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Smart-Tech in Cement!

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An invigorating discussion amongst industry experts, on digital transformation, sustainability and cybersecurity, threw interesting insights.

The cement industry is at a crucial juncture, with digital transformation, sustainability, and automation shaping its future. The panel discussion explored key points on digitalisation, sustainability and automation, emphasising the importance of a multidisciplinary approach to modern cement manufacturing.
The webinar was moderated by Dr SB Hegde, Professor, Jain College of Engineering & Technology, Hubli; and Visiting Professor, Pennsylvania State University, USA.

Speakers included:

  • Dr Hemantkumar Aiyer, VP & Head R&D, Nuvoco Vistas Corp
  • Dr Raju Goyal, Executive President, Chief Technical and Sustainability Officer,

UltraTech Cement

  • Dr Rizwan Sabjan, Head – Global Sales and Proposals, Process Control and Optimisation, FLSmidth Cement
  • Prosenjit Dutta, Director Operations, PS Digitech-HR India
  • Raghu Vokuda, Chief Digital Officer,

JSW Cement

  • Sachin Vaidya, Regional GM – Digital, Process Industries, ABB

Role of digital transformation
Dr Hegde emphasised the need for integrating emerging technologies with a multidisciplinary approach to enhance cement plant efficiency. He highlighted that “understanding of systems and how to integrate them” is essential for maximising the benefits of digital tools.
Sabjan echoed this sentiment, stressing that cement plants need to embrace a cultural and mindset shift to fully leverage digital technologies. He pointed out, “Software can do wonders for the plant, but only if the workforce understands and implements it effectively.” He warned against isolated implementations, advocating for a holistic approach where departments like OT, quality control and automation work together.

Sustainability: The road ahead
With sustainability becoming a global priority, cement manufacturers must adapt to new environmental regulations and carbon reduction goals. Dr Hegde posed a critical question: “How is the cement industry moving towards sustainability, and how can plants prepare for these changes?”
Sabjan responded by highlighting the importance of long-term planning and commitment. “Often, discussions happen, but after two months, we forget about them and restart from scratch. This approach will not work. We need a structured, goal-oriented plan with defined KPIs,” he said. Sabjan emphasised the need for a systematic approach, focusing on tangible metrics such as energy savings. “If a plant aims to improve energy efficiency by five percent, it must set this as a goal and track progress,” he suggested.
The discussion also underscored the need for strong leadership to drive digital adoption. “A motivated team and a dynamic leader can make all the difference,” Dr Hegde noted.

Enhancing durability with digital tools
Strength and durability remain critical concerns in cement production. Goyal explained, “Machine learning-based lab technologies enable predictive analysis, allowing manufacturers to forecast 28-day, 7-day, and 1-day strengths before the material leaves the mill.” He also emphasised the importance of soft sensors, which “help predict strength and optimise mix design before production.”
He elaborated on the role of XRF/XRD analysis: “These tools provide elemental and mineralogical insights, allowing for quick adjustments to raw materials and ensuring consistent quality.” Furthermore, digital twins are revolutionising cement quality optimisation. “They allow us to simulate and test mix designs before implementation, reducing errors and optimising durability.”

Cybersecurity risks in IT-OT integration
As cement plants become increasingly digitalised, cybersecurity threats pose significant risks. Vaidya expressed concern that many manufacturers underestimate cybersecurity risks. “As a technology provider, I often struggle to convince cement manufacturers of the importance of cybersecurity. Some benefits are intangible but essential for plant security.”
He outlined major threats, including malware attacks, unauthorised network access, and operational disruptions. “Preventive measures include secure data transactions, network monitoring, and regular cybersecurity training for staff to minimise insider threats,” he said.
He urged cement companies to take cybersecurity seriously: “As digital transformation advances, cybersecurity is not an option—it is a necessity. Without proper security protocols, cement plants risk cyberattacks that could halt production.”
Dr Hegde agreed, adding, “People often ignore cybersecurity until they experience financial loss. Awareness must be proactive, not reactive.”
Dutta stated, “Advanced process control (APC) is a game-changer for cement manufacturing, allowing us to stabilise operations, optimise fuel efficiency, and reduce energy consumption through real-time data insights.”
He emphasised the transformative impact of real-time data analytics and advanced process control (APC) in cement manufacturing. He highlighted that APC enables manufacturers to optimise raw mix design, fuel efficiency and kiln operations through data-driven decision-making. By continuously monitoring critical parameters, APC minimises process variations, improves stability, and reduces energy consumption, leading to cost savings and enhanced productivity. Additionally, he stressed the role of predictive maintenance in preventing equipment failures, extending machinery lifespan and minimising downtime, ultimately ensuring consistent quality and operational efficiency in cement production.

