Concrete

Actively Fostering Renewables

Published

2 years ago

March 19, 2024

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Keeping a close eye on the use of alternative fuels and raw materials (AFR) in cement manufacturing, we delve into the progress made by key players in increasing the use of AFR by using advanced automation, technology and innovative practices.

Cement plays a vital role in building the economic development of any country. The Indian cement industry is the largest cement producing country in the world, next only to China. With the adoption of massive modernisation and assimilation of state-of-the-art technology, Indian cement plants are today the most energy-efficient and environment-friendly and are comparable to the best in the world in all respects, whether it is size of the kiln, technology, energy consumption or environment-friendliness. The cement industry contributes to environmental cleanliness by consuming hazardous wastes like fly ash (around 30 Mnt) from thermal power plants and the entire 8 Mnt of granulated slag produced by steel manufacturing units and also using alternative fuels and raw materials using advanced and environment friendly technologies.
At present, the installed capacity of cement in India is 500 MTPA with production of 298 million tonnes per annum. Majority of the cement plants installed capacity (about 35 per cent) is located in the states of south India. In PAT scheme, total installed capacity of cement in India is 325 MTPA, which contributes to 65 per cent coverage of total installed capacity in India. With the increase in growth of infrastructure, the cement production in India is expected to be 800 million tonnes by 2030, according to the Bureau of Energy Efficiency, India.
With over 7 per cent of global CO2 emissions, decarbonisation of the cement industry will play a key role in achieving the Paris Climate Agreement targets. The deep decarbonisation of the cement industry can be achieved through measures such as material efficiency, clinker substitution, alternative binding materials, carbon capture and storage, energy efficiency improvements, electrification and the use of alternative fuels.
According to the World Economic Forum report Net-Zero Industry Tracker 2023, Absolute CO2 emissions declined by less than 1 per cent over the last four years amid increases in global production. Emissions intensity remained static over the same time period despite a 9 per cent rise in the clinker-to-cement ratio. The average ratio is currently 72 per cent, while the proposed GCCA target is 56 per cent. The twin forces of urbanisation and population growth are driving cement consumption in China (51 per cent global demand) and India (9 per cent global demand), which necessitates accelerated action to decarbonise the sector to mitigate the impacts of increased production.
According to Dr Anjan K Chatterjee, Managing Director, Conmat Technologies, “Among the industrial activities, the production of Portland cement ranks high in generating CO2, creating up to 8 per cent of worldwide man-made emissions of this gas. This is identified as a major contributor to the probable rise in average global temperature exceeding 20oC. In recent years, a school of thought has emerged whether it is justified to consider the amount of CO2 emitted directly from the cement manufacturing process as the total cement industry emissions to affect the global temperature rise. This is due to the fact that cement is used mainly in the form of concrete, mortar and plaster in built structures, which over time undergo carbonation involving reverse penetration of CO2. The knowledge about carbonation of existing concrete structures is well-established. The CO2 uptake by the cement-based products including concrete has not been considered historically in the CO2 estimation for climate change.
Furthermore, there are many technologies in development, which promise significant potential of enhancing the recycling of CO2 in concrete and cement-based products. Thus, it seems justified to consider that, while the cement production is a carbon source, the cement-based products may act as carbon sinks. The concept of concrete as a carbon sink will be a game-changer for the cement and concrete industry as a whole for improving the climate performance of the sector.

TRADITIONAL RESOURCES
Traditional fuels and raw materials play a pivotal role in the cement production process. Commonly used fuels include coal, petroleum coke and lignite, which are primarily utilised to generate the high temperatures required for clinker production in cement kilns. These fossil fuels have been the go-to choices due to their availability and relatively low cost, but their usage raises concerns about environmental pollution and carbon emissions. Conventional raw materials used in cement production in India typically include limestone, clay and iron ore. Limestone serves as the primary source of calcium, essential for the formation of clinker, while clay provides silica, alumina, and iron oxide. Iron ore acts as a source of iron oxide, which contributes to the cement’s strength and colour.
Hari Mohan Bangur, Managing Director, Shree Cement, says, “The major raw material used for manufacturing of cement is limestone at our plants. There is not a lot of variation done in the use of alternative materials for cement manufacturing.”
“However, if we consider alternative fuels, Shree Cement was the first to use pet coke, which in today’s time is not an alternative fuel. We use a small quantity of Refuse Derived Fuel (RDF) and more quantities of agro waste as an alternative fuel. We burn hundreds of tonnes of agro waste as an alternative fuel in our plants,” he adds.
Relying solely on traditional fuels and raw materials poses environmental challenges, including air pollution, greenhouse gas emissions, and depletion of natural resources. To address these issues, the Indian cement industry is increasingly exploring alternative fuels such as biomass, waste-derived fuels, and alternative raw materials like industrial by-products and agricultural wastes. Adopting alternative fuels and raw materials not only helps reduce the environmental footprint of cement production but also enhances resource efficiency and promotes sustainable development. As the industry continues to evolve, the integration of alternative fuels and raw materials is becoming increasingly important for ensuring the long-term viability and sustainability of the Indian cement sector.

