Economy & Market

Stepping Up Sustainability

Published

1 year ago

November 23, 2024

Roshna

Supplementary Cementitious Materials (SCMs) offer a sustainable way to reduce cement usage, enhance concrete durability and lower the environmental impact of construction. ICR discusses integrating industrial byproducts like fly ash and slag as SCMs support resource conservation, cost savings, and long-lasting infrastructure.

The construction industry is at a pivotal juncture, facing increasing pressure to adopt sustainable practices amidst growing environmental concerns. As a major contributor to global greenhouse gas emissions, the industry recognises the urgent need for innovative solutions to minimise its ecological footprint. One such solution is the use of Supplementary Cementitious Materials (SCMs), which have emerged as vital components in the quest for sustainable concrete production. SCMs not only reduce the reliance on Portland cement—one of the most significant contributors to carbon emissions in construction—but also enhance the performance and durability of concrete.
According to a research report published by Spherical Insights & Consulting, the Global Supplementary Cementitious Materials Market Size is Expected to Grow from USD 25.40 Billion in 2023 to USD 47.70 Billion by 2033, at a CAGR of 6.50 per cent during the forecast period 2023-2033. Asia Pacific is estimated to hold the largest share of the supplementary cementitious materials market over the forecast period.
The market for supplementary cementitious materials is experiencing rapid growth, driven by factors such as rapid/fast-paced urbanisation and infrastructure development in emerging economies like China, India, Malaysia, and Singapore. Supportive policies and regulations, coupled with rising demand for durable concrete with lower penetrability, are key drivers impelling the surge in demand for supplementary cementitious materials.

Understanding SCMs
SCMs are materials that can be used to replace a portion of Portland cement in concrete. They react with calcium hydroxide to form additional cementitious compounds, thereby enhancing the concrete’s properties. SCMs include a variety of materials, such as fly ash, ground granulated blast-furnace slag (GGBS), silica fume and natural pozzolans.

Fly ash: Fly ash is a byproduct from burning pulverised coal in electric power generating plants. It is collected from the flue gases and is commonly used in concrete due to its pozzolanic properties. Fly ash can improve workability, reduce water demand, and enhance long-term strength and durability. Its fine particles fill voids within the concrete matrix, resulting in a denser and more impermeable material.
In an authored article by Dr Supradip Das, Vice Chairman, CED 41 (BIS), for NBM&CW, he points out that compared to cement and water, the chemical reaction between fly ash and calcium hydroxide occurs at a slower pace, leading to a delayed setting time in concrete, which promotes enhanced hardening. He explains how this slower hardening, together with the varying properties of fly ash, can present substantial challenges in concrete production. In India, ash ponds currently occupy approximately 65,000 acres, and fly ash production is projected to exceed 235 million tonnes by 2024, he elaborates.
GGBS: This material is obtained by rapidly cooling molten iron slag from a blast furnace with water or steam. GGBS is known for its high strength and durability, particularly in aggressive environments where concrete is exposed to chlorides or sulphates. It not only enhances the concrete’s mechanical properties but also contributes to its resistance to corrosion and shrinkage.
Silica fume: Silica fume is a byproduct of the production of silicon metal or ferrosilicon alloys. It is extremely fine, with a particle size much smaller than that of cement. When added to concrete, silica fume significantly increases strength, reduces permeability, and enhances durability. Its high silica content promotes additional pozzolanic reactions, leading to a denser concrete matrix.
Natural pozzolans: Natural pozzolans, such as volcanic ash and pumice, have been used in construction for centuries. They react with calcium hydroxide in the presence of moisture to form compounds with cementitious properties. These materials are particularly valuable in regions where volcanic ash is abundant, as they are sustainable alternatives that can improve concrete’s performance.

Benefits of Using SCMs
The incorporation of SCMs into concrete mixtures offers numerous benefits that align with sustainable construction practices:

Enhanced durability: Concrete containing SCMs exhibits improved durability characteristics, including increased resistance to sulfate attack, reduced permeability, and enhanced longevity. This durability translates into lower maintenance costs and longer service life for structures.
Reduced carbon footprint: The use of SCMs significantly decreases the amount of Portland cement required in concrete. As cement production is responsible for approximately 8 per cent of global CO2 emissions, reducing its usage through SCMs can lead to substantial reductions in greenhouse gas emissions.
Improved workability: SCMs like fly ash improve the workability of fresh concrete, making it easier to place and finish. This can lead to enhanced productivity on construction sites and reduced labour costs.
Cost-effectiveness: By substituting a portion of cement with SCMs, construction projects can achieve cost savings. Fly ash and GGBS, being industrial byproducts, are often more affordable than Portland cement.
Waste Utilisation: The use of SCMs promotes recycling and waste reduction. By utilising industrial byproducts such as fly ash and slag, the construction industry can contribute to a circular economy.

