Technology

Technology for alternative fuel firing

Published

3 years ago

July 1, 2021

admin

Use of low-grade alternative fuels such as waste coal, tyres, sewage sludge, and biomass fuels (such as wood products, agricultural waste, etc.) in pre-calciners is a feasible option since combustion in pre-calciner takes place at a lower temperature.

India is the second largest cement producer in the world and accounted for over 8 per cent of the global installed capacity as of 2019 with an overall cement production capacity of around 545 MT in FY20. The Indian cement industry is swiftly developing due to the increasing demand of construction sectors, be it housing, commercial, industrial, etc.

Cement manufacturing being a high energy consuming and heavy polluting process accounts for at least 8 per cent of the total emission of greenhouse gases. At the same time, energy-related expenses in the cement sector, mostly on fossil fuels and electricity, account for 30 to 40 per cent of the industry?? cash costs.

Historically, the primary fuel used in cement industry is coal. Recent increases of coal prices in the Indian market again made the cement industry vulnerable to fuel cost. Since then, petroleum coke has been successfully used as fuel and the use alternative fuels in cement kilns is now common and increasing. Although fossil fuels such as coal, petroleum, natural gas, etc. can provide all the energy the world needs for the time being, their finite nature, high prices and most importantly, their damaging effect on the environment underscore the need to develop alternative fuels.

Today?? cement industry becomes more challenging for the following main factors: the lowest production cost and minimum environmental impact. Beyond the cost-reduction benefits of alternative fuels, use of these fuels can contribute greatly to the environmentally sound disposal of waste and to the mitigation of greenhouse-gas emissions (GHG). Therefore, key cement players have started to consider alternative fuels as a lever to improve their contribution to sustainable development and as a key component of corporate social responsibility.

This is certainly a win-win option for both cement industry and the society at large. There is, hence, an urgent need to implement appropriate policies and practices in favor of co-processing in the country so that it can contribute reasonably towards the waste management needs of the country and help industry in substituting alternative resources in the cement manufacturing process. This would require substantial capacity building in the relevant stakeholder community ??particularly the policy makers, authorities, waste generators, facility providers and the cement plants.

Alternative Fuel options available

The range of alternative fuels is extremely wide. Use of low-grade alternative fuels such as waste coal, tyres, sewage sludge, and biomass fuels (such as wood products, agricultural waste, etc.) in pre-calciners is a feasible option since combustion in pre-calciner takes place at a lower temperature. The major Alternative Fuel available to use in India would be MSW (Municipal Solid Waste).

Sewage sludge: In several countries, sewage sludge is used in cement production. The sludge is usually co-fired with coal in pre-dried form. Pre-dried sludge is easier to store, transport and feed. However, it has a high content of SiO2, Al2O3 and Fe2O3 which could affect the quality of cement if excess amounts are used.

Used Tyres: Combustion of whole tyres requires long residence times to obtain complete conversion. In some cement installations, tyres are fired whole, mostly in the rotary kiln. More commonly, they are shredded in a slashing process, producing tyre chunks or chips, and co-fired with coal in the precalciner. They cannot, however, be finely comminuted economically. FLSmidth offers HOTDISC? Combustion Device for high efficient firing of used tyres.

Agricultural Biomass- A largely untapped renewable energy source: The type of biomass utilized by cement plants is highly variable, and is based on the crops that are locally grown/available. For e.g., rice husk, hazelnut shells, coconut husks, corn stover, coffee pods, and palm nut shells are among the many varieties of biomass currently being burned in cement kilns. Biomass fuels are considered carbon neutral because the carbon released during combustion is taken out of the atmosphere by the species during the growth phase.

Major challenges of using agricultural biomass residues include the relatively low calorific value which can cause flame instability, and availability since most of the agricultural residues are seasonal (not available all year round). The flame instability problems could be overcome with lower substitution rates and ability to adjust air flow and flame shape.

Other major Alternative Fuels include waste oil, liquid waste, Plastic, Meat and bone meal, etc.

Benefits of using Alternative Fuels in Cement Production

Cement producers are striving to lower their production costs. One effective method of achieving this end is the use of alternative fuels.

The reduction in emissions to the atmosphere and the positive environmental impact it holds is a major benefit of Alternative Fuel firing. In pre-calciners where kiln exhaust gases pass through, the NOx emissions are much reduced due to reburn reactions. Also, there is an increased net global reduction in CO2 emissions when waste is combusted in the cement kiln systems as opposed to dedicated incinerators, resulting a reduction in penalties.

Key considerations and challenges for co-processing Alternative Fuels

The potential benefits of burning alternative fuels at cement plants are numerous. However, the contrary is possible where poor planning results in higher emissions or when they are not put to their best use with best practices.

Alternative fuels used in cement manufacturing have different characteristics compared to the conventional fuels. Switching fuels present several challenges that must be addressed in-order to achieve successful application. The type of fuel used can introduce some material components which can interfere with the chemistry of the cement materials as well as affect the operation of the system. The use of a type of fuel is hence subject to the constraints imposed by any effect on cement quality, refractory life, gas and material flow or potential emissions to the atmosphere.

Poor heat distribution, unstable pre-calciner operation, blockages in the preheater cyclones, build-ups in the kiln riser ducts, higher emissions and dusty kilns are some of the major challenges.

FLSmidth Alternative Fuel Firing Technology

Introducing alternative fuels has an impact across the plant. The materials can have totally different characteristics from fossil fuels. They can be sticky, fluffy, moist, and fluctuating in size and quality or you may need to switch between different types of fuel with very different characteristic due to governed by availability. They will burn differently, have a different reaction in the kiln and may require you to take other actions to ensure consistent clinker quality. There are a lot of variables at play ??which is why you need an experienced partner on your side.