THE SHIFT TOWARDS AFR
The Indian cement industry is undergoing a significant transformation as it shifts towards alternative fuels and raw materials, marking a pivotal transition towards sustainability and environmental responsibility. This shift is primarily driven by a growing recognition of the environmental challenges associated with conventional cement production, including air pollution, greenhouse gas emissions, and depletion of natural resources. Moreover, stringent regulations and evolving market dynamics are compelling cement companies to seek greener and more sustainable production practices.
According to a report An Overview of the Utilization of Common Waste as an Alternative Fuel in the Cement Industry by Hindwai, concrete is one of the most commonly used construction materials, there is a massive production of cement, which causes cement manufacturing to be an energy-intensive industry. A significant amount of the cost of cement production, ranging from 20 per cent to 25 per cent, is attributed to thermal energy. In addition, the action of mining and burning fossil fuels results in the unfavorable emission of hazardous compounds into the environment. Therefore, the switch from conventional fossil fuels to alternative fuels in the cement manufacturing business has attracted attention due to environmental and financial concerns.
There are four commonly used alternative fuels, which are waste tires, municipal solid waste, meat and bone meal and sewage sludge. It is found that each alternative fuel has a unique calorific value and properties, attributed to its source, treatment and technology. Furthermore, the availability of alternative fuel is important as the amount varies depending on the location. In addition, their effects on gaseous emissions from the cement plant and the quality of clinker are found to be inconsistent. Thus, there will not be a single best type of alternative fuel option to be used in the cement industry. A good alternative fuel should be able to provide sufficient thermal energy while reducing the environmental impacts and costs. A careful analysis and multicriteria decision-making approach are always vital when employing alternative fuels to prevent environmental problems, cost increases, as well as clinker quality degradation.
One of the key drivers behind this transition is the adoption of alternative fuels, which offer several advantages over traditional fossil fuels. Biomass, waste-derived fuels, industrial by-products, and even tires are being utilised as viable substitutes, providing cost savings, reducing dependency on finite resources, and diverting waste from landfills. Simultaneously, there is a concerted effort to explore alternative raw materials that can supplement or replace traditional inputs like limestone and clay. Industrial by-products, such as fly ash, slag, and silica fume, are increasingly being utilised in cement production, not only reducing the reliance on virgin resources but also mitigating the environmental impact of waste disposal.
Sanjay Joshi, Chief Projects and Manufacturing Officer, Nuvoco Vistas Corp, says, “The selection of AFR for usage in a cement kiln involves a thorough assessment of their potential impacts on clinker and cement manufacturing operations, product quality and the environment. Several important factors must be considered before finalising the choice of AFR.”
“Among these, key parameters include alkali, sulphur, chloride, trace element content, heat (calorific) value and moisture content. Regular reviews of the acceptance criteria are conducted in accordance with local regulations to ensure ongoing alignment with environmental standards and manufacturing requirements. This comprehensive evaluation process ensures that the selected AFR optimally contributes to the cement kiln process while minimising adverse effects on both the product and the surrounding environment,” he adds.
Murielle Goubard, Global Sector Manager for Building Materials, Malvern Panalytical, mentions to AZoMaterials, “For over 40 years, cement manufacturers have been working to reduce their environmental impact, particularly their CO2 emissions. To achieve this, several actions have been taken like Improving the energy efficiency of kilns and processes, using alternative fuels (industrial residues, biomass, etc.) to partially replace the fossil fuels used to power cement kilns, using alternative raw materials and manufacturing new multi-constituent cements (combining clinker with slag, fly ash, calcined clay, limestone, etc.) and reducing the clinker content plays a crucial role in mitigating the environmental impact of concrete production. Traditional cements like Portland cement and Portland-composite cement typically contain over 95 per cent and 65 per cent clinker, respectively. These high clinker ratios contribute significantly to the environmental footprint of concrete.”
“To address this issue, supplementary cementitious materials like fly ash from coal power plants and blast furnace slag from steel making can be used to partially replace clinker. This substitution not only reduces the energy required for clinker production but also mitigates process emissions associated with clinker manufacturing. However, the availability of these alternative feedstocks depends on the decarbonisation efforts in the power and steel sectors. As these industries transition to cleaner practices, these feedstocks may become scarcer. This has led to the emergence of innovative cement types
like LC3 (limestone calcined clay cement). LC3 comprises 50 per cent clinker, 30 per cent calcined clay, 15 per cent limestone, and 5 per cent gypsum, in contrast to classical Ordinary Portland cement, which consists of 95 per cent clinker and 5 per cent gypsum,” he added.
The Indian cement industry’s embrace of alternative fuels and raw materials reflects a broader commitment to sustainability, circular economy principles, and compliance with global environmental standards. This transition not only enhances the industry’s environmental credentials but also fosters innovation, resource efficiency, and long-term resilience in the face of evolving market dynamics and regulatory pressures.
Pankaj Kejriwal, Whole Time Director and COO, Star Cement, says, “The use of AFR in the cement industry has a bright future. Due to scarcity of fossil fuel, it is the need of the century to increase the use of AFR. All cement industry globally is in line with it and is continuously working towards maximising use of AFR. This will help the society to decrease waste dump in soil and reduce emission of CO2 and NOx in the environment. In some cement industries in ASIA pacific and Europe, they are taking it as a CSR (corporate social responsibility) to clean the environment. In India, too, the Government is encouraging use of MSW in cement plants. Our organisation is also aligned in the same path. After commissioning of our AFR feeding system, we also have a way forward towards the usage of AFR in our cement plant and have a target of 15-20 per cent TSR by 2026 depending on the availability in the northeast.”

USE OF TECHNOLOGY IN AFR
Automation and technology are instrumental in facilitating the adaptation of alternative fuels and raw materials in the Indian cement industry. These advancements optimise the manufacturing process by enabling precise control and monitoring of parameters such as temperature, pressure, and composition in real-time. Automated systems streamline the blending, handling and feeding of diverse alternative fuels to the kiln, ensuring efficient utilisation while minimising manual intervention. Additionally, automation plays a vital role in maintaining product quality and consistency by monitoring raw material composition and emissions in real-time, thereby enhancing reliability and reducing environmental impact. Furthermore, automation platforms
equipped with data analytics capabilities enable the identification of optimisation opportunities and the improvement of process efficiency, contributing to sustainability and competitiveness in cement manufacturing operations.
Sunil Kumbhar, CEO and Director, AltSF Process, says, “Handling alternative fuels, specifically these days, unprocessed municipal solid waste coming to cement plants is of very hazardous nature. Bad odour, unhygienic waste has a hazard to deploy people to work in handling these materials. Hence, cement plants require fully automated arrangements monitored from their control room for all operations. AltSF delivers fully automated arrangements for all handling stages like storage management, extraction of waste, accurate weighing, conveying and safe feeding inside the kiln.”