Vimal Joshi, Assistant General Manager – Quality Control, Wonder Cement, says, “SCMs like fly ash, slag and silica fume significantly enhance the durability and strength of concrete, particularly under diverse environmental conditions. Fly ash improves workability and extends the setting time, making it ideal for mass concrete projects and hot climates. The fine particles fill voids in the cement matrix, reducing permeability and enhancing resistance to sulphate and chloride attack, thus increasing durability. Slag, with its slow hydration properties, improves long-term strength and is particularly effective in reducing thermal cracking in massive concrete structures. It also enhances resistance to aggressive chemicals, making it suitable for marine environments and industrial applications.”
“Silica fume, known for its ultrafine particles, increases the density of concrete, boosting both compressive strength and durability, especially in harsh environments. By incorporating SCMs, we create concrete that is more resilient to environmental stressors, ensuring longer-lasting structures with reduced maintenance needs” he adds.

Sustainable construction
Sustainable construction practices are increasingly prioritised due to their environmental, social and economic impact. SCMs play a pivotal role in this paradigm shift. By integrating SCMs into concrete production, the construction industry can achieve:

Reduced resource consumption: By minimising the reliance on virgin materials, SCMs contribute to the conservation of natural resources. This is particularly important in regions where natural aggregates and raw materials are scarce.
Promotion of circular economy: The use of byproducts like fly ash and slag exemplifies a circular economy approach, where waste materials are repurposed for new applications. This not only reduces landfill waste but also promotes sustainable sourcing practices.
Alignment with green building certifications: Many green building rating systems, such as LEED (Leadership in Energy and Environmental Design), encourage the use of SCMs. By incorporating these materials, projects can earn credits for sustainability, making them more appealing to environmentally conscious clients.

Tushar Khandhadia, General Manager – Production, Udaipur Cement Works, says, “SCMs provide an environmentally friendly alternative to traditional Portland cement by reducing the amount of clinker required to produce cement. Clinker is the main ingredient in Portland cement and is produced by heating limestone and other raw materials to high temperatures, which releases significant GHG emissions. Thus, by using SCMs, less clinker is required, thereby reducing GHG emissions, energy use and the environmental impact of cement production. Some SCMs such as fly ash and slag are by-products of other industrial processes, meaning that their use in cement production reduces waste and enhances resource efficiency. Moreover, the use of SCMs can enhance the properties of concrete, thereby increasing its durability and service life which helps to further reduce the overall embodied carbon of the structure.”

“In short, the use of SCMs contributes to reducing the carbon footprint of cement production by improving the efficiency of resource utilisation and reducing greenhouse gas (GHG) emissions during the production process. This has led to an increased demand for SCMs in the construction industry, as environmental concerns and sustainable development goals have become more prominent factors in the selection of building materials,” he adds.

Performance Characteristics of SCMs
The performance characteristics of concrete are significantly enhanced when SCMs are incorporated. Key attributes include:

Increased Compressive Strength: Studies have demonstrated that concrete containing SCMs, particularly silica fume and GGBS, can achieve higher compressive strengths compared to conventional concrete mixtures. This is crucial for high-performance applications, such as high-rise buildings and infrastructure.

Dr SB Hegde, Professor, Jain College of Engineering and Technology, Hubli, and Visiting Professor, Pennsylvania State University, USA states, “The raw mix plays a vital role in clinker formation. A high liquid phase due to improper ratios of silica, alumina, and iron oxide can lead to excessive melting. Controlling the silica modulus (SM: 2.3-2.7) and alumina modulus (AM: 1.3-1.8) ensures a more stable clinker and reduces the risk of red river formation. If the raw mix is improperly proportioned, red river formation becomes more likely due to high fluxing compounds that melt at lower temperatures. The occurrence of red river has numerous negative impacts on both clinker quality and kiln performance.”