Will Indian plants become fully autonomous?
With AI, robotics and digital twins transforming global cement production, the question arises: Can Indian cement plants become fully autonomous within the next 5–10 years?
Vokuda was skeptical about complete automation in the near future. “Indian cement plants will see significant automation, but full autonomy remains unlikely within a decade. A hybrid model, combining AI-powered decision-making with human oversight, is more practical.”
He highlighted key challenges: “Unlike developed nations, India’s low labour costs may make full automation less attractive. Additionally, digital twin technology in India is still in its early stages, focusing more on process twins than asset twins.”
Another challenge is data management. “AI-ML models require vast amounts of data, which necessitates ultra-low latency networks like 5G and edge computing. We are not yet at that level of technological maturity,” he explained.
Despite these hurdles, he remains optimistic: “While full automation may take longer, the industry will continue to evolve with advancements in digital twins, real-time analytics, and AI-driven insights.”

Conclusion
Experts agree that while technology holds immense potential, its successful implementation depends on cultural shifts, strong leadership, and structured execution.
Key takeaways from the discussion include:

  • Integration of digital tools: Multidisciplinary collaboration is essential for successful implementation.
  • Sustainability goals: Defined KPIs and a long-term approach are crucial.
  • Quality optimisation: Machine learning, real-time analysis, and digital twins are improving cement strength and durability.
  • Cybersecurity: As digital transformation progresses, cement plants must prioritise cybersecurity.
  • Automation: While full autonomy is unlikely soon, AI and digital tools will play a growing role in decision-making.
    As the industry moves forward, cement manufacturers must embrace technological advancements while ensuring resilience against cybersecurity threats and operational challenges. With the right strategies, India’s cement sector can achieve greater efficiency, sustainability, and innovation in the years to come.

ICR’s virtual panel discussion was supported by FLSmidth Cement as the Presenting Partner and ABB as the Gold Partner.

