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We are using AI to developour process control

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Dr Paula Carey, Co-Founder & Chief Scientific Officer, Carbon8 explains the impact of carbon capture technology at Carbon8 on the productivity, efficiency and circular economy of cement plants.

Tell us about your carbon capture technology.
Carbon8’s carbon capture utilisation and storage (CCUS) technology is known as Accelerated Carbonation (ACT). In the process, carbon dioxide derived directly from flue gas generated by a cement plant is reacted with calcium minerals within the cement by-pass or kiln dust produced by the same plant without the need for purification.

The reaction occurs at atmospheric temperatures and pressures over 20-30 minutes and can be engineered so that a carbon negative lightweight aggregate is produced, through granulation of the fine grained dusts.

The technology is delivered in a containerised plant (known as the CO2ntainer) with a small footprint that is plugged directly into the flue stack of the cement plant without affecting the cement manufacturing process.

What role can your technology play when implemented in a carbon intensive industry like the cement industry?
The amount of carbon dioxide that is captured is limited by the amount of residue available, but the economics of our system means that a profit can be made for every tonne of CO2 captured without the need for subsidies, or large energy penalties or the use of expensive toxic chemicals such as amines. The process results in the sustainable management of an industrial residue that might otherwise be destined for landfill and produces a low carbon product for the construction industry reducing the need for the extraction of natural aggregate.

What is the impact of your technology on the productivity and cost of cement manufacturing?
The installation of our technology has no effect on the productivity of the cement plant, it has a low energy requirement and its installation adds to the bottom line of the cement production.

How does your technology impact the energy efficiency of a cement plant?
Because our technology operates at atmospheric temperatures and pressures, it has a low energy demand and does not have an impact on the efficiency of the cement plant.

How does your tech support the circular economy?
Carbon8’s technology produces a carbon negative, lightweight aggregate from an industrial residue, breaking the route to landfill disposal and producing a sustainable product for the construction industry that replaces the need for the extraction of natural virgin aggregate. On our website – www.carbon8.co.uk – we describe ourselves as a “circular impact company

What are the major challenges in implementation and execution of your technology?
Because the amount of CO2 captured is relatively small compared with large-scale, expensive carbon capture projects, it has been more challenging to demonstrate the economic and environmental benefits of deploying and operating our technology within the global cement industry. A Vicat cement plant in France has been using our CO2tainer since 2020, after successful trials with CRH in Canada and Hanson (now part of Heidelberg Cement Group) in the UK.

The variability of the waste streams that are available to Carbon8 also raises a challenge; every cement works is slightly different and demands a unique solution in terms of mix design for our process.

What innovations can the world expect from Carbon8 in the near future?
We are using AI to develop our process control to overcome the variability of the residues that are generated by the different hard-to-abate industries, and so facilitate the deployment of ACT solutions into other sectors, like Energy From Waste, biomass and steel.

Concrete

30-Day Traffic Diversion In Place For CC Road Works In Madhapur

Diversions in place from May 16 for cement concrete road works

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The Cyberabad Traffic Police issued a traffic advisory as road works begin for the laying of a cement concrete (CC) road from Jaya Shankar Statue to RRR Restaurant at Parvathnagar in Madhapur limits. The advisory indicated that traffic diversions will be in place for 30 days from May 16 to ensure the smooth flow of vehicles and to minimise congestion on the affected stretch. The measure aims to balance uninterrupted construction activity with the movement needs of commuters.

Traffic moving from Toddy Compound towards Parvathnagar village will be diverted at Parvathnagar junction towards Sunnam Cheruvu and the 100 feet road. Local motorists and public transport operators have been advised to follow the diversionary route as directed by traffic personnel on duty. Alternate routes and signage have been planned to mitigate delays and to manage peak hour congestion.

Police officials said the diversion had been planned to facilitate uninterrupted road works while maintaining traffic movement in the area. Commuters were urged to plan their travel accordingly and to cooperate with traffic staff managing the stretch. Authorities indicated that enforcement of diversions would be active and that violations could attract penalties.

