Economy & Market

The Best can still get better

Published

8 years ago

April 30, 2018

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Having crossed several milestones in energy efficiency and sustainability, Indian cement industry is set to achieve the pinnacle.
Increasing competitive pressures, rising energy prices, coupled with stricter regulations for environmental protection are making energy efficiency and sustainable use of resources a top priority for the manufacturers in the recent years, and the cement industry is no exception.
Indian cement industry has already crossed several milestones on energy efficiency ans sustainability parameters. It has emerged as one of the most energy-efficient industry globally with the lowest carbon footprint in the world and it is among few large scale modern industries that do not produce any hazardous solid or liquid discharge, according to Cement Manufacturers’ Association (CMA).
But the icing on the cake has come from the Cement Sustainability Initiative (CSI) an initiative of the World Business Council for Sustainable Development (WBCSD). In 2015 itself CSI had said, "The member companies from India are more efficient.
They emit less CO2 than the companies in Europe and the US. Their energy consumption is also less." The distinction between Indian firms from those in the US and Europe is technology. Indian companies use the latest technology since many of the cement plants are relatively new, CSI had said. CSI was then a 23-member organisation including nine Indian cement companies, including UltraTech Cement and Dalmia Bharat, and seven global companies with operations in India.
Since then the industry is taking a number of measures aimed at further improving its performance on parameters like specific heat consumption, setting up of waste recovery systems and use of alternate fuels. In fact, all these measures help the companies attain the GreenCo rating, where the core focus is on energy efficiency. For example, the industry has increased the Thermal Substitution Rate (TSR) through use of alternative fuels and raw materials to 4 per cent in 2017, from a meagre 0.6 per cent in 2014. Performance
The cement production process is quite energy intensive, both in terms of electrical and thermal energy consumption (E&TEC). There are plants in India that have achieved energy efficiency figures which are considerable to the world’s best. However, the presence of old plants with high specific energy consumption (SEC) brings down the average figures. Cement production involves the heating, calcining and sintering of blended and ground materials to form clicker. As a result, cement manufacturing is the third largest cause of man-made CO2 emissions due to the production of lime, the key ingredient in cement. Therefore, energy savings during cement production could lead to lower environmental impact.
Improvement in the cement industry’s energy efficiency and reduction of CO2 emissions could be mainly achieved through two procedures:
(i) By changes in the manufacturing and production processes, and
(ii) By adjusting the chemical composition of cement.
Improvement in manufacturing and production processes can be achieved by changing energy management processes and by investing in new equipment and/or upgrades. The same way, changes in the chemical formulation of cement have proved to save energy and reduce CO2 emissions. The same holds good for cement industry, which is a highly capital intensive and competitive sector with long economic lifetimes, making changes in the existing capital stock difficult.
"The average electrical energy consumption in India is around 90-95 kWh/tonne cement (OPC) whereas the best achievement is around 80 kWh/tonne cement (OPC). Similarly, average TEC is around 760 kcal/kg clinker, whereas the best figures achieved are around 680 kcal/ kg clinker. There is scope for reduction in both E&TEC in many of the cement plants in India," says PK Ghosh, Group Managing Director, Ercom Engineers.
The best achievable figures are generally observed for the larger scale plants in India using the state of the art technology when operating at or higher than design levels, Ghosh added.
The contribution of the various departments to power and heat consumption is given in the Table-1.PAT Scheme
Perform, Achieve & Trade (PAT) scheme of the Bureau of Energy Efficiency (BEE), a market-based mechanism focused on reducing specific energy consumption – energy used per unit of production – in large industries, has managed to save a whopping Rs 47,185 crore in three years between 2012 and 2015 in the form of energy savings achieved on the back of robust implementation of energy efficiency measures. The scheme facilitates these large, energy-intensive industries to achieve their legal obligation under the Energy Conservation Act of 2001, while also motivating them with market-based incentives to reduce their energy use and surpass their individual energy saving targets.
A Government of India initiative, PAT’s first cycle covered 478 designated industries from 8 energy-intensive sectors – Aluminium, Cement, Chlor-alkali, Fertilizer, Iron and Steel, Pulp and Paper, Textiles and Thermal power plant. Together, these sectors account for around one-third of India’s primary energy consumption.
