Economy & Market

Cementing Change: India’s Innovation Blueprint

Published

4 months ago

November 17, 2025

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ICR delves into the groundbreaking innovations transforming India’s cement industry — from carbon capture and digitalisation to sustainable engineering and material resilience. Discover how technology and collaboration are shaping a low-carbon, competitive future.

India’s cement industry is at a pivotal turning point—evolving from traditional production methods to an era defined by advanced technology, sustainability, and operational reinvention. According to a report by the India Brand Equity Foundation (IBEF), demand growth of 6 per cent to 7 per cent is projected for FY25, following a robust 7 per cent to 8 per cent YoY increase in the last quarter of FY24. This momentum, driven by urbanisation, infrastructure expansion, and policy pushes like the PM Gati Shakti National Master Plan, underscores the need for the industry to evolve not just in capacity but in how it innovates, optimises, and decarbonises. Meanwhile, a report by ResearchAndMarkets estimates the Indian cement market will reach US $18.39 billion by 2025 at a 6.6 per cent CAGR, while the green-cement segment is expected to grow from US $2.31 billion (2024) to US $3.28 billion (2030)—clear signs that innovation has shifted from aspiration to necessity for competitiveness and carbon compliance. Amid this growth and environmental urgency, path-breaking innovations are transforming every link in the cement value chain—from carbon capture and digitalisation to sustainable packaging, data-driven manufacturing, and energy optimisation. As plants embrace Industry 4.0 and embed sustainable engineering at their core, the industry is transitioning from volume-led expansion to value-led transformation. The trajectory is clear: India’s cement producers are no longer just making cement—they are redefining it, building a low-carbon foundation for the nation’s next phase of infrastructure and sustainable growth.

CCUS: Cement’s Net-Zero Catalyst
For hard-to-abate process emissions in cement, Carbon Capture, Utilisation and Storage (CCUS) has moved from concept to large-scale implementation. Global first-of-a-kind projects are proving commercial viability: Heidelberg Materials’ Brevik CCS facility in Norway will capture ~400,000 tCO2/year (~50 per cent of the plant’s emissions), with its evoZero cement already pre-sold for 2025, as reported by Reuters. Similarly, Holcim’s GO4ZERO project in Belgium targets ~1.1 MtCO2/year capture by 2029, part of a broader 5 MtCO2/year ambition supported by the EU Innovation Fund. India is preparing to follow this trajectory—Dalmia Cement, in partnership with Carbon Clean, is developing a 500,000 tCO2/year CCUS plant in Tamil Nadu, aligning with its carbon-negative 2040 goal, as mentioned in company releases and an ADB analysis. Policy mechanisms are also emerging: the Global CCS Institute/GCCA policy brief (2024) proposes a Carbon Capture Finance Corporation and innovative funding tools to de-risk early projects, while NITI Aayog’s CCUS roadmap highlights the urgent need for large-scale demonstrations. Together, these moves signal that CCUS is shifting from research to reality, and India aims to be part of this global transformation.
Dr SB Hegde, Global Industry Expert say, “The cement industry’s path to net zero requires a phased and coordinated innovation roadmap. In the near term (2025–2030), emphasis must be on energy efficiency, clinker substitution, AFR, WHR, and digital optimisation, which are already proven and cost-effective. The next decade (2030–2040) will see wider adoption of electrification and carbon capture technologies, supported by renewable energy and green hydrogen. By 2040–2050, advanced low-carbon clinkers, carbon-negative binders, and circular material use will dominate, enabling deep decarbonisation. Together, these phases form a realistic pathway to cut CO2 emissions by over 70 per cent while ensuring competitiveness and resilience.”
Beyond capture, CO2 utilisation is equally vital—turning emissions into economic value through mineral carbonation, CO2-cured concrete, and carbonated aggregates. Europe’s Northern Lights project under Norway’s Longship program has already begun receiving CO2 shipments from Brevik, with plans to scale to ~5 MtCO2/year, as mentioned in the Financial Times. For India, where geological storage mapping and pipeline infrastructure are still evolving, near-site utilisation in construction materials or chemical feedstocks can bridge the economic gap until storage clusters—such as those planned along the west coast—are operational. The strategic path forward involves modular, retrofit-friendly capture systems, integration with energy efficiency and AFR initiatives, and the use of offtake and CFD-style instruments to offset early costs. As a report by TERI emphasises, India’s net-zero pathway by 2070 hinges on CCUS alongside clinker substitution, alternative binders, and renewable integration. The opportunity for Indian cement lies in acting early—turning CCUS from an obligation into a competitive advantage in the race for sustainable manufacturing.

Digital transformation
From quarry to kiln to bagging, Indian cement plants are rapidly shifting from manual set-points to sensor-driven, AI-supervised operations. Advanced Process Control (APC) and machine learning now fine-tune dozens of variables in real time—stabilising the pyroprocess, optimising fuel use, and minimising quality variance. As mentioned in ABB’s Expert Optimiser materials, these systems typically deliver 3 per cent to 5 per cent energy savings and 3 per cent to 5 per cent production gains while cutting emissions—results that have converted skeptics into advocates. For Indian operators navigating volatile fuel mixes and ambitious Thermal Substitution Rate (TSR) goals, such optimisations provide tangible, repeatable ROI. India already holds a global efficiency edge—as reported by the CII–Sohrabji Godrej Green Business Centre (2023), the top 10 plants operate below 70 kWh/t cement and 690 kcal/kg clinker, with best-achieved benchmarks of 56.1 kWh/t and 675 kcal/kg, underscoring the impact of digitisation on sustaining world-class performance.
Tushar Kulkarni, Business Head – Minerals – Cement & Mining, Innomotics India says, “India’s cement industry has long been at the forefront of adopting cutting-edge industrial technologies—ranging from Intelligent MCCs and MV/LV drive systems to full-scale plant DCS automation—placing it among the global leaders in energy-efficient and digitally enabled manufacturing. These initiatives have translated into significant gains in energy reduction and operational efficiency across plants. The sector is now entering a new phase of transformation, embracing innovations like AI-driven process optimisation (AI Pyro, AI Mill), electrification of kilns, and Carbon Capture, Utilisation & Storage (CCUS). Encouragingly, several of these technologies are already under feasibility assessment or pilot implementation, reflecting the industry’s readiness to leverage advanced automation and electrification as key enablers of decarbonisation.”
“However, scaling these innovations industry-wide still faces tangible barriers. Many plants continue to operate with legacy systems that lack seamless data connectivity or structured historians, making AI model training and deployment difficult. Challenges such as non-standardised data formats, limited transparency of AI model performance, and uncertainty in calculating ROI often slow down investment decisions. Strengthening data infrastructure, building trust in AI outcomes, and upskilling teams in digital analytics will be crucial to unlocking the full potential of smart drives, advanced predictive control, and electrification. In the coming years, AI-based optimisation tools and CCUS technologies are poised to become game changers—helping India’s cement sector strike the balance between industrial productivity and its low-carbon future” he adds.
The next leap lies in scaling the digital flywheel—integrating process, maintenance, and logistics data into unified platforms powered by AI and predictive analytics. Plants combining APC, predictive maintenance, and digital twins will achieve steadier clinker quality, lower specific energy, and reduced downtime while preparing for CCUS-ready, low-carbon operations. With six-stage preheaters globally averaging 717–812 kcal/kg, India’s continuous optimisation keeps it at the efficient end of this spectrum. The lesson is clear: Industry 4.0 isn’t a parallel initiative—it’s the operating system of tomorrow’s path-breaking cement plant, where automation, data, and intelligence drive both sustainability and competitiveness.

Data-driven decisions
Across Indian cement plants, production is becoming data-rich and model-driven, with IoT sensor networks, AI models, and APC systems working in tandem to optimise kiln stability, fuel mix, and quality in real time. As mentioned in Holcim’s program page and a Global Cement report, the company’s Plants of Tomorrow initiative has deployed 2,100+ digital applications across 40+ countries, with AI software expected in ~100 plants by 2028. Indian leaders already operate at world-class efficiency, achieving ~56.1 kWh/t cement (electrical) and ~675 kcal/kg clinker (thermal), benchmarks maintained through data analytics and condition-based maintenance, as reported by the CII–Sohrabji Godrej Green Business Centre (2023). Downstream, digital control towers and route analytics have helped UltraTech cut average lead distance to ~400 km and logistics costs by ~2 per cent YoY. As mentioned in reports by the GCCA (2024/25) and the World Economic Forum (2024), digitalisation is now a central pillar of the global net-zero cement strategy, proving essential for an industry that contributes ~6 per cent of global CO2 emissions to maximise efficiency from kiln to dispatch.

Sustainable engineering
Sustainable engineering in India’s cement sector is advancing beyond efficiency gains toward holistic life-cycle design, where plant layout, raw materials, and product use all align with low-carbon goals. As mentioned in TERI’s roadmap, the industry must cut CO2 intensity to ~0.35 tCO2/t cement by 2050, down from 0.62 in 2010, while as per the OECD report, new plants should target ˜70 kWh/t (electrical) and ˜680 kcal/kg clinker (thermal). On the materials front, Limestone Calcined Clay Cement (LC³) and similar low-carbon binders can reduce emissions by 30 per cent to 40 per cent versus OPC. According to the Department of Science and Technology, cement and brick production currently emit 200–250 MtCO2 annually, underscoring vast decarbonisation potential. Sustainable engineering is thus no longer conceptual—it’s materialising through plant retrofits, alternative binders, and integrated design strategies that link sourcing, production, and construction into a single, optimised low-carbon chain.
Utssav Gupta, Director, Supertech Fabrics says, “India’s cement industry, as the second-largest producer globally, has made remarkable progress in adopting advanced filtration and emission control technologies. The country now enforces some of the most stringent environmental norms among developing economies, and new plants are being commissioned with state-of-the-art filtration systems that rival international benchmarks. More importantly, there is a visible intent among manufacturers to retrofit and upgrade older units, reflecting a strong national commitment to sustainability. As a material-producing nation, India’s openness to embracing innovation has allowed advanced filtration solutions to gain acceptance swiftly. This mindset shift—where manufacturers and end-users alike are eager to align with global best practices—positions India not as a follower but as a fast-rising leader in environmental performance and technological adaptability within the cement sector.”
“When it comes to modernising emission control systems, the challenge is not the lack of technology but the need for stronger instrumentation and data transparency. Real-time monitoring and consistent data sharing between OEMs, operators, and material suppliers remain critical to fine-tuning systems and achieving peak efficiency. Broader adoption of connected instrumentation could help perform deeper root cause analyses, enabling more precise optimisation and accountability. On the technology front, filtration science itself is undergoing a transformation—driven by material innovation that enhances both performance and longevity of filters. The next wave of filtration technologies will not only reduce particulate emissions but also improve plant sustainability and energy efficiency—marking another leap forward in India’s journey toward cleaner, smarter, and more resilient cement production” he adds.

Energy optimisation
Indian plants are squeesing megawatts from every °C of kiln heat while hard-wiring renewables into their grids. Waste-heat recovery (WHR) has scaled rapidly—installed capacity in India rose from ~240 MW to ~1,289 MW over the last decade, with leaders adding triple-digit megawatts in just a few years; UltraTech reports 351 MW of WHR capacity in FY 2024–25, while Ramco commissioned a new 10 MW WHRS in September 2025, signalling steady brownfield gains, as mentioned in a report by the CII–Sohrabji Godrej Green Business Centre and as mentioned in company/press updates. On the consumption side, global pathways raise the bar: the IEA’s NZE trajectory targets average kiln thermal intensity < 3.4 GJ/t clinker and electricity < 90 kWh/t cement by 2030—benchmarks that Indian best-performers are already approaching or beating, as mentioned in a report by the IEA.
The fuel and power mix is tilting greener at scale. UltraTech has publicly set 85 per cent “green energy” in the total energy mix by 2030 (with an interim 60 per cent by FY26) and surpassed 1 GW of installed renewable capacity—tying energy optimisation directly to cost and carbon, as mentioned in company disclosures. Shree Cement lifted green power to ~56 per cent to 66 per cent with ~582–586 MW of RE capacity (solar, wind, WHR), as mentioned in broker/market reports. Meanwhile, the switch to alternative fuels remains a major lever: industry assessments show Thermal Substitution Rate (TSR) adoption is rising but uneven across firms, with availability and pre-processing still the bottlenecks—yet TSR is pivotal to hitting sector targets, as mentioned in a report by CARE Edge ESG.

Reinventing packaging and storage
Moisture remains the silent enemy of bagged cement, driving a shift from stitched sacks to block-bottom, valve bags made of coated polypropylene (PP) that resist humidity, burst less, and run seamlessly on automated lines. Designs like AD*STAR® offer higher strength, moisture protection, and recyclability within PP streams, as mentioned in Starlinger’s overview, while Indian brands such as Bharathi Cement highlight tear resistance, micro-perforation, and near-zero bursting. Recycling infrastructure is expanding too—as mentioned in a report by the India Plastics Pact (2023), 819 mechanical recycling units now process recovered PP, supporting EPR-linked sack take-back programs under CPCB’s 2023–24 inventory. On the dispatch front, plants are deploying automatic bagging, robotic palletising, and warehouse control systems to reduce breakage and boost loading efficiency, as reported in automation case studies. With bulk loading, silo telemetry, and RFID-enabled yards improving traceability, India’s cement logistics are evolving toward moisture-resistant, recyclable packaging and end-to-end automation, ensuring every bag reaches the site intact—with its strength and brand promise preserved.
Frank Ormeloh, Business Unit Manager – Cement, Haver & Boecker says, India’s cement industry presents a fascinating paradox when it comes to integrated digital and hardware adoption. Despite the country’s global reputation for software excellence, the current level of integration between digital and mechanical systems in cement plants remains modest. Most investments still lean toward mechanical upgrades—from material handling to process machinery—while digital adoption lags behind. Yet, the potential for digital transformation is immense. Digital tools, from AI-based control systems to predictive analytics and smart mesh technologies, often come with lower cost thresholds and higher ROI compared to conventional mechanical retrofits. The industry’s growing openness to innovation, combined with India’s strong IT foundation, suggests a major opportunity to elevate operational intelligence through integrated digital-hardware ecosystems.”
“The true obstacles, however, are not technological but commercial and cultural. The prevalent “lowest price possible” mindset still overshadows the “maximum profit possible” philosophy needed to scale advanced mesh, AI, and robotic systems. To accelerate adoption, pioneers within the sector must step forward—those willing to demonstrate that smart, data-integrated plants are not only more efficient but also more sustainable, safe, and investor-attractive. HAVER & BOECKER envisions this transformation through Operation & Maintenance (O&M) partnerships, where experts co-manage packing facilities alongside customers, aligning technical excellence with business value. Proven in India’s chemical sector, this service-driven model aims to bring cement producers closer to “Perfect Flow,” redefining the material not as a low-cost commodity but as a high-value, innovation-driven product that embodies efficiency, sustainability, and long-term profitability” he adds.

Material resilience
A new generation of low-carbon binders is redefining cement’s material resilience by cutting emissions without compromising performance. Limestone Calcined Clay Cement (LC3) reduces CO2 by ~40 per cent while matching or exceeding OPC strength, lowering the clinker factor to ~50 per cent or less, as mentioned in or a report by RMI’s 2024 “Business Case for LC3” and the LC3 Global Assessment. Composition-level innovations such as Calcium Silicate Cement (CSC) further show up to 45.5 per cent energy and 35.1 per cent CO2 reductions versus OPC, owing to reduced limestone demand and lower sintering temperatures, as mentioned in or a report by Williams and Yang (2024). Beyond emissions, alkali-activated concretes (AAC) deliver ~54 per cent to 61 per cent lower CO2 and ~39 per cent to 70 per cent lower embodied energy, while maintaining high strength under thermal stress, as noted in peer-reviewed studies (2024–2025). For India, reducing the clinker factor through high-quality SCMs and alternative binders remains central, as mentioned in or a report by the GCCA Net Zero Progress Report (2024/25) and CII–GBC benchmarking data. The message is clear: material resilience now means lower embodied carbon, longer service life, and regionally optimised composites tailored to India’s diverse heat, moisture, and chloride conditions.
Jignesh Kundaria, CEO and Director, Fornnax says, “India’s cement industry has made significant progress in adopting IoT and predictive analytics, though maturity remains uneven across the sector. Leading manufacturers are integrating digital tools for process optimisation, equipment health monitoring, and real-time insights, but adoption is still in the early-to-mid stage compared to Europe, where digital ecosystems are more advanced. Encouragingly, Indian plants increasingly recognise that data drives efficiency, sustainability, and competitiveness, marking a cultural shift toward digitisation. The main barriers lie in infrastructure: many plants still use legacy systems incompatible with modern automation, making integration complex and costly. A shortage of digital talent and high upfront costs further slow progress. Yet the outlook is strong—modular, interoperable, and retrofit-friendly solutions are steadily lowering adoption barriers and enabling a scalable, cost-effective transition toward intelligent, data-driven cement operations across India..”

Human–tech synergy
The cement industry’s digital transformation is as much about people as it is about technology—where human expertise evolves alongside AI, digital twins, and robotics. As plants automate and adopt AI-based process control, job roles are shifting from manual operation to analytical decision-making. According to a report by Deloitte (2024), over 60 per cent of global manufacturers now prioritise reskilling in data analytics, IoT, and automation. India mirrors this trend—as mentioned in CII’s 2024 Future of Work in Manufacturing study, cement and heavy industry players are allocating up to 3 per cent of annual operational budgets to digital training, with UltraTech and ACC establishing in-house digital academies for process engineers and maintenance teams.
Dijam Panigrahi, Co-founder and COO, GridRaster says “The core of Industry 5.0 is the human operator. By having Spatial AI systems safely take over repetitive, monotonous, or highly dangerous tasks, plant personnel are liberated to focus on the highest-value work: complex process management, troubleshooting, and continuous process optimisation. This fosters a human-machine collaboration that drives innovation, enhances safety and ensures sustainability. Spatial AI is not merely a theoretical leap in digital twin technology; it is a concrete, actionable technology that is delivering immediate, impactful change on the plant floor. By simplifying complexity and driving setup time down to minutes, this technology is the essential accelerator that makes advanced industrial automation truly accessible to all cement manufacturers, marking the definitive arrival of the human-centric, high-efficiency world of Industry 5.0.”
As mentioned in a report by the NSDC (2025), over 75,000 workers in India’s materials and infrastructure sectors will require advanced digital skills by 2030. The GCCA calls this “digital sustainability”—training workers to manage systems that cut emissions and energy use, not just boost output. In practice, kiln engineers interpret AI dashboards, maintenance teams conduct predictive analytics, and logistics managers optimise CO2-efficient routes. The cement plant of the future is, therefore, a human–machine collaboration hub, where workforce adaptability is as critical as the algorithms driving efficiency and sustainability.

Conclusion
As India’s cement sector enters its next growth phase, the challenge is no longer scale but sustainability at scale. The nation already leads in energy efficiency and alternative fuels, yet the next leap demands embedding innovation into every tonne of cement—through CCUS, low-clinker blends like LC3, AI-driven process control, and green logistics. Supported by the National Green Hydrogen Mission, PAT scheme, and 2030 renewable targets, India’s ecosystem is aligning toward low-carbon, globally competitive manufacturing that exports not just cement but expertise. Achieving this will require deep collaboration among industry, academia, and policymakers, focusing on scalable CCUS, mineral carbonation, and regionally suited binders. As led by the GCCA and CMA, shared R&D platforms and policy-backed decarbonisation clusters—akin to Europe’s CCS hubs—can fast-track progress, while green bonds, blended finance, and carbon credits can de-risk early adoption. Ultimately, path-breaking innovation is India’s passport to a net-zero construction future—where digital intelligence, sustainable engineering, and circular materials converge to make every plant a lab for efficiency and every engineer an innovator. With bold collaboration and steadfast execution, India can transform its cement industry from a top emitter into a cornerstone of global green growth.

– Kanika Mathur

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Economy & Market

Smart Pumping for Rock Blasting

Published

1 week 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

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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

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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.