can help reduce the demand for traditional resources and promote sustainable practices. Industrial byproducts like fly ash, slag, and silica fume can be used as supplementary cementitious materials. These materials not only enhance the performance and durability of cement but also contribute to waste reduction and resource conservation.
Improving energy efficiency in the cement manufacturing process is vital for sustainability. Energy-efficient technologies, such as high-efficiency kilns, preheaters, and waste heat recovery systems, can significantly reduce energy consumption and greenhouse gas emissions. Optimal process control, insulation, and equipment maintenance are also essential for minimising energy waste.
Carbon capture technologies capture carbon dioxide (CO2) emissions from cement plants, which can then be utilised or stored to prevent its release into the atmosphere. Captured CO2 can be used in various applications or stored underground in geological formations. CCUS has the potential to substantially reduce carbon emissions from cement production.
Cement manufacturing is water-intensive, and sustainable water management practices are crucial. Implementing water conservation measures, such as recycling and reusing water, optimising cooling systems and adopting efficient irrigation techniques, can minimise water consumption and reduce the impact on local water sources.
Efficient waste management practices can significantly contribute to the sustainability of cement manufacturing. Implementing waste segregation, recycling, and utilising industrial byproducts as raw materials or fuels promotes a circular economy approach and reduces the environmental impact of waste disposal.
Cement manufacturers can implement measures to conserve biodiversity and minimise the negative impact on ecosystems. This includes responsible
land use practices, reclamation and rehabilitation of quarries, and protection of surrounding habitats to preserve biodiversity and promote sustainable development.

Fly ash reduces the demand for traditional raw materials such as limestone and clay, thereby
conserving natural resources.

Engaging with stakeholders, including local communities, environmental organisations, and regulatory bodies, is crucial for sustainable cement manufacturing. Transparency, regular reporting
on environmental performance, and addressing concerns of stakeholders help build trust and ensure responsible operations.

ALTERNATIVE FUELS
The cement manufacturing industry is actively adopting alternative fuels to reduce reliance on fossil fuels and promote sustainability. Biomass fuels, including agricultural waste, wood chips and energy crops, are commonly used in cement kilns. These renewable fuels offer a carbon-neutral or carbon-negative impact when sourced sustainably. They contribute to waste reduction and provide a renewable energy source for cement production.
Biomass fuels have the advantage of being renewable resources derived from organic matter. By utilising biomass fuels in cement kilns, the industry can reduce its carbon footprint and decrease reliance on non-renewable resources. When sourced sustainably and burned efficiently, biomass fuels have the potential to offset carbon emissions through the absorption of carbon dioxide during biomass growth.
The use of biomass fuels also addresses waste management concerns. Agricultural residues and energy crops that would otherwise go to waste can be repurposed as fuel, diverting them from landfills and contributing to waste reduction efforts. This aligns with the principles of a circular economy, promoting resource efficiency and minimising environmental impact.
Another significant category of alternative fuels in cement manufacturing is waste-derived fuels. These fuels are derived from non-recyclable industrial and municipal waste materials. Co-processing waste-derived fuels in cement kilns provides a responsible waste management solution. It diverts waste from landfills and utilises the energy content effectively, resulting in waste reduction and energy recovery. Substituting traditional fossil fuels with waste-derived fuels allows for energy savings and reduced greenhouse gas emissions.
Shredded tyres are gaining attention as an alternative fuel source in cement kilns. Waste tyre disposal poses environmental challenges, but when shredded tyres are used as fuel, they offer benefits such as waste tyre management and enhanced energy efficiency. Shredded tyres have a high calorific value, making them suitable for energy recovery in cement production. By using tyres as a fuel source, the cement industry addresses waste tyre concerns and reduces reliance on fossil fuels.
“Safety and quality form the basis of AFR usage across the cement plants. Same is the case in our plant, too. First and foremost, we use only the alternative fuels that are authorised by CPCB/SPCB, the basis for the authorisation is the coprocessing trials taken across different cement kilns in India. The purpose of the trials was to ensure that the waste co-processed safely in terms of safety, quality, environmental norms etc. Even for this waste we do have our process trials and we have got a full-fledged AFR lab at our plant, which confirms the detailed analysis of waste used. The analysis is done prior to taking the waste first time and also regular monitoring of the quality of the AFR is done on every consignment basis. Dedicated laboratory and skilled manpower are engaged for testing the quality of AFR fed, and received and the one that is stored,” says Umashankar Choudhary, Plant Unit Head, Muddapur, JK Cement.
“The safety at AFR is the most important factor to be considered while handling AFR. There is a big risk of fire with the small amount of AFR that we handle. Hence, we have got a full-fledged automatic fire detection and suppression system for the AFR storage area, AFR feeding areas and the AFR shredding systems. There is round the clock monitoring of the storage yard through CCTV cameras. Special kinds of PPEs such as canister masks, goggles, nitrile hand gloves and full body suits are given to the workers engaged in AFR handling,” he adds.
While adopting alternative fuels offers sustainability benefits, proper sourcing, handling, and combustion practices are essential to minimise adverse impacts. Adhering to environmental standards and implementing emission control measures ensures air quality and local environmental protection. By effectively leveraging alternative fuels, the cement industry can reduce its environmental footprint, contribute to waste management and enhance overall sustainability.