"The scheme resulted in saving of energy equivalent to 8.67 million tonnes of oil, exceeding the target of 6.86 million tonnes by about 30 per cent. This also resulted in avoided generation of about 5,635 MW of power, resulting in monetary savings of
Rs 37,685 crore. At the same time Rs 9,500 crore has been saved due to reduction in energy consumption," according to BEE.
The third PAT cycle was also notified from April 1, 2017 for 3 years including 116 new units with a reduction target of 1.06 MTOE. Key processes
The energy efficiency achieved is the result of optimisation between capital expenditure and reducing operating expenses.
Adoption of alternative fuels as a means of increasing cost competitiveness is gaining ground. But the industry has a long way to go before achieving 25% TSR. The Thermal Substitution Rate (TSR) in India has shown a very positive trend year on year, reaching a level of around 4 per cent in 2017. As indicated in the CII approach paper, India plans to achieve 25 per cent TSR by 2025. "In comparison to global standards, we are far behind as in many countries the substitution is in the range of 60-100 per cent," says Milind Murumkar, Advisor AFR, Vicat India.
Another way to reduce energy and process emissions in cement production is to blend cements with increased proportions of alternative (non-clinker) feed stocks, such as volcanic ash, granulated blast furnace slag from iron production, or fly ash from coal-fired power generation. Indian cement plants consume a quarter of the fly ash produced in the country annually, according to CMA. For the long run, cement industry lacks a viable carbon-free alternative, and the IEA suggested scenarios imply a heavy reliance on Carbon Capture and Storage (CCS) cement kilns with xy-fuelling. Waste heat recovery systems are expected to play a much bigger role as more of it gets tapped. "In case of specific heat consumption, approximately 20 per cent losses are through preheater exhaust gases, 12 per cent are through cooler exhaust gases and around 4-5 per cent are radiation losses (for 6 stage preheater – precalciner system with the state-of-the-art cooler), says Ghosh.
The cement grinding department and the raw material grinding are the major consumers of electrical energy. The material transport systems have also to be looked in to ensure that the power consumption is lowered.
Ghosh of Ercom says, "The implementation of MIS (management Information systems) like SAP helps in keeping track of key performance indicators. Management is able to monitor both plant operations and the productivity in a continuous manner for achieving energy efficiency targets."
When comparing the state of the art technologies in terms of sustainability, suitability, performance, robustness, cost-efficiency, patent restrictions (availability), and competence requirements, it can be expected that at least in the short term cement companies are going to be based on pyro processing and grinding mills.
Having tasted the fruits of energy efficiency measures over the recent years, and development of a host of case studies highlighting several achievements and sustainable development, the Indian cement industry is set to reach the pinnacle in energy efficiency in the world.Underutilisation and Energy Efficiency
Consider a Cement manufacturing unit which is designed for clinkerisation capacity of 5000 tpd (tonnes per day) and correspondingly OPC of 5250 tpd for the sake of this discussion.
The specific heat consumption of this precalciner kiln will lie in range of 695-700 kcal/ kg clinker at the design capacity. The operating temperatures for calcination (900-950oC) and clinkerisation (1350-1400oC) will be the same irrespective of the operating level. The gas and material temperatures in the preheater stages will also to be maintained at similar levels. As a result, the total heat loss due to radiation will remain the same at all production levels. This will cause a higher specific heat consumption for lower than design operating levels as depicted in Figure 1.
The specific electrical energy consumption is around 90 kWh/t of Cement (OPC). The electrical drives, the fans and the HT motors are also designed to have maximum efficiency at their design operating levels. As a result, they will have suboptimum energy consumptions at lower than design production levels. This is depicted in Figure 2.
One of the ways to take care of underutilisation is by operating at design capacities and keeping the plant idle for extended periods of time. This may be feasible for those plants with multiple Pyro processing lines. At 80% annual production, the plant can be shut down for a total of 2 more months, and at 70% there are 3 extra months of shut down. However, the clinker storage section will be a constraint for this mode of operation.
Increased number of kiln shutdowns leads to wastage of heat during kiln cool down and start-up. The refractory life also reduced even though these shutdowns are planned. There are maintenance issues if the equipment has extended idle times.
Hence most plants settle for a production level which helps them meet the demands of the market while continuing to keep the kiln under operation for extended levels of time. However, it is important to note that there is a minimum turndown level, below which gas velocities in cyclones will reduce to a value which will not support the efficient heat transfer in the preheater and affect the gas-solid reaction in the calciner.– P. K. Ghosh, Group Managing Director,
Ercom Engineers

