Connect with us

Concrete

Every drop of water matters

Published

on

Shares

Dr Hitesh Sukhwal, Deputy General Manager (Environment), Udaipur Cement Works, discusses the importance of efficient water management in a cement plant, to make production more sustainable and water positive.

Tell us about the role of water in the cement manufacturing process.
Cement manufacturing is a dry process. Previously, the cement manufacturing process was based on a wet process. At present, about 99 per cent of installed cement industries in India use the dry process of manufacturing. Cement production requires water for cooling of heavy machineries, vent gases, in operation of captive thermal power plant/waste heat recovery boiler, etc. Hence, water conservation and management are important environmental aspects for all cement companies.

Does the process of cement manufacturing impact water positivity of the organisation?
As stated earlier, there are two processes of manufacturing of cement i.e. dry and wet. Dry manufacturing is now the dominant process in India as well as across the globe. When we talk about consumption of water in the dry process, there is no direct mixing/use of water in the process itself to produce cement. Water is only used for cooling purposes, generation of power and mitigation of secondary pollutants at some places in the process layout.
On the contrary, in the wet process of manufacturing, water mixes with raw material to make slurry and feeds into the wet process kiln for drying and calcination to form clinker. The wet process requires a large amount of water, which is a significant environmental concern. In addition to that, the wet process is much more expensive than the dry process, due to a large amount of energy required to evaporate the excess water in the slurry.
Process cooling is a major component of water consumption in the cement industry. During the cement manufacturing process, a large amount of heat is generated by the pyro-processing. Water is used to cool down at various stages, likely the exhaust gases from the kiln, pollution control equipment, compressor, etc. during the process cooling, a large amount of water lost through evaporation and blowdown. The cooling water is usually recycled within the plant and replenished with water lost due to evaporation.
Earlier, in most of the cement plant, a major cooling device was a Gas Conditioning Tower (GCT). The tower was used for reducing the flue gas temperature from pre-heater before entering a dust separation system like ESP/Bag filter. Now, the cement industry replaced such types of GCT with a robust pollution control system and waste heat recovery boiler for power generation.
Now, cement industries are only dealing with solids and gases. In other words, water utilisation is only counted during the cement product life cycle but not in the cement manufacturing processes. Dry manufacturing process, the 3Rs principle, water positivity, etc. will sustain the cement business.
Tell us about the ways in which water is conserved in a cement plant.
Efficient water usage during the cement manufacturing process is a key performance indicator for the cement industry. In India, major cement industry clusters are in dry and arid regions of water scarcity, such as Rajasthan and Andhra Pradesh. Green-based solutions like rainwater harvesting and artificial recharge structures are two key components for water conservation within and beyond the fence.
The change in cement manufacturing technology from wet to dry was a paradigm shift for cement production. The story of water conservation started from the dry manufacturing process in cement production. Although there are no direct uses of water in the dry process, it is still one of the important resources for cement production. If the cement plant is in a dry and arid region, then water consumption can become a significant issue.
Cement industry has taken various steps of water conservation and management as stipulated below:
Transition of manufacturing process from wet to dry – paradigm shift.
Industry is framing up water conservation and management policy and abiding with.
Encouraging water footprint assessment as per ISO 14046:2014 and water audit from competent authority for effective implementation of conservation and management aspects.
Industry is abiding with 3Rs principle i.e. Reduce, Reuse and Recycle for water conservation
and management.
Adopted zero liquid discharge (ZLD) system. This is a closed loop wastewater management system with a high recycling rate and no discharge of industrial wastewater into the environment.
Installed Air Cooled Condenser (ACC) for its captive thermal power plant instead of water-cooled condenser.
Process optimisation for lesser water consumption.
Adopting air cooling-based compressors instead of water cooling.
Overhead water pipeline to address leakage promptly, instead of underground for all kinds of operational machines.
Increase share of renewable energy sources which require less/zero water requirement for power generation, such as solar energy (water required only for panel cleaning) and wind energy (zero water requirements).
Installation of waste heat recovery boiler-based power plant along with ACC for cooling purposes.
Strengthened monitoring and measurement for 24×7 hrs. of water consumption through Industry Internet of Things (IIoT).
Installed online monitoring systems to check 24X7 wastewater quality for taking prompt action to maintain the quality of water.
Automatic water (sensor based) sprinkler for haul roads in mine, sensor based fogging system for dust suppression over mine’s crusher hopper.
Automatic drip irrigation for horticulture use.
Paved road and parking area for minimal use of water to prevent fugitive dust emissions.
Deployment of road vacuum sweeping machine for housekeeping.
Sensor-based water tap for office, canteen, guest house etc.
Installed efficient Sewage Treatment Plant (STP) and effluent treatment plant for automobile workshop and captive power plant.
Digitalised 24X7 monitoring and level checking.
Constructed artificial recharge structures for augmentation of ground water table. Harvesting rainwater through a mine pit and artificial pond within and beyond the fence.
Encourage community participation for water conservation and management through CSR activity such as watersheds, village ponds, bunds, check dams, wells, drip irrigation, etc.
Educating and conducting awareness programmes for community, schools, employees, suppliers and vendors on water conservation aspects.
Afforestation and green belt development with maintaining local biodiversity.
Moreover, the regulatory authorities are also creating standards (for quality and consumption) to make industry water efficient. For instance, recently the Ministry of Environment and Forests and Climate Change (MoEFCC) notified a standard on water consumption for thermal power plant i.e. new plants shall have to meet specific water consumption up to maximum 2.5 Cum per MWh and achieve zero wastewater discharge, installed after 01st January 2017. The Central Ground Water Authority (Ministry of Jal Shakti) also notified standards and guidelines on groundwater abstraction and imposed abstraction/consumption fees in different categories.

