Concrete
Sustainable processes are crucial for climate change
Published
2 years agoon
By
admin
Arpan DilipKumar Parekh, Technical Head – Vice-President, JK Cement, discusses the intricate interplay of economic considerations and environmental regulations in the methods of pyroprocessing.
Tell us about the process of pyroprocessing and how does it differ with various blends of cement raw materials?
Pyroprocessing is a term used in the cement manufacturing industry to describe the high-temperature processes involved in converting raw materials into clinker, the intermediate product that is then ground into cement. The primary raw materials used in cement manufacturing are limestone, clay, silica, and iron ore. The pyroprocessing stage typically involves a series of chemical and physical transformations that take place in a kiln.
The pyroprocessing of cement can be broadly divided into the following stages:
Drying and Preheating: Raw materials, usually limestone and clay, are quarried and then crushed to small sizes. The crushed raw materials are then dried in kiln preheaters to remove moisture, and preheated to temperatures of around 800 to 900 degrees Celsius. This helps in reducing the energy required for subsequent stages.
Calcination: In this stage, the preheated raw materials are subjected to high temperatures (around 1400 to 1500 degrees Celsius) in the kiln. The key reaction during calcination is the decomposition of calcium carbonate (limestone) into calcium oxide (quicklime) and carbon dioxide.
Clinker Formation: The partially calcined material undergoes a series of complex chemical reactions to form clinker. Alumina and iron oxide from the raw materials combine with silica to form liquid phases, which then react with lime to form
clinker nodules.
Cooling: The clinker is cooled rapidly to minimise the formation of undesirable crystalline phases. The cooling process is critical to the quality of the final product, as it influences the mineralogical composition and, consequently, the cement properties.
Grinding: The cooled clinker is ground into a fine powder along with gypsum to regulate the setting time of the cement. The process of pyroprocessing can be influenced by the types and proportions of raw materials used in cement manufacturing. The blends of raw materials can vary based on factors like geographical location, availability of resources, and desired cement properties.
Limestone Quality: The composition of limestone affects the amount of heat required for the calcination process. Higher limestone content may require additional energy in the kiln.
Clay Content: The clay content influences the reactivity and the formation of liquid phases during clinkerisation. It also affects the temperature at which clinker formation occurs.
Silica and Alumina Content: These components influence the liquid phase formation and, consequently, the properties of clinker.
The process parameters and kiln design may be adjusted based on the raw material blend to optimise the efficiency and quality of the pyroprocessing stage. Therefore, the variation in raw material blends can lead to differences in energy consumption, emissions, and the properties of the final cement product. It is important for cement manufacturers to carefully control and monitor these parameters to ensure consistent and high-quality cement production.
What is the role of technology in the process of pyroprocessing?
Technology plays a crucial role in pyroprocessing within the cement manufacturing industry. Advancements in technology have led to improvements in efficiency, energy conservation, environmental sustainability, and overall process control. Here are some key aspects of the role of technology in pyroprocessing:
Kiln design and optimisation: Modern technology allows for the design and optimisation of kilns to enhance heat transfer, minimise heat losses, and improve overall energy efficiency. Computational fluid dynamics (CFD) simulations and modelling are employed to optimise the design of kiln systems.
Process automation and control systems: Advanced control systems, such as distributed control systems (DCS) and programmable logic controllers (PLC), enable precise control and automation of the pyroprocessing parameters. This includes temperature control, fuel and air ratios, and material feed rates.
Sensors and instrumentation: High-tech sensors and instrumentation are used to monitor various aspects of the pyroprocessing stage, including temperature profiles, gas compositions, and pressure conditions. This real-time data is crucial for process optimisation and control.
Alternative fuels and raw materials: Technology has facilitated the incorporation of alternative fuels and raw materials in the pyroprocessing stage. This includes the use of alternative fuels like biomass, waste-derived fuels, and alternative raw materials, which can contribute to sustainability and reduce the environmental impact of cement production.
Waste heat recovery: Advanced technologies enable the capture and utilisation of waste heat generated during pyroprocessing. This recovered heat can be used for power generation or for other processes like drying of limestone, coal or slag within the cement plant, contributing to increased energy efficiency.