Reduced permeability: SCMs improve the density of the concrete matrix, leading to reduced permeability. This characteristic is vital for structures exposed to harsh environmental conditions, as it minimises water ingress and subsequent damage.
Altered hydration kinetics: The presence of SCMs can influence the hydration process of cement, often resulting in a slower but more sustained release of heat. This is beneficial in mass concrete applications where heat buildup can lead to cracking.
Long-term strength development: Concrete containing SCMs typically exhibits improved long-term strength characteristics. While initial strength development may be slower, the overall strength continues to increase over time as the pozzolanic reactions progress.

Guidelines and Standards
The effective use of SCMs in concrete is governed by various guidelines and standards. In India, the Bureau of Indian Standards (BIS) has established specific specifications for the use of fly ash and GGBS in concrete.

IS 456:2000: This Indian Standard provides general guidelines for the use of SCMs in concrete and outlines performance requirements to ensure the quality of construction materials. Adherence to these standards is crucial for maintaining the integrity and performance of concrete.
IS 1489 (Part 1 and Part 2): These standards specifically address the use of fly ash and GGBS, providing criteria for their quality, chemical composition, and performance in concrete.

Following these guidelines ensures that SCMs contribute positively to concrete performance, supporting the construction of durable and sustainable structures.

Challenges in SCM Adoption
Despite their numerous advantages, several challenges hinder the widespread adoption of SCMs in India:

Quality variability: The quality of SCMs can vary significantly depending on their source and production methods. This variability can lead to inconsistencies in concrete performance, necessitating rigorous quality control measures.
Regulatory barriers: A lack of comprehensive regulations and standards for SCMs can impede their acceptance and use in construction projects. Greater clarity and uniformity in regulations would facilitate broader adoption.
Compatibility issues: Different types of cement and SCMs may not always be compatible, leading to challenges in mix design. It is essential to conduct thorough testing to ensure that the chosen SCMs integrate well with the cement used in a specific project.

Shreesh A Khadilkar, Consultant and Advisor, and Former Director Quality and Product Development, ACC says, “Clinkers with good reactivity are observed to show 1 Day strengths in lab ground cements of 30 to 35 MPa. Higher values being observed when clinker alkali sulphates are high (especially with Petcoke as fuel), the achieved Blaine’s and quantity of nibs removed from the lab ground cement, in the fixed grinding time is also indicative of clinker grindability. Judicious raw mix optimisation with existing or alternative corrective materials (with the fuel mix used by the plant) can be attempted so as to have a clinker with improved reactivity/hydraulic potential. In a running plant the approach has to be by attempting small gradual changes to clinker composition and assessing the impact of the changes, on kiln performance and clinker quantity.”
Awareness and training: There is a need for increased awareness and training among construction professionals regarding the benefits and proper use of SCMs. Educating stakeholders can drive their acceptance and utilisation.

Successful Applications of SCMs
Several projects across India have successfully demonstrated the benefits of using SCMs, showcasing their effectiveness in enhancing concrete performance while reducing environmental impact:

Delhi Metro Rail Corporation (DMRC): In the construction of the DMRC, high volumes of fly ash were used to produce concrete. This decision resulted in substantial cost savings, improved workability, and reduced environmental impact. The use of SCMs also contributed to the project’s overall sustainability goals.
Narmada River Valley Project: In this project, GGBS was incorporated into the concrete mix, enhancing the durability and longevity of structures exposed to the water-saturated environment. The use of GGBS ensured that the concrete could withstand the harsh conditions prevalent in the region, reducing maintenance needs and extending the service life of the structures.

These case studies illustrate the practical benefits of using SCMs in large-scale construction projects, reinforcing their viability as sustainable alternatives.

Future Trends in SCM Use
As the Indian cement industry evolves, several trends are expected to shape the future of SCM utilisation:

Innovations in materials: Research into new SCMs, such as bio-based materials and advanced pozzolans, is on the rise. These innovations may expand the range of materials available for sustainable concrete production, providing more options for construction professionals.
Increased awareness: Growing awareness among construction professionals about the benefits of SCMs is likely to drive their adoption. Workshops, seminars, and training programs can play a crucial role in educating stakeholders about proper mix design and applications.
Government support: Policymakers can promote the use of SCMs by offering incentives for sustainable construction practices. This can include subsidies, tax breaks, or recognition for projects that utilise SCMs, encouraging broader acceptance.
Technological advancements: Advances in technology may facilitate better quality control, enabling more consistent production of SCMs and improving their integration into concrete mixtures.