Elaborate the steps taken by your organisation to reduce its water footprint.
Our commitment is to reduce freshwater consumption and increase utilisation of wastewater after necessary treatment. We are emphasising upon harvesting rainwater in mine pits and artificial ground water recharge structures. Process optimisation is a key performance indicator for our cement production on every environmental aspect like energy, raw material and water uses.
We have implemented all the above points to reduce our water footprint. We have developed an in-house IoT based monitoring system in all our units. Recently, we developed a mini dense forest in a 4000 sq metres area to maintain local biodiversity, prevent soil erosion and for augmentation of ground water table, which is a nature-based solution.

Has your organisation achieved milestones with respect to water positivity?
Around 70 per cent of the Earth’s surface is covered with water, but only around 3 per cent is fresh water and barely 1 per cent is usable for humanity since most of the freshwater is frozen in glaciers and in polar ice caps. Water is a scarce resource and an essential component for every living creature on the earth. As availability of freshwater is scarce, cement industries are committed to reduce their water consumption and enhance water management.
Udaipur Cement Works Limited (UCWL) has done considerable work in water conservation and becomes 3.6 times water positive (FY 2022-23). We installed a digital water flow metre for each abstraction point and digital ground water level recorder for measuring ground water level 24X7. All digital metres and level recorders are being monitored by an in-house designed IoT based dashboard. Through this live dashboard, we can assess the impact of rainwater harvesting (RWH) and ground water monitoring.
All points of domestic sewage are well connected with Sewage Treatment Plant (STP) and treated water is being utilised in industrial cooling purposes, green belt development and in dust suppression. The Effluent Treatment Plant (ETP) is installed for the mine’s workshop. Treated water is being reused in washing activity and the unit is maintaining ZLD.
UCWL installed a unique floating solar power plant in mine, which reflects the company’s innovative approach towards reducing carbon emissions and water evaporation. This floating solar power plant will help the company to save nearly 8000 cum per annum water due to decrease in evaporation loss. Going beyond the general industry practice, the company has also inventoried its carbon and water footprint as per ISO 14064–1 and ISO 14046.

How do you measure water positivity and what are the ideal benchmarks?
Water positivity means creating more freshwater than what is being used in the manufacturing process and other business activities. However, new water cannot be created, so the focus of water positivity is on the efficient use of water, and to recharge and harvest more rainwater from the ground and/or from the Earth’s surface. A water positive cement plant draws minimal freshwater from ground/surface source, consumes 100 per cent self-generated wastewater for its processes and puts more freshwater back into nature (ground/harvest). Reducing dependency on freshwater is also one of the best ways to become water positive.
UCWL is abiding by the guidelines of CGWA (Ministry of Jal Shakti) to implement and estimate ground water recharge potential and harvest rainwater. To become a water positive company, we are putting our all efforts on monitoring, measurement and mapping of water withdrawal, consumption with the help of artificial intelligence (AI). It is a long journey. At present we are 3.6 times water positive, and we are determined to increase the potential of it. The ideal benchmark is continual improvement in conservation of this precious natural resource. We must improve at all levels like process optimisation, green / clean energy use, monitoring, measurement, awareness and individual responsibility to save water in all aspects.

