The smart integration of artificial intelligence, technology and data analytics not only improves operational efficiency but also supports the cement industry’s commitment to sustainability by reducing emissions, enhancing material efficiency and aligning with global environmental objectives. ICR looks at the latest technological innovations that help optimise sustainable efforts of the stakeholders of the cement industry through predictive maintenance and real-time monitoring.

Sustainability refers to the ability to meet the needs of the present without compromising the ability of future generations to meet their own needs. It involves a balanced and responsible use of resources, considering environmental, social, and economic factors. The concept of sustainability recognises the interconnectedness of these three pillars—environmental, social, and economic—and aims to create a harmonious and enduring system that benefits both current and future generations.
India is the second-largest producer of cement in the world. The current emphasis on infrastructure development in the country is expected to drive cement demand further. The Indian cement industry has established itself as one of the frontrunners in driving efficiency measures and setting ambitious net-zero targets. The successful implementation of the PAT scheme has played a key role in adopting energy-efficient technologies.
According to the report, Evaluating Net Zero for the Indian Cement Industry, published by Council of Energy, Environment and Water, October 2023, the cumulative CO2 emissions from manufacturing 337 million tonnes of cement in 2018-19 were estimated at 218 million tonnes. Baseline estimates show that nearly 56 per cent of the total 0.66 tonnes of CO2 per tonne of cement produced is due to the calcination of limestone in the kilns. Most of the remaining emissions, 32 per cent is due to the combustion of fuels for process-heating applications, while only 12 per cent is due to the electricity used for manufacturing. The analysis indicates that, with the adoption of only those decarbonisation measures that have a negative cost of mitigation, the cost of cement reduces by three per cent while its emission intensity decreases by 20 per cent. Further, with the use of measures that have a positive cost of mitigation, a breakeven can be achieved with the current cost by reducing the emissions intensity by 32 per cent. The net-zero cost of cement is estimated to increase by 19–107 per cent, depending on the cost of CCS (carbon capture and storage) and CCU (carbon capture and utilisation). Energy efficiency in cement production will have a limited effect on emission reduction at 9 per cent. The use of renewable energy, alternative fuels and raw materials has the potential to abate 13 per cent of cement emissions, while reduction in clinker factor will reduce another 11 per cent. However, 67 per cent of the cement industry’s emissions would need to be abated through carbon management techniques like CCUS and carbon offsetting.

Real-time monitoring of energy consumption patterns, allow for data-driven decision-making, thus, enhancing energy efficiency and reducing carbon emissions.

ALTERNATIVE FUELS AND RAW MATERIALS
The adoption of alternative fuels and raw materials in the cement industry is a dynamic area driven by the need for sustainability and resource efficiency. As technology advances and regulatory frameworks evolve, the industry is likely to explore and implement new solutions to reduce its environmental footprint.
Ajay Kapur, CEO – Cement Business, Adani Group, says, “Being an energy-intensive sector, cement manufacturers have started investing in cleaner sources of energy like solar and wind as captive generation units to run their plants. This shift in no small measure is supported by the falling cost of renewable energy India. Between 2010 and now, the cost of solar modules in India have dropped by more than 80 per cent, making it one of the most sought-after sources of clean energy for large industrial units including cement. Similar efforts are also on to move finished cement, packed and bulk on more sustainable or green logistics like soya extract-based biofuel powered shipping. Bulk terminals and grinding units along India’s long coastline can enable the movement of clinker and cement through the sea route at the lowest possible cost.”
The use of alternative fuels and raw materials is a key strategy to enhance sustainability by reducing environmental impact and conserving natural resources. Cement manufacturing is energy-intensive, and the production of clinker—the key ingredient in cement—requires significant amounts of heat, primarily obtained by burning fossil fuels. Making the energy usage in the cement industry more sustainable involves improving efficiency, reducing carbon emissions, and exploring alternative energy sources. The transition to sustainable energy use in the cement industry requires a holistic approach that encompasses technological advancements, changes in operational practices, and collaboration across the supply chain. Continued research, investment, and a commitment to sustainability will be essential for the industry to achieve meaningful progress in making its energy use more sustainable.
The Indian cement industry has been increasingly incorporating sustainable energy sources to reduce its environmental impact and enhance energy efficiency. One notable source is renewable energy, particularly solar power. Many cement plants in India have started harnessing solar energy through on-site solar installations. For instance, UltraTech Cement, one of India’s largest cement producers, has adopted solar power solutions across multiple plants. The organisation has commissioned more than 25 megawatts (MW) of solar power capacity and aimed to increase this to 130 MW by 2022. This transition to solar energy not only reduces the industry’s reliance on conventional power sources but also contributes to a significant decrease in greenhouse gas emissions associated with electricity consumption. The adoption of sustainable energy sources is likely to continue as the Indian cement industry strives to meet its sustainability goals and align with the country’s commitment to renewable energy expansion.
Vimal Kumar Jain, Director – Technical, HeidelbergCement India, says, “The production of cement requires a high degree of thermal energy. The traditional fuels used in the kilns are coal, oil, petroleum coke etc. The substitution of fossil fuels by alternative fuels in the production of cement clinker is of great importance for society and climate control because it conserves fossil fuel reserves and reduces greenhouse gas emissions.”
“We are aiming to maximise the usage of alternative fuels such as Industrial wastes, plastics, used tires, biomass wastes and municipal wastes thus replacing conventional fuels,” he adds.
The Indian cement industry primarily relies on a set of key raw materials for cement production. These include limestone, clay, shale, silica sand, and iron ore. Limestone is the predominant raw material and serves as a crucial source of calcium, an essential component in the production of clinker—the main ingredient in cement. The use of these raw materials contributes to the sustainability of the Indian cement industry in several ways.
Firstly, limestone and other raw materials are abundant in India, reducing the industry’s dependence on imported resources. This enhances the sector’s resilience and minimises the environmental impact associated with transportation. Additionally, the incorporation of certain industrial by-products and alternative raw materials, such as fly ash and slag, into cement production helps reduce the demand for traditional raw materials and promotes a more circular economy. This approach not only conserves natural resources but also mitigates the environmental footprint of cement manufacturing.