ENVIRONMENTAL IMPACT OF AFR
The use of alternative fuels and raw materials in the Indian cement industry significantly impacts the environment by reducing carbon emissions, conserving natural resources, mitigating waste generation and promoting the circular economy.
By substituting traditional fossil fuels with cleaner alternatives like biomass and waste-derived fuels, the industry can lower its carbon footprint and contribute to climate change mitigation. Moreover, incorporating alternative raw materials such as industrial by-products and agricultural residues reduces reliance on virgin resources, minimising environmental degradation associated with extraction activities.
Waste-derived fuels not only divert materials from landfills but also provide a sustainable solution for waste disposal while generating energy. This shift towards alternative fuels and raw materials promotes a circular economy by repurposing waste materials as valuable resources in industrial processes, fostering resource efficiency, reducing environmental impact, and contributing to sustainable development.

CONCLUSION
The Indian cement industry’s adoption of alternative fuels and raw materials reflects a commitment to environmental stewardship and sustainability, with positive implications for air quality, resource conservation, waste management, and the promotion of circular economy principles. The industry is reducing its carbon footprint, conserving natural resources, mitigating waste generation and promoting circular economy principles.
Automation and technology play a critical role in facilitating this transition, optimising processes, ensuring product quality and enhancing operational efficiency. The adoption of alternative fuels and raw materials not only aligns with global efforts to combat climate change but also fosters innovation, resilience, and competitiveness in the Indian cement sector. Moving forward, continued investment in research, technology and collaborative initiatives will be essential to drive further progress towards a greener, more sustainable future for the Indian cement industry and the environment as a whole.

–Kanika Mathur

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Concrete

Material Flow Efficiency

Published

1 day ago

March 18, 2026

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We explore how material handling systems are becoming strategic assets in cement plants, enabling efficient movement of raw materials, clinker and finished cement. Advanced conveying, automation and digital technologies are improving plant productivity while supporting energy efficiency and sustainability goals.

Material handling systems form the operational backbone of cement plants, enabling the efficient movement of raw materials, clinker and finished cement across complex production networks. With India’s cement industry producing over 391 million tonnes of cement in FY2024 and possessing an installed capacity of around 668 mtpa, according to the CRISIL Research Industry Report, 2025, efficient material logistics have become critical to maintaining plant productivity and cost competitiveness. At the same time, cement production is highly energy intensive and contributes around 7 per cent to
8 per cent of global CO2 emissions, making efficient material flow and logistics optimisation essential for reducing operational inefficiencies and emissions states the International Energy Agency Cement Technology Roadmap, 2023. As plants scale capacity and integrate digital technologies, modern material handling systems, ranging from automated conveyors to intelligent stockyards, are increasingly recognised as strategic assets that influence plant stability, energy efficiency and environmental performance.

Strategic role of material handling
Material handling is no longer viewed as a secondary utility within cement plants; it is now recognised as a strategic system that directly influences production efficiency and process stability.
Cement manufacturing involves the continuous movement of large volumes of limestone, clay, additives, clinker and finished cement across multiple production stages. Even minor disruptions in conveying systems or storage infrastructure can lead to kiln feed fluctuations, production delays and significant financial losses. According to Indian Cement Industry Operational Benchmarking Study, 2024, unplanned downtime in large integrated cement plants can cost between Rs.15–20 lakh per hour, highlighting the economic importance of reliable material handling systems.
Modern cement plants are therefore investing in advanced mechanical handling systems designed for high throughput and operational reliability. Large integrated plants can process over 10,000 tonnes per day of clinker, requiring highly efficient conveying systems and automated stockyards to maintain continuous material flow, suggests the International Cement Review Industry Analysis, 2024. Efficient material handling also reduces spillage, minimises dust emissions and improves workplace safety. As cement plants become larger and more technologically advanced, the role of material handling is evolving from simple transport infrastructure to a critical operational system that supports both productivity and sustainability.

From quarry to plant
The transport of raw materials from quarry to processing plant represents one of the most energy-intensive stages of cement production. Traditionally, limestone and other raw materials were transported using diesel-powered trucks, which resulted in high fuel consumption, dust generation and increased operational costs. However, modern plants are increasingly adopting long-distance belt conveyors and pipe conveyors as a more efficient alternative. These systems allow continuous material transport over distances of 10–15 kilometres, significantly reducing fuel consumption and operating costs while improving environmental performance, states the FLSmidth Cement Industry Technology Report, 2024.
Milind Khangan, Marketing Manager, Vertex Market Research & Consulting, says, “Efficient and enclosed handling of fine materials such as cement, fly ash and slag requires modern pneumatic conveying systems. By optimising the air-to-material ratio, these systems can reduce energy consumption by 10 per cent to 15 per cent while ensuring smooth material flow. Closed-loop conveying further minimises dust loading and improves the performance of bag filters, supporting cleaner plant operations. In addition, flow-regulated conveying lines help prevent clogging and maintain reliable dispatch performance. Overall, automation in pneumatic conveying delivers immediate operational benefits, including improved equipment uptime, lower energy use, reduced material spillage and more stable kiln and mill performance.”
Pipe conveyor systems are particularly gaining traction because they provide a completely enclosed transport system that prevents material spillage and dust emissions. According to global cement engineering studies, conveyor-based transport can reduce energy consumption by up to 30 per cent compared to truck haulage, while also improving operational reliability. Several cement plants in India have already implemented such systems to stabilise quarry-to-plant logistics while reducing carbon emissions associated with diesel transport.

