Olli Hänninen, Owner and Co-founder, Moviator Oy, discusses the future of decarbonising cement through smart material utilisation.

Over the decades, the cement sector has advanced from scale to sophistication, and now it faces its most profound transformation yet — decarbonisation of one of the world’s most carbon-intensive industries.
The theme — The 3Cs: Cut, Cement, Carbon — captures a new mindset. Cutting emissions is no longer just about compliance; it is central to competitiveness. Cement, once seen as a fixed formula, is being reimagined through technology and circularity. And carbon itself, traditionally treated as waste, is emerging as a potential input. Together, these three Cs define not only a challenge but also a remarkable opportunity.

Cement’s dual carbon burden
Cement production carries a double carbon burden — from both the energy required to heat kilns and the chemical release of CO2 from limestone during clinker production. Even with modern efficiency improvements, the underlying chemistry of the process remains inherently carbon-intensive.
Traditional ‘Cut’ measures — improving thermal efficiency, using alternative fuels, or lowering the clinker factor — are vital, but not sufficient on their own. The next step lies in rethinking the materials themselves: how we process them, how we use them, and how we can capture and store carbon directly within them.

Slag: From by-product to resource
Among industrial by-products, steelmaking slag stands out as one of the most underused materials in the journey to decarbonisation. Produced at roughly 200 kg per tonne of steel, it is often stockpiled or landfilled, despite containing valuable calcium- and magnesium-bearing compounds.
Blast-furnace slag from ironmaking is already widely used in blended cements, but steel slags from basic oxygen or electric arc furnaces remain challenging. They are heterogeneous, often solidifying into massive rock-like blocks known as steel skulls, or into finer, inconsistent fractions. These forms are difficult to process and integrate reliably into cement production.
Yet this complexity conceals opportunity. Slag is abundant, stable, and — with the right processing — capable of replacing a large share of clinker while storing CO2 within its structure.

Unlocking the hidden value in slag
At Moviator Oy, we focus on two critical and often overlooked fractions of steelmaking slag that have historically been difficult to process — but which hold immense untapped potential for decarbonising cement and improving circularity in steel production.

1. Large solidified steel skulls
These massive, irregular formations solidify at the bottom of ladles or converters and have traditionally been cut apart using oxygen lances — a slow, energy-intensive, and hazardous process. Moviator has developed an innovative process that enables the efficient treatment of solidified steel skulls, eliminating the need for conventional thermal cutting and improving material recovery.
Once treated, the recovered metallic portions are returned to the steelmaking cycle, while the mineral component is directed for cementitious applications. This dual recovery approach maximises resource efficiency, reduces waste, and lowers both carbon and energy footprints across the steel and cement value chains.

2. The sub-50 mm fine fraction
At the other end of the size spectrum, finer slag particles can be further refined through advanced grinding techniques, achieving reactivity levels well above standard cement benchmarks. This transformation enhances the slag’s ability to act as an effective supplementary cementitious material (SCM), capable of replacing a substantial portion of the clinker in blended cements.
Together, these two complementary approaches — recovery and recycling of steel skulls and activation of fine slag through precision grinding — enable Moviator to transform slag from an inert by-product into a high-performance, low-carbon cement material, while simultaneously closing the loop within the steel industry.
This material transformation is only the first step. The next challenge — and opportunity — lies in what we do with carbon itself.

Beyond storage: Turning CO2 into stone
Most global attention focuses on carbon capture and storage (CCS) — compressing CO2 and injecting it underground. While CCS has value, it raises questions of permanence, cost, and long-term monitoring.
Moviator takes a different path: carbon utilisation through mineral carbonation. In simple terms, captured CO2 reacts with calcium- and magnesium-rich compounds in slag to form stable carbonates, effectively turning gaseous emissions into solid minerals within a controlled process environment.

