Concrete

Improving Operations using AI

Published

3 years ago

January 12, 2024

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Tushar Kulkarni, Business Head – Minerals, Cement & Mining, Siemens Large Drivers India, discusses the role of Artificial Intelligence (AI) and premium efficiency standard products in making cement plant operations more sustainable.

By FY27, cement consumption in India is expected to reach 450.78 million tonnes, driven majorly by expanding demand from housing, commercial construction, national infrastructure projects and industrial construction*. To meet the growing demand, many cement companies are planning or are undertaking capacity expansions. Despite market growth, challenges such as fluctuating raw material prices, energy costs, transportation costs, skill shortages and regulatory complexities continue to persist for cement plants.
Cement plants constantly strive to improve productivity and cost efficiency through sustainable manufacturing and operations. It is imperative for them to maintain continuous and reliable machine operations for producing high-quality cement that comply with industry standards, while also adhering to the environmental emission norms and regulations.
Over the last two decades, various technologies for advanced process control (APC) have been developed for the cement industry, viz fuzzy logic, expert systems and rudimentary approaches of artificial intelligence – these being the most widespread form of technology applied to process control. However, with the changes in technology and increasing use of alternate fuel residual (AFR) and alternative raw materials, the current optimisation systems (APC) have limited performance over process control and require excessive retuning.
In this context, adoption of latest technologies viz digitalisation solutions and use of Artificial Intelligence (AI) will significantly help cement plants in their efforts towards innovation, efficiency and sustainability goals through improved process optimization and increased productivity. Our SICEMENT® Operations Digital solutions portfolio (AI based) is well-positioned to support the cement industry in this endeavor.
*Source: IBEF Aug 23

Transforming Data into Insights
Digitalisation involves the integration of digital technologies, automation and data exchange, which creates large volumes of diverse and continuous data. To leverage such a wealth of data, data science is the catalyst that transforms data into actionable intelligence. Data science involves leveraging advanced techniques and technologies to extract meaningful insights, patterns and knowledge from a large volume of data.
Data science being the backbone of digitalisation process, plays a pivotal role to harness the power of data for strategic decision making, efficiency gains and innovation, such as:
Data-driven decision making: Extracting valuable insights from large datasets for insights driven informed decision making.
Predictive analytics: Forecasting future trends and enhancing operational efficiency.
Process optimisation: Identifying areas of optimisation, which can lead to more efficient production and reduced energy consumption.
Smart maintenance: Predictive maintenance models can forecast potential failures, allowing for proactive interventions and minimising downtime.
Integration of AI in data science increases the capabilities of extracting valuable insights, making predictions and automating various tasks. It empowers data scientists to manage complex problems and extract meaningful information from diverse datasets.
To understand more on applying AI in cement production, let us look at an example of the rotary kiln in cement production. It is known that the different parameters of the kiln react differently to changes in the control parameters – some are sensitive, others do not react at all. In addition, some parameters have linear characteristics, while others behave nonlinearly. These significant differences require a differentiated approach to improve the control strategy. AI technology is designed to manage linear and nonlinear behaviour in a complex environment where numerous dependencies determine the engineering process.
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.
The advantage of the AI-based solution over the previously described APC / MPC solutions is the development of a dedicated machine learning based kiln model that leads to more accurate insights into the future trends of the burning process than conventional approaches, which are usually based on a generic mathematical toolbox and a simple aggregation of recent historical data.