Stockyard management and homogenisation
Stockyards play a critical role in maintaining raw material consistency and stabilising kiln feed quality. Modern cement plants use advanced stacker and reclaimer systems to ensure efficient storage and blending of raw materials before they enter the grinding and pyroprocessing stages. Automated stacking methods such as chevron or windrow stacking enable uniform distribution of materials, while bridge-type or portal reclaimers ensure consistent extraction during kiln feed preparation. These systems are essential for maintaining stable chemical composition of raw meal, which directly influences kiln efficiency and clinker quality. The Cement Plant Operations Handbook, 2024 indicates that advanced homogenisation systems can reduce raw mix variability by up to 50 per cent, significantly improving kiln stability and energy efficiency. Integrated stockyard management systems also incorporate sensors for monitoring bulk density, moisture levels and stockpile volumes, enabling real-time control over material blending processes.

Clinker and cement conveying technologies
Once clinker is produced in the kiln, it must be efficiently transported to storage silos and subsequently to grinding and packing units. Modern cement plants rely on high-capacity belt conveyors, bucket elevators and pneumatic conveying systems to manage this stage of material flow. Steel-cord belt bucket elevators are now capable of lifting materials to heights exceeding 120 metres with capacities reaching 1,500 tonnes per hour, making them suitable for large-scale clinker production lines, states the European Cement Engineering Association Technical Paper, 2023.
For fine materials such as cement, fly ash and slag, pneumatic conveying systems provide a reliable and dust-free solution. These systems transport powdered materials using controlled airflow, ensuring enclosed and contamination-free movement between grinding units, silos and packing stations. Optimised pneumatic systems can reduce energy consumption by 10 per cent to 15 per cent compared to older conveying technologies, while also improving plant cleanliness and environmental compliance, according to the Global Cement Technology Review, 2024.

Automation and digitalisation
Digitalisation is transforming material handling systems by introducing real-time monitoring, predictive maintenance and automated control. Advanced sensors and Industrial Internet of Things (IIoT) platforms enable plant operators to track conveyor health, stockpile levels and equipment performance in real time. Predictive maintenance systems analyse vibration patterns, temperature fluctuations and equipment load data to detect potential failures before they occur. According to McKinsey’s Industry 4.0 Manufacturing Report, 2023, for heavy industries, digital monitoring and predictive maintenance technologies can reduce equipment downtime by up to 30 per cent and increase productivity by 10 per cent to 15 per cent. Digital control centres also integrate data from conveyors, stacker reclaimers and dispatch systems, enabling centralised management of material flows from quarry to dispatch.

Handling of AFR
The growing adoption of Alternative Fuels and Raw Materials (AFR) has introduced new challenges and opportunities for material handling systems in cement plants. AFR materials such as refuse-derived fuel (RDF), biomass and industrial waste often have irregular particle sizes, variable moisture content and lower bulk density compared to conventional fuels. As a result, specialised storage, dosing and feeding systems are required to ensure consistent kiln combustion. According to the Cement Sector Decarbonisation Roadmap published by NITI Aayog in 2026, increasing the use of AFR could enable India’s cement sector to achieve thermal substitution rates of around 20 per cent in the coming decades. To support this transition, plants are investing in automated receiving stations, shredding units, drying systems and precision dosing equipment to stabilise AFR supply and combustion performance.

Energy efficiency and dust control
Material handling systems also play a crucial role in improving plant energy efficiency and environmental performance. Modern conveyor systems equipped with variable speed drives and energy-efficient motors can significantly reduce electricity consumption. Permanent magnet motors used in conveyor drives can deliver 8 per cent to 12 per cent energy savings compared to conventional induction motors, improving overall plant energy efficiency according to the IEA Industrial Energy Efficiency Study, 2023. Dust control is another major concern in cement plants, particularly during material transfer and storage operations. Enclosed conveyors, dust extraction systems and advanced bag filters are widely used to minimise particulate emissions and improve workplace safety.

Future trends in material handling
The future of material handling in cement plants will be shaped by automation, digitalisation and sustainability considerations. Emerging technologies such as AI-driven logistics optimisation, autonomous mobile equipment and digital twins are expected to further improve plant efficiency and operational visibility. Digital twin models allow engineers to simulate material flow patterns, optimise stockyard operations and predict equipment performance under different operating conditions. According to the International Energy Agency Digitalisation and Energy Report, 2024, the adoption of advanced digital technologies could improve industrial energy efficiency by up to 20 per cent in heavy industries such as cement manufacturing. As cement plants expand capacity and adopt low-carbon technologies, intelligent material handling systems will play a critical role in maintaining productivity and reducing environmental impact.

Conclusion
Material handling systems have evolved from basic transport infrastructure into strategic operational systems that directly influence plant efficiency, reliability and sustainability. From quarry transport and automated stockyards to digital dispatch platforms and advanced conveying technologies, modern material handling solutions enable cement plants to manage large production volumes while maintaining process stability.
As India’s cement industry continues to expand to meet infrastructure and urban development demands, investments in advanced material handling technologies will become increasingly important. By integrating automation, digital monitoring and energy-efficient systems, cement manufacturers can improve operational performance while supporting the industry’s long-term sustainability and decarbonisation goals.

Kanika Mathur

Concrete

Modernise to Optimise

Published

1 day ago

March 18, 2026

admin

Cement plant modernisation is reshaping the industry through upgrades in
kilns, energy systems, digitalisation, AFR integration and advanced material
handling. We explore these technologies that improve efficiency, reduce
emissions, strengthen competitiveness, while preparing the industry for India’s
next phase of infrastructure growth.