ALTERNATIVE RAW MATERIALS
In the pursuit of sustainable cement manufacturing, the industry is actively exploring the use of various alternative raw materials to reduce reliance on traditional resources and minimise environmental impact. These alternative raw materials offer unique properties and benefits, making them valuable additions to the cement production process.
Fly ash, a byproduct of coal-fired power plants, is rich in silica, alumina, and other reactive materials.

Shredded tyres have a high calorific value, making them suitable for energy recovery in cement production

It is commonly used as a supplementary cementitious material in the production of blended cement. The utilisation of fly ash has several positive impacts. Firstly, it reduces waste by diverting fly ash from landfills and utilising it effectively. This contributes to improved waste management practices and reduces the environmental burden associated with waste disposal. Secondly, fly ash reduces the demand for traditional raw materials such as limestone and clay, thereby conserving natural resources. Additionally, the use of fly ash in cement production requires lower temperatures, resulting in reduced energy consumption and greenhouse gas emissions. This not only contributes to the sustainability of the
cement industry but also helps mitigate climate change impacts.
Blast furnace slag is a byproduct of the iron and steel industry, obtained during the production of pig iron. It is a glassy granular material that can be ground and used as a supplementary cementitious material. The utilisation of blast furnace slag offers significant advantages. Firstly, it contributes to waste reduction by repurposing a byproduct that would otherwise be disposed of in landfills. This promotes a circular economy approach and minimises the environmental impact associated with waste accumulation. Secondly, the incorporation of blast furnace slag in cement production reduces the need for traditional raw materials, such as limestone and clay, leading to resource conservation. Moreover, blast furnace slag enhances the performance of cement by improving durability, workability, and resistance to chemical attacks. This results in stronger and longer-lasting concrete structures.
Silica fume is a highly reactive byproduct of silicon and ferrosilicon alloy production. When added to cement, it improves strength, durability, and resistance to chemical attacks. The utilisation of silica fumes brings several benefits to cement manufacturing. Firstly, it contributes to waste reduction by repurposing a byproduct that would otherwise be discarded. This aligns with sustainable waste management practices and reduces the environmental impact of waste accumulation. Secondly, silica fume enhances the mechanical properties of cement, including compressive strength and durability, resulting in high-performance concrete. Moreover, by incorporating silica fume into cement production, the demand for traditional raw materials is reduced, promoting resource conservation.
Rice husk ash is an agricultural byproduct obtained from the burning of rice husks. It contains high levels of silica and can be used as a supplementary cementitious material. The utilisation of rice husk ash offers several environmental benefits. Firstly, it provides an eco-friendly solution for the disposal of agricultural waste, reducing the volume of waste sent to landfills and mitigating associated environmental issues. Secondly, the incorporation of rice husk ash in cement production reduces the need for
primary raw materials, such as limestone and clay, conserving natural resources. Additionally, rice husk ash improves the strength, durability, and resistance to chemical attacks of cement, leading to longer-lasting concrete structures.
By incorporating these alternative raw materials into cement manufacturing, the industry not only reduces its environmental impact but also promotes waste reduction, resource conservation, and the production of high-performance sustainable concrete. The use of these materials aligns with the principles of a circular economy and contributes to the overall sustainability of the cement industry.