Driving Sustainability through Efficient Products
Industry has to adapt to products that have the highest possible efficiency standards. There is a huge drive by regulatory bodies as well as the manufacturers to scale up efficiencies of products used in process. Let us take an example of Low Voltage Motors. Currently the Minimum Efficiency Performance Standard (MEPS) in India is IE2 efficiency. Motors in IE3 and IE4 efficiency class also are available in the market. Due to the very lucrative ROI and also a concern on carbon emission, the penetration of motors with efficiency standard > IE2 is rapidly increasing and as per the estimation, > 30 per cent by kW of LV Motors produced are with efficiency class > IE2. With this encouraging voluntary shift to motors in efficiency class > IE2, industry is expecting the regulatory body to make IE3 as MEPS soon. Sectors such as the cement industries have already started moving towards IE4 in recent years.
The standards allow tolerance in efficiency declared by manufacturers for the purpose of accommodating manufacturing inconsistencies. However, many motors sold to users are by-design, utilising the negative side tolerances meant for manufacturing inconsistencies. Bearing this in mind, IEC has revised the criteria for CE Compliance w.e.f. 1st July 2022 which are stringent and so users are now assured of minimal utilisation of tolerance on the negative side. This will ensure IE3 and IE4 motors with enhanced operational efficiencies. Further, condition monitoring of motors with the help of cloud-based platforms can enhance the operational efficiencies.
Stringent standards, responded positively by manufacturers and aware users will pave a
path of higher level of sustainability in the cement industry.

ABOUT THE AUTHOR:
Tushar Kulkarni, Business Head – Minerals, Cement & Mining, Siemens Large Drivers India, leads the business verticals of Minerals – Cement & Mining within Innomotics India Pvt Ltd. With over 20 years of experience, he has held positions across business development, customer relationship management and project management amongst others.

Case Study: Retrofitting of lower efficient DC Motor by compact and highly efficient SIMOTICS H-Compact AC motor for Kiln Main Drive at one of India’s largest cement manufacturers. An Innomotics engineer was invited by a customer with an existing motor based on Direct Current Technology and was installed approx. 30 years ago. Based on the customer’s request, the Innomotics engineer visited the site to replace this old motor with a high efficiency AC Motor for Kiln Main Drive application. The customer’s priority was to have a tailor-made solution without disturbing existing mechanical and foundation set-up. After a detailed study during the site visit, the solution was a H-Compact 1PQ4 motor with high efficiency (97.7 per cent @ 75 per cent load) which enabled a reduction in annual energy consumption by 682,000 kWh. This helped in CO2 emission reduction by 440 Tons per annum which approximately would require 17,600 full grown trees to offset. Rating: 1000kW/6P/690V/50Hz/60°C, Application: Kiln Main Drive; Frame: H-Compact, 1PQ4 500 frame.

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JK Lakshmi Cement to Expand EV Fleet to 120 Vehicles by March 2027

JK Lakshmi Cement has deployed more than 70 EVs across its logistics network.

Published

3 hours ago

October 30, 2026

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JK Lakshmi Cement has deployed more than 70 electric vehicles (EVs) across its logistics network and plans to increase the fleet to 120 vehicles by March 2027. The expansion is part of its decarbonisation strategy, which aims to reduce transport-related emissions and improve operational efficiency.

The company has achieved nearly 100 per cent EV-based clinker dispatches from its Sirohi plant in Rajasthan to the Kalol Grinding Unit in Gujarat. The transition marks an increased use of electric mobility for long-haul cement transportation and is intended to lower the environmental impact of logistics operations.

The existing fleet operates on routes connecting the Sirohi plant with the Kalol Grinding Unit, Palanpur Unit and Surat Grinding Unit. JK Lakshmi Cement is working with electric vehicle logistics providers SwitchLabs and Billion E to support fleet deployment and manage transportation requirements across these routes.

The company expects the planned expansion to increase the use of electric mobility throughout its logistics network for moving cement and clinker. Chairperson and Managing Director Vinita Singhania said the programme reflected the integration of sustainable practices with the company’s focus on long-term business efficiency, while describing the Sirohi–Kalol transition as an important step in its wider decarbonisation strategy.