How do communities surrounding your plant contribute towards your water footprint?
UCWL is continuously doing efforts on minimal use of fresh water from ground. Unit has installed artificial ground water recharge structures, dug ponds, watersheds for augmentation of groundwater tables. We are educating our surrounding stakeholders (especially schools) and raising awareness about the importance of water sanitation, hygiene and conservation. Udaipur city is known for its lakes worldwide. We have conducted lake cleaning drives with our stakeholders.
Harvesting of rainwater in a mine pit and implementation of artificial ground water recharge structures is impacting groundwater tables and improving the quality of water of surroundings. We have installed an online piezometer and digital water monitoring for 24X7 checking and monitoring.

Tell us about the major challenges regarding water consumption and optimum utlisation.
We are running our cement plant in the water-scarce state of Rajasthan, where we have implemented an efficient water management policy. Recently, water management is becoming a big topic for cement business. It is our prime duty to conserve water and manage it effectively for our next generation. At present, almost all our cement plants are doing their best for optimum utilisation of water.

How do you foresee achieving water positivity and optimising its consumption?
Dependence on only freshwater consumption is now a big question for sustaining business. We are raising our bar for effective utilisation of wastewater in every step of manufacturing. At present, we are 3.6 times water positive and our target to become 5 times water positive in coming years. It will help us to improve our process and to produce cement with less water consumption. We are utilising 100 percent of wastewater and maintaining zero liquid discharge from our all operations. Every drop of water matters. We are actively preventing use of freshwater consumption by optimising processes, implementing AI for monitoring and following 3Rs principle through harvesting and recycling of water.

Concrete

Smart-Tech in Cement!

Published

on

By

Shares



An invigorating discussion amongst industry experts, on digital transformation, sustainability and cybersecurity, threw interesting insights.

The cement industry is at a crucial juncture, with digital transformation, sustainability, and automation shaping its future. The panel discussion explored key points on digitalisation, sustainability and automation, emphasising the importance of a multidisciplinary approach to modern cement manufacturing.
The webinar was moderated by Dr SB Hegde, Professor, Jain College of Engineering & Technology, Hubli; and Visiting Professor, Pennsylvania State University, USA.

Speakers included:

  • Dr Hemantkumar Aiyer, VP & Head R&D, Nuvoco Vistas Corp
  • Dr Raju Goyal, Executive President, Chief Technical and Sustainability Officer,

UltraTech Cement

  • Dr Rizwan Sabjan, Head – Global Sales and Proposals, Process Control and Optimisation, FLSmidth Cement
  • Prosenjit Dutta, Director Operations, PS Digitech-HR India
  • Raghu Vokuda, Chief Digital Officer,

JSW Cement

  • Sachin Vaidya, Regional GM – Digital, Process Industries, ABB

Role of digital transformation
Dr Hegde emphasised the need for integrating emerging technologies with a multidisciplinary approach to enhance cement plant efficiency. He highlighted that “understanding of systems and how to integrate them” is essential for maximising the benefits of digital tools.
Sabjan echoed this sentiment, stressing that cement plants need to embrace a cultural and mindset shift to fully leverage digital technologies. He pointed out, “Software can do wonders for the plant, but only if the workforce understands and implements it effectively.” He warned against isolated implementations, advocating for a holistic approach where departments like OT, quality control and automation work together.

Sustainability: The road ahead
With sustainability becoming a global priority, cement manufacturers must adapt to new environmental regulations and carbon reduction goals. Dr Hegde posed a critical question: “How is the cement industry moving towards sustainability, and how can plants prepare for these changes?”
Sabjan responded by highlighting the importance of long-term planning and commitment. “Often, discussions happen, but after two months, we forget about them and restart from scratch. This approach will not work. We need a structured, goal-oriented plan with defined KPIs,” he said. Sabjan emphasised the need for a systematic approach, focusing on tangible metrics such as energy savings. “If a plant aims to improve energy efficiency by five percent, it must set this as a goal and track progress,” he suggested.
The discussion also underscored the need for strong leadership to drive digital adoption. “A motivated team and a dynamic leader can make all the difference,” Dr Hegde noted.

Enhancing durability with digital tools
Strength and durability remain critical concerns in cement production. Goyal explained, “Machine learning-based lab technologies enable predictive analysis, allowing manufacturers to forecast 28-day, 7-day, and 1-day strengths before the material leaves the mill.” He also emphasised the importance of soft sensors, which “help predict strength and optimise mix design before production.”
He elaborated on the role of XRF/XRD analysis: “These tools provide elemental and mineralogical insights, allowing for quick adjustments to raw materials and ensuring consistent quality.” Furthermore, digital twins are revolutionising cement quality optimisation. “They allow us to simulate and test mix designs before implementation, reducing errors and optimising durability.”