– BS Srinivasalu Reddy

Economy & Market

Smart Pumping for Rock Blasting

Published

10 hours 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

Refractory demands in our kiln have changed

Published

2 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.

Concrete

Digital supply chain visibility is critical

Published

2 weeks ago

February 20, 2026

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MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, discusses how data, discipline and scale are turning Industry 4.0 into everyday business reality.

Over the past five years, digitalisation in Indian cement manufacturing has moved decisively beyond experimentation. Today, it is a strategic lever for cost control, operational resilience and sustainability. In this interview, MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, explains how integrated digital foundations, advanced analytics and real-time visibility are helping deliver measurable business outcomes.

How has digitalisation moved from pilot projects to core strategy in Indian cement manufacturing over the past five years?
Digitalisation in Indian cement has evolved from isolated pilot initiatives into a core business strategy because outcomes are now measurable, repeatable and scalable. The key shift has been the move away from standalone solutions toward an integrated digital foundation built on standardised processes, governed data and enterprise platforms that can be deployed consistently across plants and functions.
At Shree Cement, this transition has been very pragmatic. The early phase focused on visibility through dashboards, reporting, and digitisation of critical workflows. Over time, this has progressed into enterprise-level analytics and decision support across manufacturing and the supply chain,
with clear outcomes in cost optimisation, margin protection and revenue improvement through enhanced customer experience.
Equally important, digital is no longer the responsibility of a single function. It is embedded into day-to-day operations across planning, production, maintenance, despatch and customer servicing, supported by enterprise systems, Industrial Internet of Things (IIoT) data platforms, and a structured approach to change management.

Which digital interventions are delivering the highest ROI across mining, production and logistics today?
In a capital- and cost-intensive sector like cement, the highest returns come from digital interventions that directly reduce unit costs or unlock latent capacity without significant capex.
Supply chain and planning (advanced analytics): Tools for demand forecasting, S&OP, network optimisation and scheduling deliver strong returns by lowering logistics costs, improving service levels, and aligning production with demand in a fragmented and regionally diverse market.
Mining (fleet and productivity analytics): Data-led mine planning, fleet analytics, despatch discipline, and idle-time reduction improve fuel efficiency and equipment utilisation, generating meaningful savings in a cost-heavy operation.
Manufacturing (APC and process analytics): Advanced Process Control, mill optimisation, and variability reduction improve thermal and electrical efficiency, stabilise quality and reduce rework and unplanned stoppages.
Customer experience and revenue enablement (digital platforms): Dealer and retailer apps, order visibility and digitally enabled technical services improve ease of doing business and responsiveness. We are also empowering channel partners with transparent, real-time information on schemes, including eligibility, utilisation status and actionable recommendations, which improves channel satisfaction and market execution while supporting revenue growth.
Overall, while Artificial Intelligence (AI) and IIoT are powerful enablers, it is advanced analytics anchored in strong processes that typically delivers the fastest and most reliable ROI.

How is real-time data helping plants shift from reactive maintenance to predictive and prescriptive operations?
Real-time and near real-time data is driving a more proactive and disciplined maintenance culture, beginning with visibility and progressively moving toward prediction and prescription.
At Shree Cement, we have implemented a robust SAP Plant Maintenance framework to standardise maintenance workflows. This is complemented by IIoT-driven condition monitoring, ensuring consistent capture of equipment health indicators such as vibration, temperature, load, operating patterns and alarms.
Real-time visibility enables early detection of abnormal conditions, allowing teams to intervene before failures occur. As data quality improves and failure histories become structured, predictive models can anticipate likely failure modes and recommend timely interventions, improving MTBF and reducing downtime. Over time, these insights will evolve into prescriptive actions, including spares readiness, maintenance scheduling, and operating parameter adjustments, enabling reliability optimisation with minimal disruption.
A critical success factor is adoption. Predictive insights deliver value only when they are embedded into daily workflows, roles and accountability structures. Without this, they remain insights without action.