The EV programme forms part of JK Lakshmi Cement’s green logistics and sustainability roadmap, alongside initiatives to improve efficiency and reduce emissions across its value chain. The company has set a long-term target of achieving net-zero emissions by 2047. It is part of the JK Organisation and operates integrated cement plants in Rajasthan and Chhattisgarh, along with grinding units in Gujarat, Haryana and Odisha. The company has an annual turnover of more than Rs. 60 bn, combined cement capacity of approximately 18 mn t per annum and a target to raise capacity to 30 mn t by 2030. Its portfolio includes ready-mix concrete, gypsum plaster, wall putty, primer, adhesives and fly ash blocks.

Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

10 hours ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

Concrete

CII Calls for Greater Alternative Fuel Use in Cement Industry

Published

1 day ago

October 29, 2026

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The Confederation of Indian Industry (CII), through its Green Business Centre and Energy Efficiency Council, inaugurated the 16th Conference on Alternative Fuel and Raw Material Usage (AFR) in Goa on 27 October 2026. The two-day conference brought together more than 350 industry leaders, policymakers, waste management experts and technology providers to explore strategies for accelerating alternative fuel adoption in India’s cement industry.

Held under the theme ‘Preparation for Net-Zero: Alternative Fuels & Raw Material in Cement Manufacturing’, the conference focused on reducing dependence on conventional fuels, improving waste utilisation and strengthening circular economy practices across cement manufacturing operations.

E R Raj Narayanan, Chairman, AFR Conference 2026, and Business Head and Chief Manufacturing Officer, UltraTech Cement, highlighted the industry’s progress in alternative fuel adoption. He emphasised the need to scale implementation, strengthen supply chains and extend circularity beyond fuel substitution to alternative raw materials through technological innovation and industry collaboration.

Harish Adconkar, Managing Director, Goa Waste Management Corporation, highlighted Goa’s progress in scientific waste management and refuse-derived fuel (RDF) production. He stated that approximately 765,000 tonnes of RDF had been supplied to cement plants, contributing to an estimated displacement of 320,000–560,000 tonnes of coal. He emphasised the importance of consistent RDF offtake and stronger coordination between urban local bodies, waste management agencies and cement manufacturers.

Dr L P Singh, Director General, National Council for Cement and Building Materials, identified AFR as an important opportunity for decarbonisation and resource efficiency. Drawing parallels with the industry’s successful utilisation of fly ash, he stressed the need to address quality, technological and economic challenges to expand alternative fuel adoption.

Dr Sharad P Kale, Special Advisor to the Chief Minister of Goa and former Head of Technology Transfer and Collaboration at BARC, emphasised treating waste as a resource. He highlighted decentralised biodegradable waste processing, reduced food waste and improved resource recovery as essential measures for minimising landfill dependence.

Kiran Ananth, Executive Director, Energy Efficiency, Renewable Energy and Green Entrepreneurship, CII-Green Business Centre, noted that India’s cement production reached approximately 491 million tonnes in FY2025-26, while the industry’s thermal substitution rate (TSR) stood at 7.5 per cent, with around 7 million tonnes of alternative fuels utilised annually.

He added that the industry had invested over Rs 12 billion in co-processing infrastructure during the past six years. Improving RDF supply reliability and quality assurance would be crucial to maximising the utilisation of existing infrastructure and accelerating industrial decarbonisation.

The conference also featured discussions on advanced AFR co-processing technologies, waste pre-processing solutions and industrial best practices for improving fuel substitution and resource recovery.

A publication titled ‘From Waste to Kiln: Scaling the Use of MSW-Derived RDF in Indian Cement Plants’ was launched during the inaugural session. The report identified inconsistent RDF supply and quality as major barriers to achieving higher thermal substitution rates.

According to the publication, many cement kilns already possess the technical capability to achieve higher alternative fuel substitution. However, variations in RDF availability, moisture content, particle size and calorific value continue to limit utilisation. The report emphasised the need to strengthen waste segregation, pre-processing and aggregation systems to establish reliable RDF supply chains.

The conference’s second-day agenda includes discussions on innovative domestic and industrial waste management solutions, alternative raw materials for low-carbon cement and strategies to increase alternative fuel utilisation across India’s cement manufacturing sector.