The 30 day schedule is intended to allow contractors to complete the laying and curing phases with minimal interruption to vehicular flow. Residents and businesses in adjacent localities have been advised to factor the diversion into deliveries and travel plans. The traffic police promised continuous monitoring of the works and the operational diversions and emphasised that temporary inconvenience was necessary for longer term improvement of the road network. Traffic personnel will be stationed at key junctions and additional signage and temporary markings will be displayed to guide motorists and pedestrians through the revised alignments while public transport services will follow the diversion where feasible and operators have been asked to adjust timetables to minimise disruption.

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Concrete

HeidelbergCement India Receives Consent For Khandwa Grinding Unit

Consent granted by Madhya Pradesh Pollution Control Board

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HeidelbergCement India (HeidelbergCement India) has received regulatory consent to establish a cement blending and grinding unit at Village Dongaliya, Tehsil Punasa, District Khandwa in Madhya Pradesh. The consent was granted by the Madhya Pradesh Pollution Control Board under the Water (Prevention & Control of Pollution) Act, 1974 and the Air (Prevention & Control of Pollution) Act, 1981 and is dated 17 May 2026. The company disclosed the development in a filing made under Regulation 30 of the SEBI (Listing Obligations and Disclosure Requirements) Regulations, 2015.

The project plan envisages procurement of long term availability of fly ash and the allotment of land on lease for setting up the unit. The proposed facility is described as a blending and grinding installation which will process cementitious materials sourced from nearby operations and suppliers. Company filings state the measures required to secure raw material logistics and statutory compliance before commencing construction.

The addition of a grinding unit in Khandwa is intended to strengthen regional supply and improve logistical efficiency by reducing haulage distances for finished product. The unit is expected to complement existing capacities in central India and to offer flexibility in product mix through blending operations. The reliance on fly ash as a supplementary cementitious material will necessitate long term supply agreements with thermal power producers and coordination with waste utilisation policies.

The disclosure to the regulator and to the stock exchanges follows standard corporate governance practice and aims to keep investors apprised of capital expenditure initiatives. The company indicated that subsequent permits and clearances would be sought in accordance with applicable environmental and land use rules. The project is presented as part of HeidelbergCement India’s broader strategy to optimise capacity distribution and to respond to regional demand dynamics.

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Concrete

PROMECON introduces infrared-based tertiary air measurement system for cement kilns

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The new solution promisescontinuous, real-time tertiary air flow measurement in cement plant operations.

PROMECON GmbH has launched the McON IR Compact, an infrared-based measuring system designed to deliver continuous, real-time tertiary air flow measurement in cement plant operations. The system addresses the longstanding process control challenge of accurate tertiary air monitoring under extreme kiln conditions. It uses patented infrared time-of-flight measurement technology that operates without calibration or maintenance intervention.

Precise tertiary air measurement is a critical requirement for stable rotary kiln operation. The McON IR Compact is engineered to function reliably at temperatures up to 1,200°C and in the presence of abrasive clinker dust. Its vector-based digital measurement architecture ensures that readings remain unaffected by swirl, dust deposits or drift. Due to these conditions conventional measurement systems in pyroprocess environments are often compromised.

The system is fully non-intrusive and requires no K-factors, recalibration or periodic readjustment, enabling years of uninterrupted operation. This design directly supports plant availability and reduces the maintenance overhead typically associated with process instrumentation in high-temperature zones.

PROMECON has deployed the McON IR Compact at multiple cement facilities, including Warta Cement in Poland. Plant operators report that the system has aided in identifying blockages, optimising purging cycles for gas burners, and supplying accurate flow data for AI-based process optimisation programmes. The practical outcomes include more stable kiln operation, improved process control, and earlier detection of process disturbances.

On the energy side, real-time tertiary air data enables reduction in induced draft fan load and helps flatten process oscillations across the pyroprocess. This translates to lower fuel and energy consumption, fewer unplanned shutdowns, and a measurable reduction in NOx peaks. This directly reflects on the downstream cost implications for plants operating SCR or SNCR systems for emissions compliance.

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