PATH TO DECARBONISATION
Achieving decarbonisation goals in the cement industry requires a comprehensive and multi-faceted approach that combines energy efficiency improvements, alternative fuels and raw materials, carbon capture technologies, renewable energy integration, process optimisation, collaboration, and supportive policies. By implementing these strategies collectively, the cement industry can significantly reduce its carbon emissions and contribute to global efforts to combat climate change.

Cement market is expected to reach 4,832.6 MT by 2028, exhibiting a growth rate (CAGR) of 4.94 per cent.

Energy efficiency improvements: Enhancing energy efficiency in cement production is crucial for reducing carbon emissions. The industry can invest in energy-efficient technologies, such as advanced kiln designs, waste heat recovery systems, and efficient grinding processes. Optimising operational practices and implementing energy management systems can also contribute to significant energy savings.
Carbon capture, utilisation, and storage (CCUS): Implementing carbon capture technologies in cement plants allows for the capture and storage of carbon dioxide emissions. CCUS involves capturing CO2 during cement production and either utilising it in other industries or storing it underground. This technology has the potential to significantly reduce the carbon footprint of cement manufacturing.
Guilherme Mendonca, Head Energy Business, Siemens Limited, says, “Waste Heat Recovery System is a key area for cement producers to improve plant efficiency and reduce their carbon footprint by utilising the waste heat from the cement manufacturing process. Siemens Energy’ waste heat recovery system is highly efficient with Heat ReCycle Power Plants offsetting the emissions when compared to other technology that is typically used to generate equivalent power, like diesel generators and reciprocating engines or small coal fired power plants. This results in overall reduced emissions and reduction in dependability on fossil fuels.”
Renewable energy integration: Increasing the use of renewable energy sources in cement production can greatly contribute to decarbonisation. Investing in on-site renewable energy systems such as solar, wind, or biomass power can help reduce the reliance on fossil fuel-based grid electricity and lower emissions
KC Jhanwar, Managing Director, UltraTech Cement Limited, says, “As a founding member of the GCCA, we are committed to the sectoral aspiration of delivering Net Zero concrete by 2050. Towards this end, we are continuously striving to innovate at every stage of the whole life of concrete. Coolbrook’s RDH technology represents an exciting technological pathway that we believe has the potential to exponentially accelerate our progress towards full decarbonisation. Every megawatt of clean energy we add to our mix makes a big difference.”
Alternative fuels and raw materials:
Shifting towards alternative fuels and raw materials is vital for decarbonisation. By substituting fossil fuels with renewable and low-carbon alternatives like biomass, waste-derived fuels, and shredded tyres, the industry can reduce its reliance on fossil fuels and decrease carbon emissions. Similarly, incorporating alternative raw materials like fly ash, blast furnace slag and silica fume can lower the carbon intensity of cement production.
Circular economy principles: Embracing circular economy principles can reduce waste generation and promote resource efficiency. Recycling and reusing concrete waste, implementing alternative cementitious materials, and promoting sustainable sourcing of raw materials contribute to decarbonisation and sustainability goals.
Collaboration and knowledge sharing: Collaborating with industry partners, research institutions, and policymakers can accelerate decarbonisation efforts. Sharing best
practices, research findings, and technological advancements can foster innovation and drive the development of sustainable solutions for the entire cement industry.

CONCLUSION
The use of alternative fuels and raw materials in the cement industry plays a significant role in promoting sustainability and reducing environmental impact. By embracing renewable and low-carbon alternatives to traditional fossil fuels and incorporating alternative raw materials, such as fly ash, blast furnace slag, silica fume, and rice husk ash, the industry can achieve multiple benefits. These alternatives not only contribute to waste reduction and resource conservation but also help in lowering carbon emissions and improving the performance of cement. The adoption of alternative fuels and raw materials demonstrates the industry’s commitment to sustainable practices and its contribution to a greener future. By prioritising the use of these alternatives, the cement industry can play a crucial role in mitigating climate change and meeting the global demand for cement in an environmentally responsible manner.