According to data from the Cement Manufacturers’ Association of India, as of 2021, the share of alternative raw materials in the total raw material consumption in the Indian cement industry was around 12 per cent, indicative of a growing trend towards more sustainable and resource-efficient practices within the sector.
Dr SB Hegde, Professor, Jain University, and Visiting Professor, Pennsylvania State University, USA, says, “Supplementary cement materials (SCMs) and creative ideas like Calcined Clay Clinker (LC3) are making a big difference. These different materials are transforming the way things are done. For example, in India, where the cement industry is one of the largest carbon emitters, LC3 technology, which incorporates calcined clays into cement, has been demonstrated to reduce CO2 emissions by up to 30 per cent and substantially decrease energy consumption during the clinker production process.”
“By 2050, it is estimated that the implementation of such alternative materials could help the cement sector reduce its global CO2 emissions by up to 16 per cent,” he adds.

CLIMATE TECHNOLOGY
New technologies represent a critical part of the world’s decabonisation mission. According to McKinsey’s article – Innovating to Net Zero: An Executive’s Guide To Climate Technology, 2021, the need for climate technology is vast—which creates large potential markets and investment opportunities. McKinsey estimates that next-generation technologies could attract $1.5 trillion to $2 trillion of capital investment per year by 2025.
These climate technologies could contribute to solving the net-zero equation while creating growth potential for sectors and geographies. At present, the technologies exhibit varying levels of maturity, performance, market demand and regulatory support. To bring them to commercial, climate-stabilising scale would require companies, financial institutions, and governments to cooperate on investment and research programmes as well as efforts to integrate technologies with existing industrial systems.
“Cement plants have adopted technologies to meet the new emission norms for PM, SO2 and NOX emissions. Plants have installed highly efficient
bag filters, ESPs, and hybrid filters to control dust emissions. For NOX reduction, plants have installed secondary control measures like SNCR. All the cement plants have installed a Continuous Emission Monitoring System (CEMS) as per the guidelines of CPCB,”
says Dr BN Mohapatra, Advisor and Consultant, UltraTech Cement.
“In the same spirit, the cement industry is the first one to adopt filtration technologies like pulse Jet Bag House (PJBH) reverse air bag house and hybrid filters for controlling dust emission from stack. Advent of new fabrics which can withstand higher temperatures and tough working conditions. Controls and advanced electrical systems provided the opportunity to reduce the dust emissions to very low levels. Cement industry embraced these technologies that helped industry today in achieving consistent and lower stack emissions of 30 mg/Nm3,” he adds.