Cybersecurity risks in IT-OT integration
As cement plants become increasingly digitalised, cybersecurity threats pose significant risks. Vaidya expressed concern that many manufacturers underestimate cybersecurity risks. “As a technology provider, I often struggle to convince cement manufacturers of the importance of cybersecurity. Some benefits are intangible but essential for plant security.”
He outlined major threats, including malware attacks, unauthorised network access, and operational disruptions. “Preventive measures include secure data transactions, network monitoring, and regular cybersecurity training for staff to minimise insider threats,” he said.
He urged cement companies to take cybersecurity seriously: “As digital transformation advances, cybersecurity is not an option—it is a necessity. Without proper security protocols, cement plants risk cyberattacks that could halt production.”
Dr Hegde agreed, adding, “People often ignore cybersecurity until they experience financial loss. Awareness must be proactive, not reactive.”
Dutta stated, “Advanced process control (APC) is a game-changer for cement manufacturing, allowing us to stabilise operations, optimise fuel efficiency, and reduce energy consumption through real-time data insights.”
He emphasised the transformative impact of real-time data analytics and advanced process control (APC) in cement manufacturing. He highlighted that APC enables manufacturers to optimise raw mix design, fuel efficiency and kiln operations through data-driven decision-making. By continuously monitoring critical parameters, APC minimises process variations, improves stability, and reduces energy consumption, leading to cost savings and enhanced productivity. Additionally, he stressed the role of predictive maintenance in preventing equipment failures, extending machinery lifespan and minimising downtime, ultimately ensuring consistent quality and operational efficiency in cement production.

Will Indian plants become fully autonomous?
With AI, robotics and digital twins transforming global cement production, the question arises: Can Indian cement plants become fully autonomous within the next 5–10 years?
Vokuda was skeptical about complete automation in the near future. “Indian cement plants will see significant automation, but full autonomy remains unlikely within a decade. A hybrid model, combining AI-powered decision-making with human oversight, is more practical.”
He highlighted key challenges: “Unlike developed nations, India’s low labour costs may make full automation less attractive. Additionally, digital twin technology in India is still in its early stages, focusing more on process twins than asset twins.”
Another challenge is data management. “AI-ML models require vast amounts of data, which necessitates ultra-low latency networks like 5G and edge computing. We are not yet at that level of technological maturity,” he explained.
Despite these hurdles, he remains optimistic: “While full automation may take longer, the industry will continue to evolve with advancements in digital twins, real-time analytics, and AI-driven insights.”

Conclusion
Experts agree that while technology holds immense potential, its successful implementation depends on cultural shifts, strong leadership, and structured execution.
Key takeaways from the discussion include:

  • Integration of digital tools: Multidisciplinary collaboration is essential for successful implementation.
  • Sustainability goals: Defined KPIs and a long-term approach are crucial.
  • Quality optimisation: Machine learning, real-time analysis, and digital twins are improving cement strength and durability.
  • Cybersecurity: As digital transformation progresses, cement plants must prioritise cybersecurity.
  • Automation: While full autonomy is unlikely soon, AI and digital tools will play a growing role in decision-making.
    As the industry moves forward, cement manufacturers must embrace technological advancements while ensuring resilience against cybersecurity threats and operational challenges. With the right strategies, India’s cement sector can achieve greater efficiency, sustainability, and innovation in the years to come.

ICR’s virtual panel discussion was supported by FLSmidth Cement as the Presenting Partner and ABB as the Gold Partner.

Continue Reading

Concrete

The Science and Application of Grinding Aids

Published

on

By

Shares



Dr SB Hegde discusses the importance of grinding aids as essential chemical additives that enhance cement grinding efficiency, reduce energy consumption and improve overall cement quality in the concluding part of his article.

Grinding aids represent a critical segment of the cement additives market, driven by their ability to enhance grinding efficiency, reduce energy consumption, and improve cement quality. The market dynamics of grinding aids vary significantly across regions, influenced by economic growth, cement production capacities and regulatory environments.

Global market size and growth projections
The global grinding aids market was valued at approximately US $ 1.2 billion in 2023 and is expected to grow at a CAGR of 5.5 per cent from 2023 to 2030, reaching nearly US $ 1.8 billion by 2030.
This growth is fueled by the increasing focus on energy efficiency and sustainable cement production practices worldwide.
Rapid urbanisation and infrastructure development, especially in emerging economies, are major growth drivers. Cement producers are increasingly adopting grinding aids to address rising energy costs, reduce carbon footprints, and improve production efficiencies. For instance, grinding aids have been shown to lower energy consumption by up to 25 per cent, making them a cost-effective solution for plants facing energy price volatility.