This approach achieves two outcomes:
1. Permanent carbon binding: CO2 is locked into a solid matrix with no risk of re-release.
2. Improved material properties: Carbonated slag is more stable and can exhibit enhanced early strength and durability.
This is more than a laboratory concept. Pilot-scale work has already demonstrated that 4–5 tonnes of slag can permanently store around one tonne of CO2, confirming that industrial by-products can become long-term carbon sinks within a circular cement economy.

A realistic path to a circular, carbon-negative loop
Our vision is a circular, carbon-negative cement ecosystem — one that absorbs more CO2 than it emits. In this system, industrial waste becomes both raw material and carbon storage medium, creating a closed loop between the steel, cement, and carbon management sectors.

This concept builds on real trends already taking shape:

• Cement plants near steelworks using slag as feedstock.
• Pilot carbonation systems integrating captured CO2 from industrial exhausts.
• Early life-cycle assessments showing that mineralised slag can achieve net CO2 reductions of 70–90 % compared to conventional clinker.

However, realising a fully circular model will require more than technology. It will demand:

• Clean energy for grinding and carbonation to ensure net carbon benefits.
• Proximity and logistics between steel, cement and CO2 sources.
• Updated standards and policies that recognise mineral carbonation as a verified form of carbon removal.

Currently, most climate frameworks credit geological storage but not yet mineralised products. Changing that will take collaboration between innovators, regulators, and investors. Still, the direction is clear: CO2 mineralisation is emerging as a credible, permanent carbon sink with industrial-scale potential.

Practical optimism: Balancing vision and reality
The idea of a carbon-negative cement industry is ambitious — and it should be. Cement contributes roughly 7-8 per cent of global CO2 emissions, so any solution must be bold. But ambition must come with realism.
Scaling up slag carbonation will take time. Reactors must handle large volumes efficiently, and the economics depend on CO2 availability, energy costs, and policy incentives. Yet progress is rapid: several European plants are already demonstrating carbonated aggregates and binder materials commercially.
Moviator’s strategy reflects this practical optimism — combining proven engineering principles with forward-looking applications. Each tonne of refined, carbonated slag replaces high-emission clinker and locks away CO2 permanently, turning waste into value step by step.

The mindset shift: The 3Cs reimagined
The 3Cs — Cut, Cement, Carbon — are not separate goals but interconnected levers of transformation:

• Cut emissions by improving efficiency and material circularity.
• Cement innovation by replacing clinker with reactive industrial by-products.
• Carbon redefined as a useful input, not just a waste stream.

To truly decarbonise, the industry must embrace both radical innovation and practical integration. Every action that converts waste to raw material and emissions to mineral stability brings us closer to a sustainable cement future.

From incremental to transformative
Decarbonising cement will not happen overnight. It will take imagination, cross-sector collaboration and new standards that reward permanent carbon binding. But the tools are already here — from smarter slag processing to direct CO2 mineralisation.
Moviator’s work in refining steel skulls and utilising slag demonstrates that circular, low-carbon materials are not science fiction. They are emerging now, one pilot and partnership at a time.
The 3Cs mindset is ultimately about shifting perception — from seeing materials as static commodities to viewing them as active agents in the carbon cycle. Through this lens, cement production can evolve from a major emitter to a permanent carbon sink, helping build not only the world’s infrastructure but also its climate resilience.

ABOUT THE AUTHOR:
Olli Hänninen, Owner and Co-founder, Moviator Oy, helps industries maximise material recovery with advanced slag processing technology.

Gaurav K Mathur, Director and Chief Executive, Global Technical Services, discusses how lubrication is the key to achieve sustainability in the cement industry.

Lubricants are one of the essential items for keeping machine running smoothly. Lubricants provides lubrication to reduce friction in the moving part of the machine. By reducing this friction machine runs for a much longer time and by good lubrication management the machine operation and reliability can be further achieved. By good lubrication and oil condition monitoring, machine can run uninterrupted for long time and provide reliability in manufacturing.
Industrial sector accounts for a fair amount of Green House Gases (GHG) emissions. In most of these Cement and Mining Industries, lubricants are used in large quantities. Lubrication can significantly impact the overall efficiency of a machine if the proper lubrication is being done. The lubricant also affects the energy efficiency of the equipment’s. In most cases, scientifically done lubrication has shown considerably reduced power consumption, besides machine reliability.