India’s cement industry, the world’s second-largest, is undergoing a rapid transformation driven by infrastructure demand, decarbonisation targets and technological advancement. The sector’s installed capacity stood at approximately 668 million tonnes per annum (mtpa) in FY2025 and is projected to reach 915–925 mtap by 2030, supported by large-scale capacity expansions and infrastructure investment cycles, suggests CRISIL Intelligence Industry Report, 2025. At the same time, cement production remains highly energy intensive and contributes about 6 per cent to 7 per cent of India’s total greenhouse gas emissions, making efficiency improvements and modernisation critical for long-term sustainability as stated in CareEdge ESG Research, 2025. As a result, cement manufacturers are investing in advanced kiln technologies, digital monitoring systems, waste heat recovery, alternative fuels, and modern material handling infrastructure to enhance productivity while aligning with global decarbonisation pathways.

Need for modernisation
The need for plant modernisation is closely linked to the sector’s rapid capacity expansion and rising operational complexity. India’s installed cement capacity has grown significantly in the last decade and is expected to exceed 900 mtpa by 2030, driven by demand from housing, infrastructure and urban development projects, as per the CRISIL Intelligence Industry Report, 2025. However, increasing scale also places pressure on energy efficiency, logistics, and production stability. The report also suggests that the cement plants must upgrade equipment and processes to operate at higher utilisation rates, which are projected to reach 75 per cent to 77 per cent by the end of the decade, compared to around 72 per cent to 74 per cent in FY2026.
Environmental imperatives are another major driver of modernisation. Cement manufacturing is responsible for a significant share of industrial emissions because clinker production requires high-temperature processes that depend heavily on fossil fuels. According to CareEdge ESG research, the cement sector contributes 6–7 per cent of India’s total greenhouse gas emissions, with approximately 97 per cent of emissions arising from direct fuel combustion and process emissions in kilns. Consequently, plant modernisation initiatives now focus not only on productivity improvements but also on reducing emissions intensity, energy consumption, and reliance on conventional fuels.
“One of the most impactful upgrades implemented at Shree Cement in the last five years has been the adoption of advanced data management platforms that provide real-time visibility across major process areas. This digital advancement has strengthened plant automation by enabling faster and more accurate responses to process variations while improving the reliability of control loops. Real-time dashboards, integrated analytics and automated alerts now support quicker, data-driven decision-making, helping optimise kiln and mill performance, improve energy control and detect deviations early. By consolidating data from multiple systems into a unified digital environment, the company has enhanced operational consistency, reduced downtime and improved both productivity and compliance. This shift towards intelligent automation and real-time data management has become a key driver of operational excellence and future-ready plant management,” says Satish Maheshwari, Chief Manufacturing Officer, Shree Cement.

Kiln and pyroprocessing upgradation
The kiln remains the technological heart of cement manufacturing, and modernisation efforts often begin with upgrades to pyroprocessing systems. Many older plants in India operate with four- or five-stage preheaters, while modern plants increasingly adopt six-stage preheater and pre-calciner systems that significantly improve heat efficiency and clinker output. These systems enhance heat transfer, reduce fuel consumption, and stabilise kiln operations under high throughput conditions.
Professor Procyon Mukherjee suggests, “Cement manufacturing is, at its core, a thermal process. The rotary kiln and calciner together account for energy consumption and emissions. The theoretical thermal requirement for clinker production is around 1700–1800 MJ per tonne, yet real-world plants often operate far above this benchmark due to inefficiencies in combustion, heat recovery and material flow. Modernisation, therefore, must begin with the
kiln system, and not peripheral automation or
isolated upgrades. The shift from wet to dry process kilns, combined with multi-stage preheaters and precalciners, has already delivered step-change improvements, making dry kilns nearly 50 per cent more energy efficient.”
Recent investment programmes across the industry have included kiln cooler upgrades, advanced burners, and improved refractory materials designed to increase operational reliability and reduce specific heat consumption. Such upgrades are essential because cement production remains highly energy intensive, and continuous efficiency improvements are required to meet global decarbonisation targets. According to the International Energy Agency (IEA) Cement Tracking Report, 2023, the cement sector must achieve annual emissions intensity reductions of around 4 per cent through 2030 to align with global net-zero scenarios.

Energy efficiency and WHRS
Energy efficiency remains one of the most important areas of modernisation in cement manufacturing, given the sector’s heavy reliance on thermal and electrical energy. Modern plants deploy advanced process controls, efficient grinding systems, and improved combustion technologies to reduce specific energy consumption. The adoption of energy-efficient technologies is particularly important in India, where energy costs account for a large share of production expenses. As demand grows and plants expand capacity, improving energy performance becomes essential to maintain competitiveness.
Waste Heat Recovery Systems (WHRS) have emerged as a key solution for improving plant energy efficiency. During cement production, large volumes of high-temperature gases are released from kilns and coolers. WHRS technology captures this waste heat and converts it into electricity, thereby reducing reliance on external power sources. According to energy benchmarking studies for the Indian cement industry, installed waste heat recovery capacity in the sector has reached approximately 840 MW, with an additional potential of around 500 MW states the Green Business Centre, Energy Benchmarking Report, 2023. Several leading producers have already implemented large WHRS installations; for example, UltraTech Cement has deployed systems with around 121 MW of waste heat recovery capacity, reducing carbon emissions by nearly 0.5 million tonnes annually according to the Energy Alternatives India Case Study, 2024.