Regional trends: Developed vs. developing markets

  • Developed markets: Europe and North America represent mature markets for grinding aids. Europe, driven by stringent environmental regulations such as the EU Emissions Trading System (EU ETS), has witnessed a steady rise in the adoption of low-VOC and eco-friendly grinding aids. Leading players in these markets emphasise sustainability and compliance with regulatory frameworks, contributing to steady demand.
    In North America, the focus is on productivity enhancements in large-scale cement plants, with grinding aids used to achieve finer cement grades and support blended cement production.
  • Developing markets: Emerging economies in Asia-Pacific, the Middle East, and Africa exhibit the fastest growth in grinding aid adoption. The Asia-Pacific region accounted for over 40 per cent of global grinding aid consumption in 2023, with countries like India, China, and Vietnam leading the way. The rapid urbanisation, rising construction activity, and increasing cement production capacities in these regions are
    driving demand.

In Africa, grinding aids are gaining traction as manufacturers focus on optimising production costs in an environment of fluctuating raw material and energy prices.

Market size and adoption rate in India
India, the world’s second-largest cement producer, offers a significant growth opportunity for grinding aids. In 2023, the grinding aids market in India was valued at US$ 150 million, with a projected growth rate of over seven per cent CAGR through 2030. The adoption rate remains relatively low at smaller plants, which prioritise cost-saving over efficiency gains. However, leading manufacturers and integrated cement plants are increasingly embracing grinding aids, particularly for blended cement production.
Blended cements, such as Portland Pozzolana Cement (PPC) and Portland Slag Cement (PSC), account for more than 70 per cent of the Indian cement market. Grinding aids tailored for fly ash and slag-blended cements are in high demand, with some products delivering up to a 15 per cent increase in mill throughput and improved early strength development.

Emerging trends

  • Eco-friendly formulations: The growing demand for sustainable grinding aids has prompted companies to develop low-VOC and biodegradable alternatives.
  • Customised solutions: Grinding aid formulations are increasingly tailored to address specific raw material challenges and production processes, such as VRMs or high-SCM cement blends.
  • Digitalisation: Smart dosing systems integrated with real-time mill monitoring are enabling optimised grinding aid usage, ensuring consistent performance across diverse production conditions.

Bridging the Trust Gap
For cement plant operators, the quality and performance of grinding aids often appear as a ‘black box.’ The lack of transparency in the formulation and quality checks of these additives has historically limited trust and widespread adoption. Grinding aid manufacturers must address this issue by fostering transparency and providing detailed insights into the testing and validation of their products. This would not only instill confidence but also strengthen collaboration with cement companies.
Grinding aid producers should provide robust documentation outlining the physical and chemical characteristics of their formulations, supported by consistent performance data from laboratory tests, industrial-scale trials, and third-party validations. This transparency is essential to demystify grinding aids’ performance and demonstrate their effectiveness across diverse operational conditions.

Emerging innovations in grinding aid chemistry
The path forward for grinding aid manufacturers lies in innovation. Recent research highlights the potential of hybrid formulations combining traditional amines and glycols with advanced polymeric additives like polycarboxylate ethers (PCEs). These hybrid products can address specific challenges such as improving grindability in blended cements containing fly ash or slag, where traditional additives often underperform. Nano-engineering of grinding aids, incorporating nanoparticles for optimised dispersion and enhanced hydration kinetics, represents another promising avenue.

Leveraging AI for optimisation

The integration of artificial intelligence (AI) and machine learning tools into grinding aid application systems is reshaping the cement industry. AI-driven systems enable real-time optimisation of grinding aid dosages by analysing mill performance data, such as power consumption, throughput, and particle size distribution. For example, a cement plant in Europe reported a 15 per cent reduction in specific energy consumption and a 10 per cent
increase in mill throughput using AI-optimised dosing systems. This innovation reduces operational variability and improves the predictability of grinding aid performance.

Expectations from grinding aid producers
The cement industry demands more than just products; it seeks partnerships with grinding aid manufacturers. Key expectations include:
1. Customised formulations: Tailored products designed for specific raw materials, clinker compositions, and mill configurations to maximise efficiency and performance.
2. Eco-friendly additives: Grinding aids with low volatile organic compound (VOC) emissions and biodegradable ingredients that align with the industry’s sustainability goals.
3. Comprehensive technical support: On-site training and technical services to help plant operators understand grinding aid chemistry, application techniques and performance optimisation strategies.
4. Advanced quality control systems: Transparent testing protocols, including real-time quality assurance of grinding aids delivered to cement plants. Regular reporting of performance consistency through defined KPIs like grindability index and Blaine fineness is essential.