Why is lubrication key to sustainability?
The cement industry plays a pivotal role in infrastructure development, providing the foundation for buildings, roads and other critical infrastructure in nation building.
Cement manufacturing and mining are energy-intensive, with emissions contributing to carbon footprints. In the pursuit of sustainable practices, cement plants are increasingly turning their attention to good lubrication, as key elements in enhancing operational efficiency while minimising environmental impact.
As awareness of climate change grows, the cement and mining Industry is proactively looking towards adopting technology to decrease their carbon footprint and attention is being given to sustainability to ensure minimal impact to the environment. Efforts and resources are being pledged to optimise every aspect of production, including good lubrication practises by adopting to Total Lubrication Management (TLM).
Lubrication and its efficient management, by adopting TLM in the plant, have great potential
to reach their sustainability goal and at the same time improve operational excellence, with sustainability objectives.
Lubrication is the fulcrum of mechanical maintenance, thus playing a critical role towards sustainable and profitable operation in the limestone quarry or at plants. Traditionally, lubricants have been chosen based on their ability to reduce friction, wear and corrosion. However, the evolving landscape of sustainability demands a more comprehensive approach to lubrication, and Oil Condition Monitoring.
Through the careful selection of high-quality lubricants and optimized application practices, friction and wear within machinery are minimized, leading to increased energy efficiency. This results in lower energy consumption, reduced greenhouse gas emissions, and extended equipment lifespan. By incorporating advanced lubrication technologies and practices, cements and mining industry can contribute to the industry’s overall commitment to achieving more sustainable and environmentally friendly manufacturing.
Energy-efficient lubricants have been formulated by the Lubricant suppliers, typically cost more because they are made of tailored synthesised chemicals rather than straight hydrocarbon base oils. Generally, users are reluctant to purchase more expensive products unless there is demonstrable value.
Energy consumption is a significant concern in cement production, with a substantial portion of it attributed to the friction and heat generated by moving components in machinery. Lubrication management plays a pivotal role in optimising energy efficiency within all manufacturing plants. Advanced lubricants with superior friction-reducing properties contribute to lower energy consumption by minimising resistance in moving parts and ultimately play important role in machine reliability.
Moreover, lubricants can be tailored to specific applications within manufacturing plants, ensuring that each type of machinery receives optimal lubrication for its unique requirements. For example, synthetic lubricants achieve the most impressive energy savings where equipment slides or rolls. This targeted approach not only enhances energy efficiency but also extends the lifespan of critical equipment, reducing the need for frequent replacements and associated resource consumption.
Over a period of time, lubricants in machines gets contaminated by dust, dirt, wear metals and moisture. This oil has to be periodically tested at an Oil Testing Laboratory and cleaned to maintain its good condition.
Oil never dies – it just needs to be cleaned to its specification by removing contaminants and may be needing additives dosage required to keep it as per operating standard. All this activity can be done at plant itself, for continuous production and minimum downtime.
Since oil is contaminated, contaminants have to be removed. There are certain methods to remove contaminants and the simplest and best way is ‘oil filtration’ which can remove all suspected impurities along with moisture.
Required additives also be doped at the site to bring oil to its normal specification levels. Hence, besides oil re-cycling, there is a need for having an oil testing laboratory at the site as oil test report must be available within 36 to 48 hours. This will pay back maximum within six months in any cement or mining enterprise. This approach not only enhances the sustainability of operations but also aligns with the principles of the circular economy.
Save the environment with green manufacturing
While the adoption of sustainable lubricants and lubrication management holds great promise for driving sustainability in Industry, several challenges and considerations must be addressed. One significant consideration is the compatibility of new lubricants with existing equipment’s. Cement plants often have long lifecycles for their machinery, and transitioning to new lubricants must be carefully planned to avoid transition issues and ensure a seamless integration.
The cement industry’s journey toward sustainability involves a comprehensive approach that extends to every facet of production, including lubrication technology. By embracing sustainable processes, optimising energy efficiency, and leveraging advanced lubrication systems, cement plants can significantly reduce their environmental impact while enhancing operational performance, all aspects being covered by simply implementing TLM.
Significant efforts are being made by cement Industries for being sustainable, TLM is being implemented majorly by cement companies. Two roadblocks to widespread adoption of TLM include the challenge of quantifying measurable improvements and arriving at payback.
The transition to sustainable lubrication practices is a strategic imperative for cement manufacturers seeking to thrive in an era of increasing environmental awareness. As the industry continues to evolve, the integration of TLM plays a pivotal role in shaping a more sustainable future for cement production, where efficiency and environmental stewardship go hand in hand.
Lubricants must be kept clean and free from moisture while maintaining a healthy balance of additives to increase its lifespan, lubricants must be dealt with same sensitivity as blood in a human body.
We, at Global Technical Services, believe oil in the machine is like blood in the human body, and implementation of TLM is an important step towards sustainability. In fact, sustainable manufacturing is not possible without the implementation of TLM.