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Concrete

Refractory demands in our kiln have changed

Published

3 days ago

February 20, 2026

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Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, points out why performance, predictability and life-cycle value now matter more than routine replacement in cement kilns.

As Indian cement plants push for higher throughput, increased alternative fuel usage and tighter shutdown cycles, refractory performance in kilns and pyro-processing systems is under growing pressure. In this interview, Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, shares how refractory demands have evolved on the ground and how smarter digital monitoring is improving kiln stability, uptime and clinker quality.

How have refractory demands changed in your kiln and pyro-processing line over the last five years?
Over the last five years, refractory demands in our kiln and pyro line have changed. Earlier, the focus was mostly on standard grades and routine shutdown-based replacement. But now, because of higher production loads, more alternative fuels and raw materials (AFR) usage and greater temperature variation, the expectation from refractory has increased.
In our own case, the current kiln refractory has already completed around 1.5 years, which itself shows how much more we now rely on materials that can handle thermal shock, alkali attack and coating fluctuations. We have moved towards more stable, high-performance linings so that we don’t have to enter the kiln frequently for repairs.
Overall, the shift has been from just ‘installation and run’ to selecting refractories that give longer life, better coating behaviour and more predictable performance under tougher operating conditions.

What are the biggest refractory challenges in the preheater, calciner and cooler zones?
• Preheater: Coating instability, chloride/sulphur cycles and brick erosion.
• Calciner: AFR firing, thermal shock and alkali infiltration.
• Cooler: Severe abrasion, red-river formation and mechanical stress on linings.
Overall, the biggest challenge is maintaining lining stability under highly variable operating conditions.

How do you evaluate and select refractory partners for long-term performance?
In real plant conditions, we don’t select a refractory partner just by looking at price. First, we see their past performance in similar kilns and whether their material has actually survived our operating conditions. We also check how strong their technical support is during shutdowns, because installation quality matters as much as the material itself.
Another key point is how quickly they respond during breakdowns or hot spots. A good partner should be available on short notice. We also look at their failure analysis capability, whether they can explain why a lining failed and suggest improvements.
On top of this, we review the life they delivered in the last few campaigns, their supply reliability and their willingness to offer plant-specific custom solutions instead of generic grades. Only a partner who supports us throughout the life cycle, which includes selection, installation, monitoring and post-failure analysis, fits our long-term requirement.

Can you share a recent example where better refractory selection improved uptime or clinker quality?
Recently, we upgraded to a high-abrasion basic brick at the kiln outlet. Earlier we had frequent chipping and coating loss. With the new lining, thermal stability improved and the coating became much more stable. As a result, our shutdown interval increased and clinker quality remained more consistent. It had a direct impact on our uptime.

How is increased AFR use affecting refractory behaviour?
Increased AFR use is definitely putting more stress on the refractory. The biggest issue we see daily is the rise in chlorine, alkalis and volatiles, which directly attack the lining, especially in the calciner and kiln inlet. AFR firing is also not as stable as conventional fuel, so we face frequent temperature fluctuations, which cause more thermal shock and small cracks in the lining.
Another real problem is coating instability. Some days the coating builds too fast, other days it suddenly drops, and both conditions impact refractory life. We also notice more dust circulation and buildup inside the calciner whenever the AFR mix changes, which again increases erosion.
Because of these practical issues, we have started relying more on alkali-resistant, low-porosity and better thermal shock–resistant materials to handle the additional stress coming from AFR.

What role does digital monitoring or thermal profiling play in your refractory strategy?
Digital tools like kiln shell scanners, IR imaging and thermal profiling help us detect weakening areas much earlier. This reduces unplanned shutdowns, helps identify hotspots accurately and allows us to replace only the critical sections. Overall, our maintenance has shifted from reactive to predictive, improving lining life significantly.