Conclusion
SCMs represent a vital component in the transition toward more sustainable concrete production. By incorporating these materials, the Indian cement industry can significantly reduce its carbon footprint, enhance concrete performance, and contribute to a circular economy. While challenges remain, the benefits of SCMs far outweigh the drawbacks, making them an essential element in the future of sustainable construction. As awareness grows
and innovations emerge, SCMs are poised to play an even more significant role in shaping a greener built environment.

– Kanika Mathur

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Economy & Market

Smart Pumping for Rock Blasting

Published

2 weeks ago

March 2, 2026

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SEEPEX introduces BN pumps with Smart Joint Access (SJA) to improve efficiency, reliability, and inspection speed in demanding rock blasting operations.
Designed for abrasive and chemical media, the solution supports precise dosing, reduced downtime, and enhanced operational safety.

SEEPEX has introduced BN pumps with Smart Joint Access (SJA), engineered for the reliable and precise transfer of abrasive, corrosive, and chemical media in mining and construction. Designed for rock blasting, the pump features a large inspection opening for quick joint checks, a compact footprint for mobile or skid-mounted installations, and flexible drive and material options for consistent performance and uptime.

“Operators can inspect joints quickly and rely on precise pumping of shear-sensitive and abrasive emulsions,” said Magalie Levray, Global Business Development Manager Mining at SEEPEX. “This is particularly critical in rock blasting, where every borehole counts for productivity.” Industry Context

Rock blasting is essential for extracting hard rock and shaping safe excavation profiles in mining and construction. Accurate and consistent loading of explosive emulsions ensures controlled fragmentation, protects personnel, and maximizes productivity. Even minor deviations in pumping can cause delays or reduce product quality. BN pumps with SJA support routine maintenance and pre-operation checks by allowing fast verification of joint integrity, enabling more efficient operations.

Always Inspection Ready

Smart Joint Access is designed for inspection-friendly operations. The large inspection opening in the suction housing provides direct access to both joints, enabling rapid pre-operation checks while maintaining high operational reliability. Technicians can assess joint condition quickly, supporting continuous, reliable operation.

Key Features

Compact Footprint: Fits truck-mounted mobile units, skid-mounted systems, and factory installations.
Flexible Drive Options: Compact hydraulic drive or electric drive configurations.
Hydraulic Efficiency: Low-displacement design reduces oil requirements and supports low total cost of ownership.
Equal Wall Stator Design: Ensures high-pressure performance in a compact footprint.
Material Flexibility: Stainless steel or steel housings, chrome-plated rotors, and stators in NBR, EPDM, or FKM.

Operators benefit from shorter inspection cycles, reliable dosing, seamless integration, and fast delivery through framework agreements, helping to maintain uptime in critical rock blasting processes.

Applications – Optimized for Rock Blasting

BN pumps with SJA are designed for mining, tunneling, quarrying, civil works, dam construction, and other sectors requiring precise handling of abrasive or chemical media. They provide robust performance while enabling fast, reliable inspection and maintenance.With SJA, operators can quickly access both joints without disassembly, ensuring emulsions are transferred accurately and consistently. This reduces downtime, preserves product integrity, and supports uniform dosing across multiple bore holes.

With the Smart Joint Access inspection opening, operators can quickly access and assess the condition of both joints without disassembly, enabling immediate verification of pump readiness prior to blast hole loading. This allows operators to confirm that emulsions are transferred accurately and consistently, protecting personnel, minimizing product degradation, and maintaining uniform dosing across multiple bore holes.

The combination of equal wall stator design, compact integration, flexible drives, and progressive cavity pump technology ensures continuous, reliable operation even in space-limited, high-pressure environments.

From Inspection to Operation

A leading explosives provider implemented BN pumps with SJA in open pit and underground operations. By replacing legacy pumps, inspection cycles were significantly shortened, allowing crews to complete pre-operation checks and return mobile units to productive work faster. Direct joint access through SJA enabled immediate verification, consistent emulsion dosing, and reduced downtime caused by joint-related deviations.

“The inspection opening gives immediate confidence that each joint is secure before proceeding to bore holes,” said a site technician. “It allows us to act quickly, keeping blasting schedules on track.”

Framework agreements ensured rapid pump supply and minimal downtime, supporting multi-site operations across continents

Concrete

Digital process control is transforming grinding

Published

3 weeks ago

February 20, 2026

admin

Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, delves into how digital intelligence is transforming cement grinding into a predictive, stable, and energy-efficient operation.