Clinker cooling technology: Efficient clinker cooling is essential for the quality of the final product. Advanced cooling technologies, such as grate coolers and air quenching, are employed to achieve rapid and controlled cooling, minimising the formation of undesirable clinker phases.
Data analytics and machine learning: Data analytics and machine learning algorithms are increasingly being applied to analyse large sets of process data. The application of condition monitoring practices is helping in predicting the equipment performance and failure modes. These technologies can identify patterns, predict equipment failures, and suggest optimisation strategies, leading to improved overall efficiency and reduced downtime. Thermography has taken the entry and has expanded the application supporting the predictive maintenance.
Environmental control and emission reduction: Technology plays a vital role in implementing environmental control measures and reducing emissions from pyroprocessing. This includes the use of advanced filters, scrubbers, and monitoring systems to comply with environmental regulations and minimise the environmental impact of cement production.
Simulation and modelling: Computer-aided simulations and models are utilised to simulate and analyse the behaviour of the pyroprocessing system under different conditions. This helps in understanding and optimising the complex interactions within the kiln.
Automated sampling process and testing: Deployment of systems having collection of raw material, in process material and finished products enables reduction in manual intervention and enhanced reliability of results which in turn help in process stabilisation and optimisation. Usage of XRF and XRD in testing helps in getting more accurate results.
The integration of these technological advancements in pyroprocessing contributes to increased energy efficiency, reduced environmental impact, and improved product quality in the cement manufacturing industry. Continuous research and development efforts in this field aim to further enhance the sustainability and competitiveness of cement production.
How has the adaptation to newer technology in pyroprocessing impacted production?
Some of the key positive effects include:
Increased energy efficiency: Advanced technologies, such as preheating and pre-calcination systems, improved kiln designs and waste heat recovery systems, have led to increased energy efficiency in pyroprocessing. This results in reduced fuel consumption, reduced electrical energy and lower greenhouse gas emissions per unit of clinker produced.
Optimised process control: Modern control systems, sensors, and automation technologies allow for precise and real-time control of various parameters in the pyroprocessing stage. This optimisation leads to better control of temperature profiles, material flows, and gas compositions, contributing to consistent and high-quality clinker production.
Alternative fuels and raw materials: The use of advanced technology has facilitated the incorporation of alternative fuels and raw materials. This not only helps in reducing the environmental impact but also provides economic benefits by utilising waste materials as energy sources or raw materials.
Reduction in environmental impact: Advanced filtration systems, improved dust collection technologies, and better environmental control measures have been implemented to minimise dust emissions and other pollutants along with the usage control of water and preservation. This results in a reduced environmental impact, meeting stringent environmental regulations and enhancing the sustainability of cement production.
Waste heat recovery: The integration of waste heat recovery systems in pyro-processing contributes to increased overall plant efficiency. The recovered heat can be used for power generation, further reducing the reliance on external energy sources, and improving the overall energy balance of the cement plant.
Clinker cooling technologies: Advanced clinker cooling technologies help achieve optimal cooling rates, reducing the formation of undesirable clinker phases. This positively impacts the quality of the final product and allows for better control over cement properties.
Data analytics and predictive maintenance: The application of data analytics and machine learning algorithms has improved predictive maintenance strategies. This helps in identifying potential equipment failures before they occur, minimising downtime, and optimising maintenance schedules.
Process modelling and simulation: Computer-aided modelling and simulation tools enable a better understanding of the complex interactions within the pyro-processing system. This knowledge allows for the testing of various scenarios and the optimisation of process parameters without disrupting production.
Product quality and consistency: The integration of advanced technologies ensures better control over the entire production process, leading to improved product quality and consistency. This is essential for meeting the standards and requirements of end-users.
Economic benefits: While initial investments may be required for implementing new technologies, the long-term economic benefits, including reduced operating costs, enhanced energy efficiency, and compliance with environmental regulations, contribute to the overall economic sustainability of production.
The adaptation of newer technology in pyro-processing has positively impacted the cement making process by improving energy in terms of electrical and thermal efficiency, environmental performance, product quality and overall operational efficiency. These advancements are crucial for the cement industry to meet the demands of a growing global population while minimising its carbon footprint.
What is the impact of using alternative fuels as sources of energy on pyroprocessing?