ABOUT THE AUTHOR:
Gaurav K Mathur, Director and Chief Executive, Global Technical Services, has been instrumental in developing advanced lubrication systems that ensure contamination-free maintenance across industries.

Jigar Shah, Head – Application Engineering, ACM SBU, Henkel Adhesive Technologies India, looks at the smarter way to keep power flowing.

In cement manufacturing, where uptime is everything, captive power plants are the backbone of uninterrupted operations. But even the most robust systems can be brought to a halt by something as deceptively simple as ash.
Ash buildup—especially in high-humidity environments—is a recurring challenge for maintenance teams. It clings to the inner walls of hoppers and silos, chokes flow paths, and forces shutdowns that no one has time for. And when the monsoon rolls in, the problem only intensifies.
This is the story of how one thermal power plant in India tackled the issue—not with more manpower or heavier hammers, but with a surface engineering solution developed by Henkel’s Loctite team. The application of Loctite® PC 7337 Anti-Stick Coating helped the plant shift from reactive maintenance to preventive control, restoring flow and reliability where it mattered most.

The sticky truth
Ash is an inevitable by-product of coal combustion. In captive power plants, fly ash is collected in electrostatic precipitators (ESPs) and directed to ash hoppers. Bottom ash, meanwhile, is sluiced with water into Hydrobin tanks—large cylindrical silos where solids settle and water is drained off for further treatment.
In theory, it’s a straightforward process. In practice, it’s anything but.
Ash particles are fine, abrasive and hygroscopic. They absorb moisture from the air, especially during the rainy season, and form stubborn layers on metal surfaces. Over time, this buildup narrows flow paths, increases system pressure, and eventually brings operations to a standstill.
At the plant in question, maintenance teams were routinely forced to shut down operations to manually clear out ash deposits. Sometimes that meant hammering on hopper walls. Other times, it meant full system stoppages. Either way, the cost—in time, labour and lost production—was significant.

A new approach
Rather than redesign the system or increase maintenance frequency, the plant’s engineering team explored a different path: surface modification.
They partnered with Henkel’s Application Engineering team to trial Loctite® PC 7337—a polymer-based anti-stick coating designed specifically for abrasive, high-moisture environments. The goal was simple: prevent ash from sticking in the first place.
Loctite PC 7337 was applied to the internal surfaces of the Hydrobin tank and ash hopper. The coating offered a low-friction, hydrophobic barrier that repelled fine particles and resisted wear. But as with any industrial solution, success depended on proper preparation and execution.