How do you balance cost, durability and installation speed during refractory shutdowns?
We focus on three points:
• Material quality that suits our thermal profile and chemistry.
• Installation speed, in fast turnarounds, we prefer monolithic.
• Life-cycle cost—the cheapest material is not the most economical. We look at durability, future downtime and total cost of ownership.
This balance ensures reliable performance without unnecessary expenditure.

What refractory or pyro-processing innovations could transform Indian cement operations?
Some promising developments include:
• High-performance, low-porosity and nano-bonded refractories
• Precast modular linings to drastically reduce shutdown time
• AI-driven kiln thermal analytics
• Advanced coating management solutions
• More AFR-compatible refractory mixes

These innovations can significantly improve kiln stability, efficiency and maintenance planning across the industry.

Concrete

Digital supply chain visibility is critical

Published

3 days ago

February 20, 2026

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MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, discusses how data, discipline and scale are turning Industry 4.0 into everyday business reality.

Over the past five years, digitalisation in Indian cement manufacturing has moved decisively beyond experimentation. Today, it is a strategic lever for cost control, operational resilience and sustainability. In this interview, MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, explains how integrated digital foundations, advanced analytics and real-time visibility are helping deliver measurable business outcomes.

How has digitalisation moved from pilot projects to core strategy in Indian cement manufacturing over the past five years?
Digitalisation in Indian cement has evolved from isolated pilot initiatives into a core business strategy because outcomes are now measurable, repeatable and scalable. The key shift has been the move away from standalone solutions toward an integrated digital foundation built on standardised processes, governed data and enterprise platforms that can be deployed consistently across plants and functions.
At Shree Cement, this transition has been very pragmatic. The early phase focused on visibility through dashboards, reporting, and digitisation of critical workflows. Over time, this has progressed into enterprise-level analytics and decision support across manufacturing and the supply chain,
with clear outcomes in cost optimisation, margin protection and revenue improvement through enhanced customer experience.
Equally important, digital is no longer the responsibility of a single function. It is embedded into day-to-day operations across planning, production, maintenance, despatch and customer servicing, supported by enterprise systems, Industrial Internet of Things (IIoT) data platforms, and a structured approach to change management.

Which digital interventions are delivering the highest ROI across mining, production and logistics today?
In a capital- and cost-intensive sector like cement, the highest returns come from digital interventions that directly reduce unit costs or unlock latent capacity without significant capex.
Supply chain and planning (advanced analytics): Tools for demand forecasting, S&OP, network optimisation and scheduling deliver strong returns by lowering logistics costs, improving service levels, and aligning production with demand in a fragmented and regionally diverse market.
Mining (fleet and productivity analytics): Data-led mine planning, fleet analytics, despatch discipline, and idle-time reduction improve fuel efficiency and equipment utilisation, generating meaningful savings in a cost-heavy operation.
Manufacturing (APC and process analytics): Advanced Process Control, mill optimisation, and variability reduction improve thermal and electrical efficiency, stabilise quality and reduce rework and unplanned stoppages.
Customer experience and revenue enablement (digital platforms): Dealer and retailer apps, order visibility and digitally enabled technical services improve ease of doing business and responsiveness. We are also empowering channel partners with transparent, real-time information on schemes, including eligibility, utilisation status and actionable recommendations, which improves channel satisfaction and market execution while supporting revenue growth.
Overall, while Artificial Intelligence (AI) and IIoT are powerful enablers, it is advanced analytics anchored in strong processes that typically delivers the fastest and most reliable ROI.

How is real-time data helping plants shift from reactive maintenance to predictive and prescriptive operations?
Real-time and near real-time data is driving a more proactive and disciplined maintenance culture, beginning with visibility and progressively moving toward prediction and prescription.
At Shree Cement, we have implemented a robust SAP Plant Maintenance framework to standardise maintenance workflows. This is complemented by IIoT-driven condition monitoring, ensuring consistent capture of equipment health indicators such as vibration, temperature, load, operating patterns and alarms.
Real-time visibility enables early detection of abnormal conditions, allowing teams to intervene before failures occur. As data quality improves and failure histories become structured, predictive models can anticipate likely failure modes and recommend timely interventions, improving MTBF and reducing downtime. Over time, these insights will evolve into prescriptive actions, including spares readiness, maintenance scheduling, and operating parameter adjustments, enabling reliability optimisation with minimal disruption.
A critical success factor is adoption. Predictive insights deliver value only when they are embedded into daily workflows, roles and accountability structures. Without this, they remain insights without action.