Concrete

India Sets Up First Carbon Capture Testbeds for Cement Industry

Five CCU testbeds launched to decarbonise cement production

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The Department of Science and Technology (DST) recently unveiled a pioneering national initiative: five Carbon Capture and Utilisation (CCU) testbeds in the cement sector, forming a first-of-its-kind research and innovation cluster to combat industrial carbon emissions.
This is a significant step towards India’s Climate Action for fostering National Determined Contributions (NDCs) targets and to achieve net zero decarbonisation pathways for Industry Transition., towards the Government’s goal to achieve a carbon-neutral economy by 2070.
Carbon Capture Utilisation (CCU) holds significant importance in hard-to-abate sectors like Cement, Steel, Power, Oil &Natural Gas, Chemicals & Fertilizers in reducing emissions by capturing carbon dioxide from industrial processes and converting it to value add products such as synthetic fuels, Urea, Soda, Ash, chemicals, food grade CO2 or concrete aggregates. CCU provides a feasible pathway for these tough to decarbonise industries to lower their carbon footprint and move towards achieving Net Zero Goals while continuing their operations efficiently. DST has taken major strides in fostering R&D in the CCUS domain.
Concrete is vital for India’s economy and the Cement industry being one of the main hard-to-abate sectors, is committed to align with the national decarbonisation commitments. New technologies to decarbonise emission intensity of the cement sector would play a key role in achieving of national net zero targets.
Recognizing the critical need for decarbonising the Cement sector, the Energy and Sustainable Technology (CEST) Division of Department launched a unique call for mobilising Academia-Industry Consortia proposals for deployment of Carbon Capture Utilisation (CCU) in Cement Sector. This Special call envisaged to develop and deploy innovative CCU Test bed in Cement Sector with thrust on Developing CO2 capture + CO2 Utilisation integrated unit in an Industrial set up through an innovative Public Private Partnership (PPP) funding model.
As a unique initiative and one of its first kind in India, DST has approved setting up of five CCU testbeds for translational R&D, to be set up in Academia-Industry collaboration under this significant initiative of DST in PPP mode, engaging with premier research laboratories as knowledge partners and top Cement companies as the industry partner.
On the occasion of National Technology Day celebrations, on May 11, 2025 the 5 CCU Cement Test beds were announced and grants had been handed over to the Test bed teams by the Chief Guest, Union Minister of State (Independent Charge) for Science and Technology; Earth Sciences and Minister of State for PMO, Department of Atomic Energy, Department of Space, Personnel, Public Grievances and Pensions, Dr Jitendra Singh in the presence of Secretary DST Prof. Abhay Karandikar.
The five testbeds are not just academic experiments — they are collaborative industrial pilot projects bringing together India’s top research institutions and leading cement manufacturers under a unique Public-Private Partnership (PPP) model. Each testbed addresses a different facet of CCU, from cutting-edge catalysis to vacuum-based gas separation.
The outcomes of this innovative initiative will not only showcase the pathways of decarbonisation towards Net zero goals through CCU route in cement sector, but should also be a critical confidence building measure for potential stakeholders to uptake the deployed CCU technology for further scale up and commercialisation.
It is envisioned that through continuous research and innovation under these test beds in developing innovative catalysts, materials, electrolyser technology, reactors, and electronics, the cost of Green Cement via the deployed CCU technology in Cement Sector may considerably be made more sustainable.
Secretary DBT Dr Rajesh Gokhale, Dr Ajai Choudhary, Co-Founder HCL, Dr. Rajesh Pathak, Secretary, TDB, Dr Anita Gupta Head CEST, DST and Dr Neelima Alam, Associate Head, DST were also present at the programme organized at Dr Ambedkar International Centre, New Delhi.

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Concrete

JK Lakshmi Adopts EVs to Cut Emissions in Logistics

Electric vehicles deployed between JK Puram and Kalol units

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JK Lakshmi Cement, a key player in the Indian cement industry, has announced the deployment of electric vehicles (EVs) in its logistics operations. This move, made in partnership with SwitchLabs Automobiles, will see EVs transporting goods between the JK Puram Plant in Sirohi, Rajasthan, and the Kalol Grinding Unit in Gujarat.
The announcement follows a successful pilot project that showcased measurable reductions in carbon emissions while maintaining efficiency. Building on this, the company is scaling up EV integration to enhance sustainability across its supply chain.
“Sustainability is integral to our vision at JK Lakshmi Cement. Our collaboration with SwitchLabs Automobiles reflects our continued focus on driving innovation in our logistics operations while taking responsibility for our environmental footprint. This initiative positions us as a leader in transforming the cement sector’s logistics landscape,” said Arun Shukla, President & Director, JK Lakshmi Cement.
This deployment marks a significant step in aligning with India’s push for greener transport infrastructure. By embracing clean mobility, JK Lakshmi Cement is setting an example for the industry, demonstrating that environmental responsibility can go hand in hand with operational efficiency.
The company continues to embed sustainability into its operations as part of a broader goal to reduce its carbon footprint. This initiative adds to its vision of building a more sustainable and eco-friendly future.
JK Lakshmi Cement, part of the 135-year-old JK Organisation, began operations in 1982 and has grown to become a recognised name in Indian cement. With a presence across Northern, Western, and Eastern India, the company has a cement capacity of 16.5 MTPA, with a target to reach 30 MT by 2030. Its product range includes ready-mix concrete, gypsum plaster, wall putty, and autoclaved aerated fly ash blocks.

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Holcim UK drives sustainable construction

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Holcim UK has released a report titled ‘Making Sustainable Construction a Reality,’ outlining its five-fold commitment to a greener future. The company aims to focus on decarbonisation, circular economy principles, smarter building methods, community engagement, and integrating nature. Based on a survey of 2,000 people, only 41 per cent felt urban spaces in the UK are sustainably built. A significant majority (82 per cent) advocated for more green spaces, 69 per cent called for government leadership in sustainability, and 54 per cent saw businesses as key players. Additionally, 80 per cent of respondents stressed the need for greater transparency from companies regarding their environmental practices.

Image source:holcim

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