Application in action
The coating process followed a meticulous five-step protocol:
1. Surface preparation: Initial cleaning involved the removal of oil, grease and other contaminants. Abrasive blasting followed, creating a surface profile of 40–60 microns to ensure strong mechanical bonding.
2. Dust removal: All residual dust was cleared to prevent contamination and ensure a clean substrate.
3. Coating application: Loctite PC 7337 was mixed and applied to a wet film thickness of 200–250 microns. No heat curing was required—ambient conditions were sufficient.
4. Curing: The coating was left to cure for 24 hours, forming a durable, glossy finish.
5. Inspection: Final checks included dry film thickness measurement, visual inspection and holiday detection to confirm coating integrity.
The result? A smooth, frictionless surface that ash simply couldn’t cling to.

Real-world results
Post-application, the plant saw immediate improvements. Ash no longer adhered to the coated surfaces, even during peak humidity. Flow paths remained clear, and the need for manual cleaning dropped dramatically.
Here’s what changed:
• Fewer shutdowns: With ash buildup under control, unplanned stoppages became a thing of the past.
• Improved flow efficiency: Material moved more freely through the system, reducing pressure fluctuations and wear.
• Regulatory compliance: The plant was able to meet its monthly ash disposal targets, aligning with environmental mandates from the National Green Tribunal (NGT).
• Cost savings: Reduced maintenance and downtime translated into measurable financial benefits.

Why it worked
The coating’s performance came down to two key properties: abrasion resistance and hydrophobicity.
In lab tests, Loctite PC 7337 showed excellent wear resistance, losing only 9 mg after 1000 cycles under a 1 kg load using CS-17 wheels (ASTM D4060). That’s critical when dealing with fine, abrasive particles like fly ash and clinker dust.
Equally important was its ability to repel moisture. The coating’s low surface energy and high contact angle created a hydrophobic barrier that prevented wet ash from bonding to the surface—a common failure point for traditional coatings.
It also proved effective across a wide range of particle sizes. From cement fines under 45 microns to pulverized coal (79–120 microns) and clinker dust (3–30 microns), Loctite PC 7337 maintained its anti-stick properties. Even particles up to 1 mm showed only moderate adhesion during internal trials.

Beyond power plants
While this case focused on a thermal power plant, the implications for cement manufacturing are clear. Many of the same challenges—fine particle buildup, moisture-induced sticking, and flow disruptions—occur throughout the plant.
Potential applications for Loctite PC 7337 include:
• ID fan coatings: To prevent dust accumulation and maintain airflow efficiency.
• Pump linings: To reduce wear and improve slurry flow in wet handling systems.
• Silo and hopper interiors: To prevent bridging and rat-holing in cement and fly ash storage.
• Chutes and ducts: To enhance flow and reduce maintenance in pneumatic conveying systems.
By proactively addressing surface behaviour, cement plants can reduce maintenance burdens, extend equipment life, and improve process reliability.

A shift in mindset
This project highlights a broader shift in industrial maintenance philosophy—from reactive fixes to preventive strategies. Instead of waiting for problems to arise, forward-thinking plants are investing in solutions that stop issues before they start.
Surface engineering, particularly with advanced coatings like Loctite PC 7337, is a powerful tool in this shift. It allows operators to tailor equipment surfaces to their specific material and environmental challenges, rather than relying on generic designs or brute-force maintenance.
And while the coating itself was a key enabler, the real success came from collaboration. The plant’s willingness to try a new approach, combined with the technical support of Henkel’s Loctite team, created a solution that was both practical and scalable.

Small change, big impact
Sometimes, the biggest operational wins come from the smallest changes. In this case, a 250-micron of Loctite PC 7337 made the difference between constant maintenance and consistent performance.
For cement plants navigating the complex demands of energy efficiency, environmental compliance, and cost control, solutions like these offer a compelling path forward. They’re not flashy. They don’t require massive capital investment. But they work—and they work where it counts.
Because when ash sticks, everything stops. And when it doesn’t, everything flows.

ABOUT THE AUTHOR:
Jigar Shah, Head – Application Engineering, ACM SBU, Henkel Adhesive Technologies India, has 20+ years of experience. He drives efficiency and sustainability through innovations.