Grinding sits at the heart of cement manufacturing, accounting for the largest share of electrical energy consumption. In this interview, Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, explains how advanced grinding technologies, data-driven optimisation and process intelligence are transforming mill performance, reducing power consumption and supporting the industry’s decarbonisation goals.

How has the grinding process evolved in Indian cement plants to meet rising efficiency and sustainability expectations?
Over the past decade, Indian cement plants have seen a clear evolution in grinding technology, moving from conventional open-circuit ball mills to high-efficiency closed-circuit systems, Roller Press–Ball Mill combinations and Vertical Roller Mills (VRMs). This shift has been supported by advances in separator design, improved wear-resistant materials, and the growing use of digital process automation. As a result, grinding units today operate as highly controlled manufacturing systems where real-time data, process intelligence and efficient separation work together to deliver stable and predictable performance.
From a sustainability perspective, these developments directly reduce specific power consumption, improve equipment reliability and lower the carbon footprint per tonne of cement produced.

How critical is grinding optimisation in reducing specific power consumption across ball mills and VRMs?
Grinding is the largest consumer of electrical energy in a cement plant, which makes optimisation one of the most effective levers for improving energy efficiency. In ball mill systems, optimisation through correct media selection, charge design, diaphragm configuration, ventilation management and separator tuning can typically deliver power savings of 5 per cent to 8 per cent. In VRMs, fine-tuning airflow balance, grinding pressure, nozzle ring settings, and circulating load can unlock energy reductions in the range of 8 per cent to 12 per cent. Across both systems, sustained operation under stable conditions is critical. Consistency in mill loading and operating parameters improves quality control, reduces wear, and enables long-term energy efficiency, making stability a key operational KPI.

What challenges arise in maintaining consistent cement quality when using alternative raw materials and blended compositions?
The increased use of alternative raw materials and supplementary cementitious materials (SCM) introduces variability in chemistry, moisture, hardness, and loss on ignition. This variability makes it more challenging to maintain consistent fineness, particle size distribution, throughput and downstream performance parameters such as setting time, strength development and workability.
As clinker substitution levels rise, grinding precision becomes increasingly important. Even small improvements in consistency enable higher SCM utilisation without compromising cement performance.
Addressing these challenges requires stronger feed homogenisation, real-time quality monitoring and dynamic adjustment of grinding parameters so that output quality remains stable despite changing input characteristics.

How is digital process control changing the way grinding performance is optimised?
Digital process control is transforming grinding from an operator-dependent activity into a predictive, model-driven operation. Technologies such as online particle size and residue analysers, AI-based optimisation platforms, digital twins for VRMs and Roller Press systems, and advanced process control solutions are redefining how performance is managed.
At the same time, workforce roles are evolving. Operators are increasingly focused on interpreting data trends through digital dashboards and responding proactively rather than relying on manual interventions. Together, these tools improve mill stability, enable faster response to disturbances, maintain consistent fineness, and reduce specific energy consumption while minimising manual effort.

How do you see grinding technologies supporting the industry’s low-clinker and decarbonisation goals?
Modern grinding technologies are central to the industry’s decarbonisation efforts. They enable higher incorporation of SCMs such as fly ash, slag, and limestone, improve particle fineness and reactivity, and reduce overall power consumption. Efficient grinding makes it possible to maintain consistent cement quality at lower clinker factors. Every improvement in energy intensity and particle engineering directly contributes to lower CO2 emissions.
As India moves toward low-carbon construction, precision grinding will remain a foundational capability for delivering sustainable, high-performance cement aligned with national and global climate objectives.

How much potential does grinding optimisation hold for immediate energy
and cost savings?
The potential for near-term savings is substantial. Without major capital investment, most plants can achieve 5 per cent to 15 per cent power reduction through measures such as improving separator efficiency, optimising ventilation, refining media grading, and fine-tuning operating parameters.
With continued capacity expansion across India, advanced optimisation tools will help ensure that productivity gains are not matched by proportional increases in energy demand. Given current power costs, this translates into direct and measurable financial benefits, making grinding optimisation one of the fastest-payback operational initiatives available to cement manufacturers today.

Concrete

Refractory demands in our kiln have changed

Published

3 weeks ago

February 20, 2026

admin

Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, points out why performance, predictability and life-cycle value now matter more than routine replacement in cement kilns.