Pyroprocessing is a group of high-temperature processes used to transform raw materials into useful products, often involving the use of heat to drive chemical reactions. The impact of using alternative fuels as sources of energy on pyro-processing can vary depending on the specific alternative fuels and the type of pyroprocessing involved, such as in cement manufacturing or metallurgical processes. Here are some general considerations:
Energy efficiency: Alternative fuels, such as biomass, waste-derived fuels, or certain types of industrial by-products, may have different combustion characteristics compared to traditional fossil fuels. The use of alternative fuels can impact the overall energy efficiency of pyroprocessing. For instance, some alternative fuels may have lower calorific value or different combustion kinetics, affecting the heat transfer and temperature profiles within the pyro-processing system. Depending upon the contents like moisture, chlorides, heavy metals etc. the pyro-process may face difference in operation.
Emissions and environmental impact: The choice of alternative fuels can influence the emissions profile of the pyro-processing facility. For example, using biomass or waste-derived fuels may result in lower carbon dioxide emissions compared to traditional fossil fuels. However, the combustion of some alternative fuels might produce different types of emissions, such as particulate matter or certain
trace gases, which could impact air quality and environmental compliance.
Raw material chemistry: The introduction of alternative fuels can alter the chemical composition of the feedstock entering the pyro-processing system. This may affect the overall chemical reactions and the quality of the final product. Impurities or different ash compositions from alternative fuels may require adjustments in the pyro-processing parameters to maintain product quality and process stability.
Operational challenges: The use of alternative fuels may pose challenges related to handling, transportation, and storage. Different combustion characteristics or impurities in alternative fuels may require modifications to the pyro-processing equipment to ensure optimal performance. specialised equipment, such as pre-processing units or additional safety measures, may be needed when integrating alternative fuels into existing pyro-processing systems.
Regulatory compliance: The regulatory environment and standards for emissions control may influence the choice and implementation of alternative fuels in pyro-processing. Facilities may need to adhere to specific regulations governing the use of certain types of alternative fuels.
The impact of using alternative fuels in pyro-processing is multifaceted and depends on
the specific characteristics of the alternative fuels and the details of the pyro-processing system. Careful consideration of technical, environmental and regulatory factors is essential when implementing alternative fuels to ensure efficient and sustainable pyro-processing operations.
How are you minimising the environmental impact of CO2 and N2O emissions?
Here are some industry-specific strategies:
Alternative fuels and raw materials: Substituting traditional fossil fuels with alternative fuels, such as biomass, waste-derived fuels, or renewable sources, can reduce CO2 emissions in industrial processes like cement manufacturing. Using alternative raw materials that have lower carbon content can also contribute to emission reduction.
Energy efficiency in pyroprocessing: Improving the energy efficiency of pyro-processing systems can reduce the overall energy consumption and, consequently, the associated CO2 emissions. Implementing advanced technologies, such as high-efficiency kilns, highly efficient clinker coolers and waste heat recovery systems, can optimise energy usage.
Process optimisation: Conducting a thorough analysis of pyro processing parameters and optimising them for maximum efficiency can lead to lower energy consumption and reduced emissions. Incorporating advanced process control systems and sensors can help in real-time monitoring and adjustments.
Nitrous oxide abatement: Implementing technologies and practices that specifically target the reduction of nitrous oxide emissions from industrial processes, such as the use of low-nitrogen oxide burners, can be beneficial.
Life cycle assessment: Conducting a comprehensive life cycle assessment of industrial processes helps identify the stages with the highest environmental impact. This allows for targeted interventions to reduce emissions throughout the entire lifecycle.
Collaboration and knowledge sharing: Encouraging collaboration within the industry and sharing best practices can accelerate the adoption of sustainable technologies and strategies.
Employee training and engagement: Training employees on sustainable practices and engaging them in emission reduction initiatives can create a culture of environmental responsibility within the organisation.
It is important for us to adopt a combination of these strategies and continually assess and update the practices to align with evolving environmental standards and expectations. Sustainable processes are crucial for climate change and for minimising the overall impact on the environment.
Tell us about the efforts taken by your organisation.