Integration of AFR
The integration of Alternative Fuels and Raw Materials (AFR) is another critical dimension of cement plant modernisation. AFR refers to the use of industrial waste, biomass, refuse-derived fuel (RDF), and other non-fossil materials as substitutes for conventional fuels such as coal and petcoke. Increasing the use of AFR helps reduce fossil fuel consumption while simultaneously addressing waste management challenges. According to the NITI Aayog Decarbonisation Roadmap, 2026, scaling the use of RDF and other alternative fuels could enable the sector to achieve thermal substitution rates of around 20 per cent in the coming decades.
However, integrating AFR requires significant plant modifications and operational adjustments. Waste-derived fuels often have inconsistent calorific values, higher moisture content, and heterogeneous physical properties compared to traditional fuels. As a result, modern plants invest in advanced fuel preparation systems, dedicated feeding equipment, and automated dosing technologies to ensure stable kiln operation. These upgrades allow plants to maintain consistent clinker quality while increasing the share of alternative fuels in their energy mix.

Digitalisation and smart plant operations
Digitalisation is rapidly transforming cement plant operations by enabling data-driven decision-making and predictive maintenance. Industry 4.0 technologies such as IoT sensors, artificial intelligence (AI), and advanced analytics are now used to monitor equipment performance, optimise process parameters, and anticipate maintenance requirements. These digital tools enable plant operators to detect early signs of equipment failure, minimise unplanned downtime, and improve operational efficiency. Predictive maintenance systems, for example, analyse vibration, temperature, and acoustic signals from rotating equipment to identify potential faults
before they escalate into major breakdowns. Digital twins and integrated control systems further allow operators to simulate plant performance under different scenarios and optimise production strategies. Such technologies are becoming increasingly important as cement plants operate at larger scales and higher levels of process complexity.
Maheshwari also adds, “Plant modernisation is also increasingly central to the global competitiveness of Indian cement manufacturers. As cost pressures rise across energy, logistics and regulatory compliance, modern plants offer the structural efficiency required to operate reliably and competitively over the long term. Technologies such as AI-driven Advanced Process Control (APC) integrated with real-time data systems are emerging as essential investments for the future. These platforms use predictive algorithms, machine learning and live process inputs to optimise kiln, mill and utility operations with greater precision than traditional control systems. By continuously analysing variations in feed chemistry, temperature profiles, energy demand and equipment behaviour, APC enables stable operations, lower specific energy consumption, reduced emissions and improved product consistency. As regulatory expectations tighten and plants pursue higher efficiency with lower carbon intensity, AI-enabled APC will play a crucial role in strengthening automation, enhancing decision-making and ensuring long-term operational resilience.”

Modern material handling and logistics
Material handling systems play a critical role in ensuring smooth plant operations and efficient logistics. Modern cement plants rely on advanced conveying systems, automated stockyards, and digital dispatch platforms to manage the movement of raw materials, clinker, and finished cement. Long-distance belt conveyors and pipe conveyors are increasingly replacing truck-based transport between quarries and plants, reducing fuel consumption, dust emissions, and operational costs. Automated stacker-reclaimers ensure consistent blending of raw materials,
which improves kiln stability and clinker quality. Meanwhile, advanced packing and dispatch systems equipped with high-speed rotary packers and robotic palletisers enhance throughput and reduce manual labour. These technologies allow cement plants to optimise logistics efficiency while supporting higher production capacities.

Emission control and environmental compliance
Environmental compliance has become a central focus of cement plant modernisation as regulators and investors place greater emphasis on sustainability performance. Modern plants deploy advanced emission control technologies such as high-efficiency bag filters, electrostatic precipitators, and selective non-catalytic reduction systems to reduce particulate matter and nitrogen oxide emissions.
Sine Bogh Skaarup, Vice President, Head of Green Innovation and R&D, Fuller Technologies says, “One of our key focus areas is decarbonisation. We help cement producers reduce CO2 and overall carbon emissions. We offer alternative fuel solutions and calcined clay technologies to enable the production of LC3 cement, which play a significant role in decarbonising the cement industry. By combining alternative fuels and calcined clay solutions, CO2 emissions can be reduced by up to 50 per cent, making this a highly impactful approach for sustainable cement production.”
Continuous emission monitoring systems are increasingly used to track environmental performance in real time and ensure compliance with regulatory standards. In addition to air pollution control, cement companies are also investing in water recycling systems, renewable energy integration, and carbon reduction initiatives. These measures are essential for aligning the sector with national climate goals and improving the environmental footprint of
cement manufacturing.

Economic benefits and future outlook
Beyond environmental and operational advantages, cement plant modernisation also delivers significant economic benefits. Energy efficiency improvements, digital process optimisation, and advanced material handling systems reduce operating costs and improve asset utilisation. Waste heat recovery and alternative fuels help lower fuel expenditure and reduce exposure to volatile fossil fuel markets. As the industry expands capacity to meet growing demand, modernised plants are better positioned to achieve higher productivity and maintain profitability. The long-term outlook for the sector remains positive, with India expected to continue large-scale infrastructure investments in roads, housing, railways, and urban development.
Milan R Trivedi, Vice President – Projects, Prod & QC, MR, Shree Digvijay Cement, says, “The main focus in case of modernisation projects drives through the investment decision, which is mainly based on IRR and impact on overall efficiency improvement, cost optimisation and improvement in reliability. However, there are certain modernisation, which has high impact on environmental impact, statutory requirements, etc. has higher priority irrespective of ROI or payback period.”
“The energy efficiency and reliability investment projects generally provide fast return on investment whereas strategic, digitalisation and environmental investment projects provide long term and compounded benefits. Typical modernisation investment projects are decided with IRR of about > 20 per cent, payback period of typically 2-3 years for fast-track projects,” he adds.
In this context, modernisation will remain a key strategic priority for cement manufacturers seeking to maintain competitiveness in an increasingly sustainability-focused market.