As Indian cement plants push for higher throughput, increased alternative fuel usage and tighter shutdown cycles, refractory performance in kilns and pyro-processing systems is under growing pressure. In this interview, Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, shares how refractory demands have evolved on the ground and how smarter digital monitoring is improving kiln stability, uptime and clinker quality.

How have refractory demands changed in your kiln and pyro-processing line over the last five years?
Over the last five years, refractory demands in our kiln and pyro line have changed. Earlier, the focus was mostly on standard grades and routine shutdown-based replacement. But now, because of higher production loads, more alternative fuels and raw materials (AFR) usage and greater temperature variation, the expectation from refractory has increased.
In our own case, the current kiln refractory has already completed around 1.5 years, which itself shows how much more we now rely on materials that can handle thermal shock, alkali attack and coating fluctuations. We have moved towards more stable, high-performance linings so that we don’t have to enter the kiln frequently for repairs.
Overall, the shift has been from just ‘installation and run’ to selecting refractories that give longer life, better coating behaviour and more predictable performance under tougher operating conditions.

What are the biggest refractory challenges in the preheater, calciner and cooler zones?
• Preheater: Coating instability, chloride/sulphur cycles and brick erosion.
• Calciner: AFR firing, thermal shock and alkali infiltration.
• Cooler: Severe abrasion, red-river formation and mechanical stress on linings.
Overall, the biggest challenge is maintaining lining stability under highly variable operating conditions.

How do you evaluate and select refractory partners for long-term performance?
In real plant conditions, we don’t select a refractory partner just by looking at price. First, we see their past performance in similar kilns and whether their material has actually survived our operating conditions. We also check how strong their technical support is during shutdowns, because installation quality matters as much as the material itself.
Another key point is how quickly they respond during breakdowns or hot spots. A good partner should be available on short notice. We also look at their failure analysis capability, whether they can explain why a lining failed and suggest improvements.
On top of this, we review the life they delivered in the last few campaigns, their supply reliability and their willingness to offer plant-specific custom solutions instead of generic grades. Only a partner who supports us throughout the life cycle, which includes selection, installation, monitoring and post-failure analysis, fits our long-term requirement.

Can you share a recent example where better refractory selection improved uptime or clinker quality?
Recently, we upgraded to a high-abrasion basic brick at the kiln outlet. Earlier we had frequent chipping and coating loss. With the new lining, thermal stability improved and the coating became much more stable. As a result, our shutdown interval increased and clinker quality remained more consistent. It had a direct impact on our uptime.

How is increased AFR use affecting refractory behaviour?
Increased AFR use is definitely putting more stress on the refractory. The biggest issue we see daily is the rise in chlorine, alkalis and volatiles, which directly attack the lining, especially in the calciner and kiln inlet. AFR firing is also not as stable as conventional fuel, so we face frequent temperature fluctuations, which cause more thermal shock and small cracks in the lining.
Another real problem is coating instability. Some days the coating builds too fast, other days it suddenly drops, and both conditions impact refractory life. We also notice more dust circulation and buildup inside the calciner whenever the AFR mix changes, which again increases erosion.
Because of these practical issues, we have started relying more on alkali-resistant, low-porosity and better thermal shock–resistant materials to handle the additional stress coming from AFR.

What role does digital monitoring or thermal profiling play in your refractory strategy?
Digital tools like kiln shell scanners, IR imaging and thermal profiling help us detect weakening areas much earlier. This reduces unplanned shutdowns, helps identify hotspots accurately and allows us to replace only the critical sections. Overall, our maintenance has shifted from reactive to predictive, improving lining life significantly.

How do you balance cost, durability and installation speed during refractory shutdowns?
We focus on three points:
• Material quality that suits our thermal profile and chemistry.
• Installation speed, in fast turnarounds, we prefer monolithic.
• Life-cycle cost—the cheapest material is not the most economical. We look at durability, future downtime and total cost of ownership.
This balance ensures reliable performance without unnecessary expenditure.

What refractory or pyro-processing innovations could transform Indian cement operations?
Some promising developments include:
• High-performance, low-porosity and nano-bonded refractories
• Precast modular linings to drastically reduce shutdown time
• AI-driven kiln thermal analytics
• Advanced coating management solutions
• More AFR-compatible refractory mixes

These innovations can significantly improve kiln stability, efficiency and maintenance planning across the industry.