Role of cement companies in promoting grinding aid usage
Cement producers must take an active role in promoting grinding aid adoption. Sharing success stories of energy savings, improved mill performance, and enhanced cement quality can encourage industry-wide adoption. For example, an Indian cement manufacturer recently documented a 20 per cent improvement in 28-day compressive strength and a 10 per cent reduction in energy consumption with glycol-based additives, driving interest among peers.
Moreover, collaborative initiatives between cement producers and grinding aid manufacturers, such as joint research programs and knowledge-sharing forums, could lead to significant advancements in grinding technology. Organisations like the Cement Manufacturers’ Association of India and the World Cement Association can facilitate these partnerships.

Conclusion
Grinding aids play a pivotal role in modern cement manufacturing, offering significant advantages in energy efficiency, mill productivity and cement quality. Despite their transformative potential, adoption remains inconsistent due to challenges like raw material variability, operational concerns and limited trust in product formulations. Transparency and collaboration between grinding aid producers and cement manufacturers are critical to addressing these issues and fostering broader acceptance.
Innovations in grinding aid chemistry, including hybrid formulations and nano-engineered additives, have unlocked new possibilities for enhancing grindability and hydration performance. Meanwhile, advancements in artificial intelligence and data analytics have opened avenues for real-time optimisation, ensuring precise dosing and measurable cost savings. These developments underscore the evolving synergy between technology and grinding aid applications.
Globally, the grinding aid market is poised for growth, with developed regions leading adoption and emerging economies like India offering immense potential driven by infrastructure demands. However, tapping into these opportunities requires grinding aid producers to align with industry expectations. Cement manufacturers expect customised solutions, eco-friendly formulations, technical support and transparent quality assurance processes to build trust and confidence.
The path forward demands a collaborative approach. Grinding aid producers must continue investing in research and innovation while actively engaging with the cement industry to educate stakeholders and demonstrate measurable benefits. Concurrently, the cement industry must champion adoption through case studies, knowledge sharing, and regulatory support. Together, these efforts will ensure grinding aids fulfill their promise of enabling a more efficient, sustainable, and resilient cement manufacturing sector.

References
1. Gao, J., Zhang, S., Wang, X., & Ma, B. (2011). “Effect of organic grinding aids on cement properties and the analysis via liquid chromatography-mass spectrometry.” Construction and Building Materials, 25(8), 3600–3605.
2. Amritphale, S. S., Patel, M., & Singh, R. (2017). “Grinding aids: A study on their mechanism of action in cement grinding processes.” Indian Cement Review.
3. Cembureau – The European Cement Association. “Cement grinding optimisation through grinding aids.” Industry Report, 2023.
4. Flatt, R. J., & Schober, I. (2012). “Superplasticisers and the rheology of concrete.” International Journal of Cement Chemistry, 64(4), 91–109.
5. Mejeoumov, G. G. (2007). “Improved cement quality and grinding efficiency by means of closed mill circuit modeling.” PhD Dissertation, Texas A&M University.
6. Global Cement. “Advances in grinding aids: Market trends and new technologies.” Published October 2024.
7. Statista. “Global grinding aids market size and forecast (2023-2030).” Published March 2024.
8. Pal, B. K., & Rath, P. C. (2020). “Influence of grinding aids on particle size distribution, strength, and hydration of cement.” Journal of Materials Science and Applications, 45(2), 234–246.
9. Indian Cement Review. “Emerging market scope of grinding aids in India.” Published July 2023.
10. Zhang, H., Li, X., & Zhao, Y. (2022). “The role of grinding aids in improving cement hydration kinetics.” Journal of Advanced Materials Science, 17(6), 527–540.
11. Sika AG. “Technical Report on Polycarboxylate Ether (PCE) based grinding aids.” Published 2022.
12. Cement and Concrete Research. “AI-driven optimisation in cement grinding: Case studies and industrial applications.” Volume 152, 2023.
13. Taylor, H. F. W. (1997). Cement Chemistry (2nd Edition). Thomas Telford Publishing.
14. Indian Bureau of Mines (IBM). “Market trends and challenges in cement manufacturing.” Annual Report, 2024.
15. World Cement Association. “Sustainability in grinding aids and cement additives.” Published 2024.

About the author:
Dr SB Hegde, a global cement industry leader with over 30 years of experience, is a Professor at Jain College of Engineering, India, and a Visiting Professor at Pennsylvania State University, USA. Recipient of the ‘Global Visionary’ award, Dr Hegde advises India’s think tank CSTEP on hydrogen usage in cement and consults for major cement companies. He also serves on expert panels of key industry bodies and journals globally.

Continue Reading

Concrete

Smart sustainable solutions

Published

on

By

Shares



Efficient bulk material handling has always been critical for seamless production, cost reduction and environmental compliance. Kanika Mathur delves into advanced automation, smart sensors and sustainable transport solutions that are key to overcoming challenges.