Conclusion
The modernisation of cement plants is no longer a purely technical upgrade but a strategic transformation that reshapes how the industry operates. As India’s cement sector expands capacity toward the next growth cycle, improvements in energy efficiency, digitalisation, alternative fuels and advanced logistics will determine the competitiveness of individual plants. Modern technologies allow producers to operate at higher productivity levels while simultaneously reducing energy consumption and emissions intensity.
Looking ahead, the pace of technological adoption will play a decisive role in shaping the future of
the cement industry. Companies that successfully integrate modern equipment, digital systems, and sustainable production practices will be better positioned to meet rising infrastructure demand while aligning with global climate commitments. In this evolving landscape, plant modernisation stands as the cornerstone of both operational excellence and environmental responsibility.

Kanika Mathur

Concrete

Building a Sustainable Future

Published

1 day ago

March 18, 2026

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Fuller Technologies (erstwhile FLSmidth Cement) presents a case study of Shree Cement’s Nawalgarh Plant.

Shree Cement achieved a new milestone and broke a world record in December 2023 when it started its new Nawalgarh plant in Rajasthan. The plant boasts both India’s largest OK® Mill and the world’s largest pyro line, which is rated at 11,500 tpd but achieving at more than 13 500 tpd. It put Shree Cement on track to exceed their target of 80 million tpa cement capacity in India by 2028. Shree Cement chose to partner with Fuller Technologies (then FLSmidth Cement) for the project, since the two groups share such similar values and Fuller offers a portfolio of solutions geared towards reducing the cement industry’s environmental impact.
Cement plays a vital role in India’s development, supporting the country’s ambitions for long-term economic growth. As urbanisation accelerates, infrastructure projects like Smart Cities, Bharat Mala, and metro rail developments are driving steady demand for cement. With per capita consumption increasing however historically lower than global averages, India’s evolving urban landscape and infrastructure needs are expected to significantly boost cement demand in the years ahead.
Shree Cement is well positioned to support India’s growth and is playing a pivotal role in the country’s expansive infrastructure development. The Nawalgarh plant will supply the wider region of north India with cement and clinker, feeding 3/4 grinding plants in the area.

The new Nawalgarh plant
With easy access to a rich supply of raw materials, Nawalgarh was an obvious choice for Shree Cement’s newest cement plant. With abundant reserves of limestone, the region also boasts strategic access to cement markets in northern India.
Though water scarcity is an issue in the region, the plant was committed to using modern, water-efficient technologies, ensuring minimal water consumption and waste. For example, the OK Mill™ can be operated without water, making it an optimal solution in regions where conserving water is particularly important.
Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, says, “We have significantly invested in alternative fuels – including hazardous waste, municipal solid waste (RDF) and biomass – to reduce fossil fuel reliance. Our new state-of-the-art solid waste feeding system for MSW is operational at one site and is being replicated at others, enhancing alternative fuel use and improving thermal substitution in kilns.” The plant also follows Shree Cement’s principal of reducing clinker content in blended cements, which aims to reduce the carbon footprint of Shree Cement products.

The world’s biggest pyro line
The project kicked off with the issuance of the Letter of Intent (LOI) on 15th September 2021 for the Raw Mill. As per the LOI, equipment was expected to be delivered within 8-13 months from the contract’s effective date. The first lot of the raw mill arrived on-site in May 2022, with the major consignment – the Grinding Table – delivered in February 2023. Civil work for the Raw Mill and its building began in May 2022 and was completed by January 2023. Fabrication was wrapped up by June 2023 and erection commenced in January 2023, concluding by September 2023. The final commissioning was successfully completed on 14th December 2023, marking the operational start of the mill.

The world’s largest clinker cooler
The Cross-Bar® Cooler at Nawalgarh is the largest in the world, with a grate area of 325 m2 and a throughput guaranteed at 11 500 tpd, though it has been running at around 13 500 tpd since commissioning. Offering both high throughput and highly stable operation, the cooler also contributes to Shree Cement’s sustainability goals thanks to its hot air recirculation, which generates about 8 MW through the waste heat recovery system.
“With a Cross-Bar Cooler, the bigger you go, the greater your efficiency gains,” says Gowrishankar Ramachandran, Senior Product Specialist, Fuller Technologies. “We were not concerned about the size of the project – we knew we could achieve the performance guarantees with ease. Start-up was paced to get the full pyro system up and running smoothly, starting at 5000 tpd and quickly ramping up to full capacity and then beyond. The combination of features ensures smooth operation whatever’s going on in the kiln and preheater, meaning the cooler is unphased by the introduction of new alternative fuels or variations in throughput.”
Featuring patented ABC Inlet technology, which ensures no build-up in the cooler, Shree Cement also benefit from the cooler’s Heavy Duty Roller Breaker (HRB) and Mechanical Flow Regulators (MFRs) to improve reliability and uptime.
• The ABC™ Inlet uses a patented in-grate design that pushes compressed air up through the grates, blasting agglomerations. Pressure sensors detect when build-up is starting to occur and the automated blast control system reacts accordingly, increasing blast frequency to disperse the clinker and prevent further buildup.
• The HRB can handle clinker boulders up to 1.5 m without blockages. It features a series of transport and crushing rollers that allow right-sized materials to pass through and crush larger materials down to a pre-set size. Its low speed contributes to a long wear life of 3-5 years, while the rollout design enables easy maintenance.
• MFRs control airflow across the whole clinker bed – irrespective of clinker bed height, particle size, distribution or temperature. This optimises heat recuperation and air distribution, reducing both fuel costs and the number of cooling
fans required.
This cooler is a ventless system, with hot air being recirculated back into the cooler instead of bringing in ambient air. This improves the WHR temperature and boosts the power generated through the system. With waste heat recovery from the preheater in addition to the cooler, the total power generated is around 15-18 MW.
Though the operation has the potential for high dust pickup, the cooler casings were enlarged so that dust pickup is less than 4 m/s. This reduces dust to the tertiary air duct and helps reduce the environmental impact of the cooler operation, as well as the wear and safety issues that come with dust settling on equipment and on the local environment.
The cooler is part of the world’s largest pyro system, with a guaranteed capacity of 11 500 tpd (with an achieved production of 13 695 tpd),
that includes:
• Four string pre-heater:
o Cyclone stage I: 7784 mm, Top (HR+)
o Cyclone stage II: 7984 mm
o Cyclone stage III-VI: 8180 mm with Low Nox Calciner
• Dia 6.0m x 88m long & 3 support kiln with forged tyres
• JETFLEX® 2.0 kiln burner (type standard
and plus)
• 2 x 750 tph PFISTER® FRW Rotor Weighfeeder 5.22/13 for Kiln feed and 6 x PFISTER® Smart Linear Feeder
The Fuller® Low NOx Calciner prevents the build-up of raw meal on the calciner walls and maintains a hot core for excellent combustion and NOx reduction. With a design based on extensive research, field tests and CFD modelling, the Low NOx calciner is capable of burning almost any fuel type, giving Shree Cement full flexibility to switch between coal, petcoke and alternative fuels. The calciner has the added advantage of reducing NOx while also minimising the need for ammonia injection, creating a cleaner, greener, more cost-effective process.
The JETFLEX burner was chosen for its high degree of fuel flexibility, further aiding Shree’s green ambitions. The burner can burn a mix of coal, petcoke, oil, natural gas and alternative fuels while maintaining an optimal flame shape. The flame formation is controlled by separate systems for axial and swirl air, ensuring fast ignition and stable flame formation with a shorter and more intense flame. That reduces volatility in the kiln and gives the Nawalgarh plant greater efficiency throughout the pyroprocess.