In a cost-sensitive market like India, how do cement companies balance digital investment with price competitiveness?
In India’s intensely competitive cement market, digital investments must be tightly linked to tangible business outcomes, particularly cost reduction, service improvement, and faster decision-making.
This balance is achieved by prioritising high-impact use cases such as planning efficiency, logistics optimisation, asset reliability, and process stability, all of which typically deliver quick payback. Equally important is building scalable and governed digital foundations that reduce the marginal cost of rolling out new use cases across plants.
Digitally enabled order management, live despatch visibility, and channel partner platforms also improve customer centricity while controlling cost-to-serve, allowing service levels to improve without proportionate increases in headcount or overheads.
In essence, the most effective digital investments do not add cost. They protect margins by reducing variability, improving planning accuracy, and strengthening execution discipline.

How is digitalisation enabling measurable reductions in energy consumption, emissions, and overall carbon footprint?
Digitalisation plays a pivotal role in improving energy efficiency, reducing emissions and lowering overall carbon intensity.
Real-time monitoring and analytics enable near real-time tracking of energy consumption and critical operating parameters, allowing inefficiencies to be identified quickly and corrective actions to be implemented. Centralised data consolidation across plants enables benchmarking, accelerates best-practice adoption, and drives consistent improvements in energy performance.
Improved asset reliability through predictive maintenance reduces unplanned downtime and process instability, directly lowering energy losses. Digital platforms also support more effective planning and control of renewable energy sources and waste heat recovery systems, reducing dependence on fossil fuels.
Most importantly, digitalisation enables sustainability progress to be tracked with greater accuracy and consistency, supporting long-term ESG commitments.

What role does digital supply chain visibility play in managing demand volatility and regional market dynamics in India?
Digital supply chain visibility is critical in India, where demand is highly regional, seasonality is pronounced, and logistics constraints can shift rapidly.
At Shree Cement, planning operates across multiple horizons. Annual planning focuses on capacity, network footprint and medium-term demand. Monthly S&OP aligns demand, production and logistics, while daily scheduling drives execution-level decisions on despatch, sourcing and prioritisation.
As digital maturity increases, this structure is being augmented by central command-and-control capabilities that manage exceptions such as plant constraints, demand spikes, route disruptions and order prioritisation. Planning is also shifting from aggregated averages to granular, cost-to-serve and exception-based decision-making, improving responsiveness, lowering logistics costs and strengthening service reliability.

How prepared is the current workforce for Industry 4.0, and what reskilling strategies are proving most effective?
Workforce preparedness for Industry 4.0 is improving, though the primary challenge lies in scaling capabilities consistently across diverse roles.
The most effective approach is to define capability requirements by role and tailor enablement accordingly. Senior leadership focuses on digital literacy for governance, investment prioritisation, and value tracking. Middle management is enabled to use analytics for execution discipline and adoption. Frontline sales and service teams benefit from
mobile-first tools and KPI-driven workflows, while shop-floor and plant teams focus on data-driven operations, APC usage, maintenance discipline, safety and quality routines.
Personalised, role-based learning paths, supported by on-ground champions and a clear articulation of practical benefits, drive adoption far more effectively than generic training programmes.

Which emerging digital technologies will fundamentally reshape cement manufacturing in the next decade?
AI and GenAI are expected to have the most significant impact, particularly when combined with connected operations and disciplined processes.
Key technologies likely to reshape the sector include GenAI and agentic AI for faster root-cause analysis, knowledge access, and standardisation of best practices; industrial foundation models that learn patterns across large sensor datasets; digital twins that allow simulation of process changes before implementation; and increasingly autonomous control systems that integrate sensors, AI, and APC to maintain stability with minimal manual intervention.
Over time, this will enable more centralised monitoring and management of plant operations, supported by strong processes, training and capability-building.

Concrete

Redefining Efficiency with Digitalisation

Published

3 days ago

February 20, 2026

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.