The cement industry is a cornerstone of infrastructure development, contributing significantly to economic growth. However, cement production involves the handling and transportation of vast quantities of raw materials such as limestone, clay, iron ore, fly ash and gypsum, as well as the final product—cement itself. Efficient bulk material handling (BMH) systems are crucial in ensuring uninterrupted production, reducing operational costs, minimising material wastage and improving overall efficiency.

In an industry where material losses, dust emissions, and energy consumption are major concerns, advancements in bulk material handling technology are playing a vital role in optimising operations. Automated and energy-efficient bulk handling solutions, such as pneumatic conveying systems, belt conveyors and stacker-reclaimer systems, are transforming the way cement plants manage their raw materials and finished products. This article explores the key aspects of bulk material handling in the cement industry, the latest technological advancements, and the challenges and opportunities in this space.

Importance of bulk material handling
Cement manufacturing requires the continuous movement of raw materials from mines and quarries to processing plants, followed by the transportation of the finished product to storage facilities and distribution networks. Bulk material handling systems ensure that this process runs smoothly, reducing downtime and enhancing productivity.
According to the Global Cement Report (2023), inefficient material handling contributes to 5 – 10 per cent of total cement production losses in India. Additionally, poor handling practices lead to high levels of dust pollution, which is a significant environmental and health concern. With cement production in India expected to reach 500 million metric tonnes by 2025, the demand for advanced and automated material handling systems is increasing rapidly.
Jacob Jose, CEO and Managing Director, Methods India, says, “With our advanced pipe conveyors, downhill conveyors and cross-country conveyors, we have revolutionised the way cement plants transport raw materials. Our technology helps reduce operational costs, minimise environmental impact and improve energy efficiency. Over the years, we have observed a positive impact in the industry, particularly with the growing adoption of pipe conveyors and cross-country conveyors, which have proven to be more efficient and environmentally friendly alternatives to traditional transport methods.”

Key bulk material handling technologies
1. Belt conveyors: The workhorse of cement plants
Belt conveyors are one of the most widely used bulk material handling solutions in the cement industry. They transport raw materials, clinker and finished cement over long distances within the plant and to storage facilities. Modern high-capacity belt conveyors can handle loads exceeding 10,000 tonnes per hour, significantly improving efficiency.

  • Advantages: High efficiency, low operational costs, and reduced manual intervention.
  • Challenges: Belt wear and tear, spillage, and maintenance requirements.
  • Technological advancement: The introduction of heat-resistant and fire-retardant conveyor belts has improved durability, while sensor-based predictive maintenance systems help detect belt failures before they occur.

2. Stacker and reclaimer systems: Optimising storage and retrieval
Stackers and reclaimers are essential for managing bulk raw materials in cement plants. Stackers pile materials such as limestone, coal, and gypsum, while reclaimers retrieve them for processing. These systems ensure homogeneous blending, reducing material variability and enhancing cement quality.

  • Latest innovation: Automated stacker and reclaimer systems with AI-driven optimisation help maximise storage space and minimise
    retrieval time.
  • Efficiency gains: Newer stacker-reclaimer designs allow for material recovery rates of over 90 per cent, reducing wastage and ensuring a steady feed to the production line.

3. Pneumatic conveying systems: Dust-free material transfer
Pneumatic conveying systems use air pressure or vacuum systems to move powdered and granular materials such as fly ash, cement and kiln dust through pipelines. They are particularly useful in reducing dust emissions and preventing material contamination.

  • Advantages: Dust-free operation, reduced environmental impact, and minimal maintenance.
  • Industry adoption: Many Indian cement plants are shifting from mechanical conveyors to high-pressure pneumatic conveying systems to comply with pollution control regulations set by the Central Pollution Control Board (CPCB).

4. Screw conveyors and bucket elevators: Compact and versatile solutions

  • Screw conveyors: Used for short-distance material movement, particularly for handling fine and powdered materials such as cement, gypsum, and pulverised coal.
  • Bucket elevators: Ideal for vertical material transport, commonly used for lifting raw meal, cement, and clinker to storage silos.
  • Technological upgrades: The introduction of wear-resistant alloy buckets and variable-speed drives has enhanced the reliability and efficiency of these systems.

Challenges in bulk material handling
Despite significant advancements, several challenges continue to hinder bulk material handling efficiency in cement plants:
1. Material spillage and dust emissions
Material spillage and dust emissions pose environmental, health, and financial challenges. Uncontrolled dust emissions from conveyors, transfer points, and storage facilities not only violate regulatory norms but also lead to material losses. Studies show that up to three per cent of bulk materials are lost due to improper handling in Indian cement plants.