India’s biggest OK Mill
The OK Mill 66.6 selected as the raw mill for this plant is the largest OK raw mill in the country with a guaranteed capacity of 1070 tph, though it has been running at 1080 tph since commissioning. The OK Mill was selected for its proven history of efficiency, low water usage and ease of maintenance. The rollers can be swung out for repair or hard-facing so that operation can continue with the remaining rollers, enabling continuous productivity. The OK-R-66-6 VRM for this plant includes a RARM-1300 separator, known for the simplicity of its design, which reduces wear and maintenance, lowers differential pressure and reduces mill fan power (and thus operational costs) while still providing efficient separation.
This is not the only OK Mill at the Nawalgarh plant. An OK 66-6 finish mill with ROKSH-1100 classifier is employed for cement grinding at 360 tph. In addition, the plant has an ATOX® 32.5 coal mill with RAKM-32.5 classifier for coal grinding, guaranteed at 46 tph but running at 56 tph.

Energy efficiency and saving
“Energy conservation remains a top priority for us, driving innovations from shop-floor experiments to major capital investments,” explains Maheshwari. “These efforts have reduced carbon emissions and production costs. Over 55 per cent of our energy needs across the company are met through green energy sources, including solar and wind power alongside our Waste Heat Recovery Systems. Combined, these systems produce in excess of 520 MW. We consistently exceed PAT Cycle targets and have been honoured as ‘Best Performer’ for the highest number of energy-saving certificates in both PAT Cycle I and II by the Bureau of Energy Efficiency.”

A digital native
Shree Cement is an advocate of the benefits and necessity of digitalisation to improve cement plant performance and efficiency. A few years ago, the company rolled out ECS/PlantDataManagement across 16 plants and 24 lines in a huge digital upgrade to drive efficiency and increase productivity. The new Nawalgarh plant won’t require a digital transformation, however, because it has been built as a digital native.
It is equipped with ECS/PlantDataManagement, which delivers all plant and process data in accessible and practical forms to plant managers and operators, maintenance teams, analysts, and decision-makers, giving them the insights necessary to optimise production lines, minimise equipment downtime, improve productivity and reduce environmental impact. ECS/PlantDataManagement includes important tools like UptimeGo, the downtime analysis solution, and SiteConnect, the mobile app that allows plant operators and managers to view real-time plant data anytime, anywhere from a mobile device.
The plant is also utilising advanced automation solutions across the plant, including in the laboratory where Fuller is enabling clinker substitution while ensuring optimal cement quality. QCX/RoboLab® is a high-tech robotics solution for automated sample preparation, analysis, and automated quality assurance (QA) and quality control (QC) procedures. This advanced automation system ensures fast, accurate, and safe analysis with as few operators as possible. It receives and co-ordinates samples from the QCX®/AutoSampling system and can take on challenging laboratory tasks to ensure optimal quality control in the face of variations in alternative fuels and changes to the cement mix. Again, this was a choice Shree Cement made to ensure the plant has the flexibility to deliver lower carbon cements without compromising on final product quality.

Conclusion
In December 2024, Shree Cement celebrated the first anniversary of the Nawalgarh plant. The plant’s rapid rise as a leading player in cement production aligns with the global position of this impressive company, whose strategic initiatives in alternative fuels, emissions reduction and water management have earned industry-wide recognition, including the acclaimed position of ‘industry mover’ in the construction materials category of the S&P Global Sustainability Yearbook 2025.
Shree Cement’s focus on blended cement production successfully lowered natural resource consumption and CO2 emissions by 7.2 million tonnes in FY23-24, with 73.52 per cent of total production comprising blended cement with an average clinker-to-cement ratio of 64.66 per cent.
“Partnering with a solutions provider like Fuller enables us to turn our sustainability ambitions into reality,” says Maheshwari. “Together we are shaping the future of our industry and our region, and we are very proud of the contributions we are making towards a more sustainable cement industry and greater economic prosperity.”