AI, TECH AND DATA
The integration of artificial intelligence (AI), technology and data analytics plays a crucial role in enhancing the sustainability of cement manufacturing.
Pankaj Kejriwal, Executive Director, Star Cement, says, “Artificial Intelligence (AI) solutions can be used to assess, predict, and mitigate climate change and support sustainable waste management. For example, AI techniques can be used to monitor environmental issues like CO2 emission. The data gathered from this is then processed, leveraging machine learning techniques, to predict environmental changes. Adaptive systems and continuous intelligence techniques are used to regularly adjust business and engineering systems to cope with environmental changes and challenges.”
“When it comes to waste management and accelerating recycling processes, AI techniques have also become commonplace. Perspective analytics and market knowledge graphs are used to map the movement of waste materials and reduce unnecessary shipping while improving material reuse,” he adds.
AI plays a pivotal role in optimising various facets of the production process, enabling more efficient resource utilisation and energy management. Advanced process control systems driven by AI algorithms enhance the precision of operations, leading to optimised raw material preparation, clinker production, and cement grinding. Predictive maintenance, powered by AI, helps prevent equipment failures, reducing downtime and ensuring more reliable and sustainable operations.
Technology facilitates real-time monitoring of energy consumption patterns, allowing for data-driven decision-making to enhance energy efficiency and reduce carbon emissions. Supply chain optimisation through AI-driven logistics not only minimises operational costs but also contributes to a reduction in the overall carbon footprint associated with transportation. AI and data analytics are instrumental in monitoring and controlling emissions, ensuring compliance with environmental standards.
“The share of green energy is enhanced through investments in Waste Heat Recovery Systems (WHRS). These systems not only adhere to the principles of the circular economy but also result in fossil fuels savings. This not only nurtures a more cost-efficient process but also directly impacts the bottom line,” says Ajay Kapur, CEO – Cement Business, Adani Group.
Moreover, these technologies aid in material efficiency by optimising the use of raw materials and exploring alternative resources, contributing to a circular economy. Life cycle assessments, powered by data analytics, allow manufacturers to evaluate and improve the environmental impact of their products. In research and development, AI analyses extensive datasets to identify innovative solutions, fostering the evolution of sustainable practices in cement production. Ultimately, the smart integration of AI, technology, and data in the cement industry is a transformative force, driving efficiency, reducing environmental impact, and bolstering the sector’s commitment to sustainability.
According to Tushar Kulkarni, Business Head – Minerals, Cement & Mining, Siemens Large Drivers India: “The main difference between a data-centric solution and traditional expert systems is the development of a dedicated machine learning-based kiln model that provides more accurate insights into future kiln process trends than traditional approaches. The latter typically provides insights that are based on a generic mathematical toolbox and a simple aggregation of recent historical data. Advanced Process Control (APC) is widely used to improve kiln and mill control. However, in practice, the limitations of the current APC approach are apparent. For instance, a typical fuzzy logic is not able to cover all operating scenarios and is sensitive to operational changes. A typical Model Predictive Control (MPC) uses linear models in most cases and any change in equipment leads to a completely new setting of the model.”
“In contrast, by incorporating long-term data sets for AI training, the trained AI models can learn from the past and establish correlations between parameters and time and between actions and outcomes. This knowledge, accumulated in the models, forms the basis for better control performance,” he adds.
Anuj Khandelwal, Business Head, JK Cement, says, “Scaling sustainability initiatives requires automation and digital solutions. This is a critical part of our capability build as we move towards the new clean-tech solutions offered. For instance, real-time power balancing solutions address the variability in green power generation profiles. Digital load and demand balancing solutions have increased the usage of green power, helping us achieve a remarkable 48 per cent+ green power mix for JK Cement in H1FY24.”
“Similarly addressing challenges associated with quality variance in alternate fuels and impact on stable kiln operations required innovative solutions. NIR sensors for online quality testing enable precise control over the alternative fuel blend. In parallel, automated feedback loops helped ensure stable kiln operations even at higher TSR levels. Investments in digital quality control systems enable the incorporation of higher alternate raw materials, crucial for maintaining product quality amid the variability of alternate materials,” he adds.
The adoption of AI, technology, and data-driven approaches in the cement manufacturing sector not only improves operational efficiency but also significantly contributes to the industry’s sustainability goals. By leveraging these technologies, cement plants can reduce resource consumption, lower emissions, and embrace more eco-friendly practices throughout the entire production process.

CONCLUSION
Technology plays a pivotal role in driving sustainability within the Indian cement industry. It emphasises the adoption of advanced technologies, such as AI, data analytics and automation, to optimise various aspects of cement manufacturing. The integration of AI facilitates real-time monitoring and control of energy consumption, leading to increased efficiency and reduced carbon emissions.
Predictive maintenance technologies ensure equipment reliability, minimising downtime and resource wastage. The use of data analytics allows for precise supply chain optimisation, contributing to lower operational costs and reduced environmental impact associated with transportation. The article underscores how these technological advancements support material efficiency by optimising raw material usage and exploring alternative resources.
Furthermore, life cycle assessments, powered by data analytics, enable manufacturers to evaluate and enhance the sustainability of their products. The overarching theme is that technology-driven solutions are instrumental in transforming the Indian cement industry, fostering sustainability, and aligning with global environmental goals.

• –Kanika Mathur