Pyroprocessing can play a significant role in supporting a circular economy by promoting the sustainable use of fuels and raw materials. The circular economy is an economic model that emphasises the reduction, reuse, recycling, and recovery of materials to minimise waste and environmental impact.
At JK Cement we are focusing on maximising the usage of alternative fuels in terms of biomass, organic wastes, RDFs and MSW. A good number of investments is done and being done to maximise the usage to the best of the industrial standards. This practice has helped to divert materials that would otherwise end up in landfills, contributing to a
more circular approach by converting waste into a valuable resource.
Usage of fly ash, pond ash, chemical gypsums and a variety of industrial wastes to reduce clinker factors in various blended cements is a prime focus area in our organisation.
The heat generated during pyroprocessing is being utilised for power generation for creating a more sustainable energy source. A very high focus is put on maximisation of power generation through waste heat recovery systems and maximising the generation per ton of clinker by carrying out various corrections and modifications.
By integrating these practices, JK Cement contributes to the principles of a circular economy by reducing waste, promoting resource efficiency and creating closed-loop systems that minimise environmental impact while supporting sustainable industrial processes.
What is the frequency of audits?
The frequency of audits for pyroprocessing operations can vary based on factors such as industry standards, regulatory requirements and individual company policies. In general, audits for pyro-processing operations are conducted periodically to ensure compliance with safety, environmental and operational standards. The specific frequency of audits may be outlined in regulatory guidelines or industry best practices.
Companies often establish their own internal audit schedules to monitor and assess the performance of pyroprocessing facilities. To obtain accurate and up-to-date information on the frequency of audits for pyro-processing operations, it is recommended to consult relevant industry standards, regulatory agencies, or the specific policies and procedures of the organisation in question. Keep in mind that regulations and practices can vary by region and industry sector.
Tell us about the major challenges in a cement plant with pyro-processing.
Cement manufacturing with pyroprocessing involves high-temperature processes for the transformation of raw materials into clinker, which is the intermediate product used to produce cement. While pyroprocessing is essential for cement production, it comes with several challenges. Here are some major challenges faced by cement plants with pyroprocessing.
Pyroprocessing in cement plants requires significant amounts of energy, primarily for the heating of raw materials and clinker production. Managing and optimising the energy consumption to improve efficiency is an ongoing challenge. The combustion of fuels and chemical transformation of the raw material in the cement kiln result in carbon, sulphur, nitrogen oxides emission. Addressing and reducing these emissions is a key challenge for cement industries nowadays.
Usage of a variety of alternative fuels in comparison to regular fossil fuels with a lot of regularities with reference to control over usage, maintaining the quality, regulating the flow etc. Without these controls it becomes difficult to maintain the clinker / cement quality, environmental norms, product output, etc. The easy combustible nature of alternative fuels
put additional challenges for fire proof storage and handling.
Usage of alternative raw materials is also an important challenge being faced by cement manufacturers. This creates fluctuations in clinker quality and in turn pose a challenge in maintaining the required standards of cement quality.
Irregular AFRs are creating uncontrolled temperature and abrasive conditions in cement kilns and other equipment. Balancing the need for regular maintenance to prevent down time while maximising operation efficiency is a crucial challenge.
Cement manufacturers face market competition and economic pressures, which can impact production decisions and investment in new projects and new technologies. Balancing economic considerations with environmental and regulatory requirements is a complex challenge. The cement industry must invest continually in research and development to adapt innovative technologies that improve efficiency, reduce emission and overall sustainability. Adapting to evolving technological advancement is crucial for long term competitiveness. Many cement plants are actively working on improving their processes to reduce environmental impact and enhance overall efficiency.
- –Kanika Mathur
Concrete
Refractory demands in our kiln have changed
Published
3 days agoon
February 20, 2026By
admin
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 agoon
February 20, 2026By
admin
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 agoon
February 20, 2026By
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.
Refractory demands in our kiln have changed
Digital supply chain visibility is critical
Redefining Efficiency with Digitalisation
Cement Additives for Improved Grinding Efficiency
Digital Pathways for Sustainable Manufacturing
Refractory demands in our kiln have changed
Digital supply chain visibility is critical
Redefining Efficiency with Digitalisation
Cement Additives for Improved Grinding Efficiency
Digital Pathways for Sustainable Manufacturing
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