  • Solution: Enclosed conveyors, dust suppression systems, and bag filters help reduce dust pollution.

2. High energy consumption
Bulk material handling systems consume a significant amount of energy, especially in large cement plants where materials need to be transported over long distances. According to a CII (Confederation of Indian Industry) report (2023), energy costs account for nearly 40 per cent of total production expenses in cement manufacturing.

  • Solution: Energy-efficient conveyor motors, regenerative braking systems, and smart automation can help reduce power consumption.

3. Wear and tear of equipment
Continuous exposure to abrasive materials like limestone and clinker leads to significant wear and tear in bulk material handling equipment, increasing maintenance costs and downtime.

  • Solution: The use of wear-resistant liners, ceramic-coated conveyor belts, and automated lubrication systems extends equipment life and reduces maintenance downtime.

4. Logistics and transportation bottlenecks
Moving bulk materials from cement plants to distribution centers requires an efficient logistics network. Rail and road congestion, inadequate infrastructure, and high transportation costs often result in delays and increased operational expenses.

  • Solution: Integrated bulk terminals and automated dispatch systems improve supply chain efficiency. The Indian government’s push for multi-modal logistics parks (MMLPs) is expected to enhance cement transportation efficiency.

Indrendra Singh Raghuwanshi, Sales Head – Cement Division, ATS Conveyors, says, “Ensuring that our systems handle diverse alternative fuels reliably is at the core of our engineering approach. Alternative fuels, such as biomass, MSW, RDF and industrial waste vary significantly in terms of composition, size, moisture content, and combustibility. All our systems are designed with flexibility and robustness to meet the unique challenges posed by these fuels while maintaining operational efficiency and safety. Also, before deployment to site, we conduct extensive testing for our equipment to ensure that they can reliably handle alternative fuels under a variety of conditions. This includes testing different fuel types, moisture levels, and feeding rates to identify any potential challenges. Our systems are then fine-tuned during the commissioning phase to ensure optimal performance in real-world conditions.”

The future is automation and digitalisation

The future of bulk material handling in the cement industry lies in automation, artificial intelligence (AI), and digital twin technologies. Leading cement manufacturers are investing in IoT-enabled bulk handling systems that provide real-time monitoring, predictive maintenance, and AI-based process optimisation.

1. Smart sensors and predictive maintenance
AI-powered sensors are now being integrated into conveyors and stackers to detect early signs of wear and tear, enabling proactive maintenance and reducing unplanned downtime.
Nishith Kundar, Co-Managing Partner, Cemtech Engineering Solutions, says, “One of our latest advancements is the introduction of drone inspection technology. Since silos are confined spaces, it is often difficult to assess their internal condition, particularly at the top. We have incorporated drone inspections for both pre-cleaning and post-cleaning assessments. Pre-cleaning drone inspections help us analyse the extent of material buildup, while post-cleaning inspections ensure that the silo has been thoroughly cleaned. This technology is also applicable to pre-heaters, allowing us to monitor internal conditions in confined spaces. By leveraging drone technology, we provide precise and efficient cleaning services, improving safety and operational efficiency.”

2. Digital twin technology
Digital twin models create a virtual replica of bulk handling systems, allowing operators to simulate various scenarios and optimise material flow before implementing changes in real time.

3. Automated Guided Vehicles (AGVs) and robotics
The adoption of AGVs and robotic material handling systems is gaining traction in cement plants for automated raw material transport, warehouse management, and truck loading/unloading.
Gaurav Gautam, Business Unit Head,
Beumer Group, says, “A major recent focus has been integrating digital monitoring tools into our equipment. These tools include condition monitoring sensors that track temperature variations, vibrations and operational anomalies in real-time. By capturing this data, plant operators can take proactive actions when conditions start deviating from normal parameters. This approach prevents sudden breakdowns and, in the long term, enhances the durability and reliability of the equipment.”
“Moving forward, digitalisation will play a key role in tackling wear and tear challenges. By increasing the number of data capture points and applying advanced analytics tools, we can gain deeper insights into equipment health and performance, ensuring a more efficient and predictive maintenance strategy,” he adds.

Conclusion
Efficient bulk material handling is the backbone of cement manufacturing, ensuring a seamless flow of raw materials and finished products while minimising environmental impact and operational costs. As India’s cement industry moves towards higher production capacities and stricter environmental norms, investing in advanced, automated and energy-efficient bulk handling solutions will be key to maintaining competitiveness.
By embracing smart technologies, automation and sustainable handling practices, cement manufacturers can enhance productivity, reduce material losses, and contribute to a greener and more efficient future for the industry.

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds