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AI at the helm

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Tushar Kulkarni, Head – Solutions, Innomotics India, writes about innovative AI-based digital solutions for the cement and mining industries, which are enhancing energy efficiency and productivity while combating greenhouse gases for a sustainable future.

Since 2019, we are continuously investing and collaborating with industry experts to develop innovative digital solutions specific for the cement and mining industry to fight greenhouse gases and contribute to climate protection.
Our digital solutions in these industries increase energy efficiency and productivity of our customers’ entire operations.
By the end of FY27, cement consumption in India is expected to reach 450.78 million tonnes, driven majorly by expanding demand from housing, commercial construction, national infrastructure projects and industrial construction*. To meet the growing demand, many cement companies are planning or already undertaking capacity expansions. Despite market growth, challenges such as fluctuating raw material prices, energy costs, transportation costs, skill shortages and regulatory complexities continue to persist for cement plants.
Cement plants constantly strive to improve productivity and cost efficiency through sustainable manufacturing and operations along with environmental emission norms and regulations.
Over the last two decades, different technologies for advanced process control (APC) have developed for the cement industry, such as fuzzy logic and expert systems. However, with the technology changes happening and the increasing use of alternative fuel residual (AFR) and alternative raw materials, the requirement of innovative technology is the need of the hour.
Adoption of artificial intelligence (AI) will significantly help cement plants in their efforts towards innovation, efficiency and sustainability
goals through improved process optimization and increased productivity.
The Innomotics Digi-Suite (AI-based) is positioned to support the cement industry in this endeavour. Built on microservices architecture, Digi-Suite offers flexible self-learning AI based solutions which can be customised or tailor-made in accordance with plant / customer requirements. It enables customers to implement their digitalisation strategies in a stepwise manner and scale it up to an entire plant or multiple plants. Through this platform, customers can monitor and manage processes centrally. This approach
provides guidance for company-wide process standardisation, knowledge sharing and optimum utilisation of expert resources.
Further, the solution is cyber secured as per our product safety and security (PSS) norms. Once deployed, it requires minimal support (patch update based on OS updates).

AI-based pyro solution
The solution assists operations by providing optimal set-point to enable efficient and stable operation, thereby enhancing productivity and energy optimisation.
It is a dedicated machine learning-based model that provides accurate insights into future pyroprocess trends.
By incorporating long-term data sets for AI training, the trained AI models can learn from the past and establish correlations between parameters and time and between actions and outcomes. This knowledge, accumulated in the models, forms the basis for better control performance.
AI pyro solution being implemented at one of the leading cement plants in Europe, it is observed that the solution is supporting customers in optimising fuel consumption between coal and AFR and maintaining stable operation continuously.

Stability: Ensuring all temperature and pressures are within operating range optimising ID fan speed and pressure after preheater.
Coal reduction: Identifying optimum points where coal can be reduced.
Fuel ratio stabilisation with coal vs AFR: Set point for step-by-step moderation of AFR/coal is carried out by AI, thereby maintaining the required heat at the calciner and kiln.
Good quality and increased production: Any change in control parameter is carried out by ensuring the alite and free lime are within operating range. Potential to increase kiln feed, thereby increasing production.
Energy saving: Optimising fans at cooler. AI can achieve energy savings.
Preheater jamming reduction: AI observes SO2 and Chloride formation, material temperature and pressures changes AFR accordingly thereby, preheater jamming occurrence is reduced.
Optimise workforce: Best expert available for 24 hours.

**With provision for input parameters like fly ash, LSF, calorific value of fuel and AFR to keep the alite and free lime in the operating range or best suitable range considering the plant condition.

AI-based mill solution
The solution assists operations by providing optimal set-point to enable efficient and stable operation, thereby enhancing productivity.
Mill operation requires quick response to multiple control parameters based on critical process indicators, which makes it very dynamic in nature. This allows the operator to balance operations between reduced capacity to avoid stoppages or multiple stoppages due to overshooting of critical parameters.
Key Features:
AI Mill solution being implemented at one of the leading cement plants in India, it was observed that the solution supported customers to improve throughput, reduce energy consumption while maintaining stable operations continuously.

About the author
Tushar Kulkarni, Head – Solutions, Innomotics India

Concrete

JK Cement marks 140 years of innovation and leadership

JK is one of India’s leading manufacturers of Grey Cement in India

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JK Cement Ltd. a leading building material company, one of India’s leading manufacturers of Grey Cement in India and one of the largest White Cement manufacturers in the world, celebrated 140 years of JK Organisation’s remarkable legacy at a grand event in the capital. The event honoured the group’s rich history, its significant contributions to multiple sectors of the Indian economy, and the unwavering dedication of its employees and partners.

The celebration gathered dignitaries, industry leaders, employees, and key stakeholders to reflect on JK Organisation’s journey from its inception to its present status as a global leader. Lieutenant Governor of New Delhi, VK Saxena, who himself started his career at JK Cement, along with Rajeev Shukla, Member of Rajya Sabha, graced the occasion. Key leaders of the JK Organisation, including Dr. Nidhipati Singhania, Vice President, JK Organisation, Dr. Raghavpat Singhania, Managing Director, JK Cement, and Madhavkrishna Singhania, Joint MD and CEO, JK Cement, were present to mark this significant milestone.

CEO’s from various known business houses both Indian and Multinational companies across sectors graced the occasion.

Reflecting on the organization’s journey, Dr. Nidhipati Singhania, Vice President, JK Organisation, said, “As we celebrate 140 years of JK Organisation, we are filled with immense pride and gratitude for our legacy, which is rooted in values of innovation, quality, and service to the nation. Our journey has been as much about business success as about driving positive change in the communities and industries we serve. The milestones we have achieved reflect our continuous efforts in advancing India’s infrastructure and industrial landscape.”

One of the key highlights of the evening was the recognising the long-serving employees and partners who have dedicated decades to JKCement. Their enduring loyalty underscores JK Organisation’s foundational values of trust and collaboration, which have been pivotal to the organisation’s success.

Addressing the guests at the event, Dr. Raghavpat Singhania, Managing Director, JK Cement, said, “This year along with the 140 years milestone, also marks two significant milestones for us: 50 years of grey cement business and 40 years of white cement business, affirming our leadership in the industry. Our recent expansion into coal mining underscores our commitment to vertical integration and sustainable resource management. We are dedicated to not only adapting to the evolving landscape but also driving positive change and creating lasting value for all our stakeholders and the nation.”

Emphasising the company’s commitment to innovation and progress, Madhavkrishna Singhania, Joint MD and CEO, JK Cement, said, “Our journey has been marked by resilience, adaptability, and a constant drive to exceed expectations. We’re committed to leveraging cutting-edge technology and sustainable practices to not only maintain our market leadership but also to contribute significantly to India’s progress. The trust of our stakeholders and the dedication of our team members have been instrumental in our success, and they will continue to be the pillars of our future endeavors.”

The event celebrated JK Organisation’s visionary outlook, showcasing its commitment to sustainable growth, technological innovation, and its influential role in driving India’s economic advancement.

VK Saxena, Lieutenant Governor, New Delhi, who was invited as the Chief Guest said “It’s an honour for me to be part of this landmark celebration for a company where I started my career as an Assistant Officer in Gotan, Rajasthan and worked for 11 years in different capacities with its White Cement plant. This exposure gave me insights of a corporate working, faster decision making and team work, which has helped me throughout my various stints thereafter. I wish all the best to JK Cement for all their Future endeavors in Nation Building”

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Concrete

Steel Ministry Proposes Rs.23.52 Lakh Crore for Decarbonisation

Steel Ministry unveils massive decarbonisation plan.

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Decarbonisation Proposal:
The Steel Ministry has outlined a substantial Rs.23.52 lakh crore proposal aimed at decarbonising the steel industry. This initiative is part of the broader sustainability and environmental goals set by the Indian government.

Objective and Goals:
The primary objective of the proposal is to reduce carbon emissions significantly and enhance the environmental performance of the steel sector. This aligns with India’s commitment to climate action and green growth.

Investment Focus:
The proposal will channel funds into advanced technologies, energy-efficient processes, and renewable energy sources. Key areas of investment include electrification, hydrogen-based steelmaking, and carbon capture technologies.

Expected Benefits:
Implementing this plan is expected to lead to major reductions in carbon emissions, improve air quality, and contribute to sustainable development. It will also bolster India’s position as a global leader in green steel production.

Industry Impact:
The steel industry, being a major emitter of greenhouse gases, will undergo a transformation. This shift will require industry-wide adaptation and could influence global steel market trends.

Government Support:
The Indian government is committed to providing policy support, incentives, and regulatory frameworks to facilitate this transition. This includes subsidies for green technologies and research and development funding.

Timeline and Phases:
The implementation will be carried out in phases over the coming years. Short-term goals will focus on immediate emission reductions, while long-term goals will target more comprehensive technological advancements.

Stakeholder Involvement:
Collaboration with industry stakeholders, technology providers, and research institutions will be crucial. Engagement with local communities and environmental groups will also play a role in ensuring the success of the proposal.

Challenges:
The initiative may face challenges such as high costs, technological barriers, and regulatory hurdles. Addressing these challenges will be essential for the successful execution of the decarbonisation plan.

Future Outlook:
The proposal positions India as a key player in the global movement towards sustainable steel production. It sets a precedent for other sectors to follow and supports the country’s broader climate goals.

Conclusion:
The Steel Ministry’s proposal for a Rs.23.52 lakh crore decarbonisation plan represents a significant step towards reducing carbon emissions in the steel industry. With substantial investment in green technologies and strong government support, this initiative aims to drive sustainable growth and position India as a leader in environmental stewardship.

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Concrete

New home prices in China fall 5.3% in August 2024

New home prices were down 5.3% from a year earlier.

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Official data revealed that China’s new home prices had fallen at their fastest rate in over nine years in August, as supportive measures failed to induce a significant recovery in the property sector. The data showed that new home prices were down 5.3% compared to the previous year, marking the sharpest decline since May 2015, compared to a 4.9% drop in July, based on calculations by Reuters from National Bureau of Statistics (NBS) data. Monthly figures indicated that new home prices had fallen for the fourteenth consecutive month, decreasing by 0.7%, which was the same drop recorded in July.

The property market in China continues to struggle with deeply indebted developers, incomplete apartments, and declining buyer confidence, which is putting a strain on the financial system and threatening the 5% economic growth target for the year. A Reuters poll had forecast that home prices in China would decline by 8.5% in 2024 and by 3.9% in 2025 as the sector struggles to stabilise.

Zhang Dawei, chief analyst at property agency Centaline, mentioned that the property market is still gradually bottoming out, with home buyers’ demand, income, and confidence expected to take some time to recover. He noted that the market was anticipating a stronger policy response. According to the official data released on Saturday, property investment had fallen by 10.2% and home sales had dropped by 18.0% year-on-year in the first eight months of the year.

Chinese policymakers have stepped up efforts to support the property sector, including reducing mortgage rates and lowering home buying costs. These measures have partially revitalised demand in major cities, while smaller cities, which have fewer home purchase restrictions and high levels of unsold inventory, are particularly vulnerable. This situation underscores the difficulties faced by authorities in balancing demand and supply across different regions.

In a research note on Friday, Nomura indicated that with the growth slowdown worsening under new headwinds in the second half of the year, Beijing might eventually need to step in as the “builder of last resort” by directly providing funding to delayed residential projects that have already been pre-sold. According to Bloomberg News, China may cut interest rates on over $5 trillion in outstanding mortgages as early as this month.

To support these mortgage rate cuts, economists at ANZ suggested that a reduction in the five-year Loan Prime Rate was likely in September, along with a 20 basis point cut to the medium-term lending facility (MLF) and a 50 basis point cut to the reserve requirement ratio (RRR).

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