In a cost-sensitive market like India, how do cement companies balance digital investment with price competitiveness?
In India’s intensely competitive cement market, digital investments must be tightly linked to tangible business outcomes, particularly cost reduction, service improvement, and faster decision-making.
This balance is achieved by prioritising high-impact use cases such as planning efficiency, logistics optimisation, asset reliability, and process stability, all of which typically deliver quick payback. Equally important is building scalable and governed digital foundations that reduce the marginal cost of rolling out new use cases across plants.
Digitally enabled order management, live despatch visibility, and channel partner platforms also improve customer centricity while controlling cost-to-serve, allowing service levels to improve without proportionate increases in headcount or overheads.
In essence, the most effective digital investments do not add cost. They protect margins by reducing variability, improving planning accuracy, and strengthening execution discipline.

How is digitalisation enabling measurable reductions in energy consumption, emissions, and overall carbon footprint?
Digitalisation plays a pivotal role in improving energy efficiency, reducing emissions and lowering overall carbon intensity.
Real-time monitoring and analytics enable near real-time tracking of energy consumption and critical operating parameters, allowing inefficiencies to be identified quickly and corrective actions to be implemented. Centralised data consolidation across plants enables benchmarking, accelerates best-practice adoption, and drives consistent improvements in energy performance.
Improved asset reliability through predictive maintenance reduces unplanned downtime and process instability, directly lowering energy losses. Digital platforms also support more effective planning and control of renewable energy sources and waste heat recovery systems, reducing dependence on fossil fuels.
Most importantly, digitalisation enables sustainability progress to be tracked with greater accuracy and consistency, supporting long-term ESG commitments.

What role does digital supply chain visibility play in managing demand volatility and regional market dynamics in India?
Digital supply chain visibility is critical in India, where demand is highly regional, seasonality is pronounced, and logistics constraints can shift rapidly.
At Shree Cement, planning operates across multiple horizons. Annual planning focuses on capacity, network footprint and medium-term demand. Monthly S&OP aligns demand, production and logistics, while daily scheduling drives execution-level decisions on despatch, sourcing and prioritisation.
As digital maturity increases, this structure is being augmented by central command-and-control capabilities that manage exceptions such as plant constraints, demand spikes, route disruptions and order prioritisation. Planning is also shifting from aggregated averages to granular, cost-to-serve and exception-based decision-making, improving responsiveness, lowering logistics costs and strengthening service reliability.

How prepared is the current workforce for Industry 4.0, and what reskilling strategies are proving most effective?
Workforce preparedness for Industry 4.0 is improving, though the primary challenge lies in scaling capabilities consistently across diverse roles.
The most effective approach is to define capability requirements by role and tailor enablement accordingly. Senior leadership focuses on digital literacy for governance, investment prioritisation, and value tracking. Middle management is enabled to use analytics for execution discipline and adoption. Frontline sales and service teams benefit from
mobile-first tools and KPI-driven workflows, while shop-floor and plant teams focus on data-driven operations, APC usage, maintenance discipline, safety and quality routines.
Personalised, role-based learning paths, supported by on-ground champions and a clear articulation of practical benefits, drive adoption far more effectively than generic training programmes.

Which emerging digital technologies will fundamentally reshape cement manufacturing in the next decade?
AI and GenAI are expected to have the most significant impact, particularly when combined with connected operations and disciplined processes.
Key technologies likely to reshape the sector include GenAI and agentic AI for faster root-cause analysis, knowledge access, and standardisation of best practices; industrial foundation models that learn patterns across large sensor datasets; digital twins that allow simulation of process changes before implementation; and increasingly autonomous control systems that integrate sensors, AI, and APC to maintain stability with minimal manual intervention.
Over time, this will enable more centralised monitoring and management of plant operations, supported by strong processes, training and capability-building.