With over 25 years of direct alternative fuels experience and more than 130 years in the cement industry, FLSmidth? offers a range of products to enable Cement Manufacturers to increase their substitution of Alternative Fuels.

JETFLEX? Burner

Cement kilns have several characteristics which make them ideal installations for disposal of waste through co-processing in an environmentally sound manner:

– High temperatures

– Long residence time

– Oxidizing atmosphere

– High thermal inertia

– Alkaline environment

– Ash retention in clinker

FLSmidth?? JETFLEX? Burner is a highly flexible kiln burner, designed to produce the best flame shape and lowest NOx emissions for various fuel types and operating conditions. It fires rotary kilns with pulverized coal or coke, oil, natural gas, or any mixture of these fuels. Alternative fuel firing of plastic chips, wood chips and sewage sludge can also occur through the same common fuel channel to improve heat and power consumption and minimize cold airflow entering from the fuel transport.

JETFLEX? PLUS Burner

For optimum combustion flexibility, our JETFLEX PLUS Burner offers superior combustion of cost-effective grade fuels, complete flame-forming control and increased fuel retention time. The two design features that characterize the JETFLEX PLUS Burner model are individually rotatable jet air nozzles and a retractable center pipe for alternative fuel firing.

The individual rotatable nozzles also enable fuel lift configuration. This is used with solid alternative fuels to increase fuel retention time in the flame. The result is less fuel drop-out, improved combustion, and improved clinker quality. The swirler is the main mechanism for shaping the flame during start-up and daily operation.

The JETFLEX PLUS burner offers retraction of the swirler and central duct. In combination with the axial air nozzles, this enables a significant drop in fuel velocity in front of the burner. This feature strongly increases the fuel retention time in the flame and enables early ignition of low grade fuels. In combination with the fuel lift configuration as noted above, spillage to the charge is minimised. This allows the burner to contribute to superior flame and clinker quality control as well as a high alternative fuel substitution.

HOTDISC? Combustion Device

The HOTDISC solution allows cement producers to substitute coal or other fossil fuels with a wide range of alternative fuels. The HOTDISC is a flagship solution for FLSmidth?? MissionZero that helps cement producers take an important step toward zero-emission cement plants by 2030. Launched in 2004 and over 35 installations worldwide, the HOTDISC Combustion Devices has already firmly established itself as an attractive technology to accelerate cement plants??transition toward alternative fuels.

From wet powders to solid waste up to 1.2 metres in diameter, our HOTDISC Combustion Device can burn them all. The waste to energy process eliminates the need for expensive shredding and gives you the flexibility to select the most economical choice from a wide range of alternative fuel options. The HOTDISC Combustion Device is designed to achieve a calciner fuel substitution rate of up to 80%, although results vary significantly depending on specific plant conditions.

As an integrated part of your kiln system, the HOTDISC Combustion Device is added onto the calciner and functions as a slow-moving disc furnace. When alternative fuel, preheated raw meal and tertiary air are fed into the HOTDISC, it produces combustion gases, partly calcined meal and combustion residues. These are then processed in the calciner alongside the other streams entering it. The result is calcined meal ready for the kiln and well-controlled emissions.

Alternative fuels are introduced onto the slowly rotating disc and they start to burn in fully-oxidising conditions when they meet the hot tertiary air. The burning fuel is transported approximately 270? on the disc until it reaches the scraper, where the remaining ash and partly calcined materials are discharged into the riser duct. Heavy combustion residues fall into the kiln inlet, while lighter fragments and combustion gases move up into the calciner.

HOTDISC-S? is a recently developed version of HOTDISC specifically to cater the needs of customers with SLC type calciners, hence enabling them to achieve Alternative Fuel firing. Two of these devices have been commissioned globally and running successfully.

Low NOx Calciner

With a goal to optimise production costs, FLSmidth?? Low NOx Calciner has been enhanced for operational stability, availability and combustion efficiency.

NOX regulations are continuously being tightened around the world. Meeting NOx emissions limits is therefore a key demand for cement producers, not only because NOx-related issues, such as smog pollution, have a direct impact on the local society, but also because your plant?? license to operate is directly linked to its NOx emissions.

Multiple fuel inlets are given to ensure optimal distribution between the kiln gases and the fuel. To achieve the best distribution between the kiln gases and the fuel, there are multiple inlets (four or six, depending on plant size). Better fuel distribution provides optimal mixing, which gives the highest average cross-sectional temperature without any build-up problems.

The Low NOX Calciner has the flexibility to burn almost any type of fuel. This includes traditional fuels, including coal and natural gas, more difficult-to-burn fuels, such as petcoke, and most solid and liquid waste fuels. These fuel types are burned while achieving low NOx and CO emissions.Primary Mitigation

Another simple solution FLSmidth? provides for reducing the NOx emissions in the existing plants is the Primary mitigation NOx reduction through calciner design changes. These are basically layout changes to create one firing location, one meal split, one air stream entering tangentially to the calciner and creating “hot zone??and ??eduction zone?? The plant system is studied and appropriate modifications are recommended. For even lower NOx emissions, FLSmidth? provides SNCR system as an add-on solution.

Kiln Gas By-pass System

Kiln gas bypass systems have traditionally only been used in regions where the local raw materials are naturally high in chloride, sulfur or alkalis. The growing use of alternative fuels and other materials is also increasing the input of chloride to kiln systems to the point that may require a bypass to maintain process stability or product quality. FLSmidth has extensive experience with the design and use of kiln bypass systems.

Main features:

– Quench chamber with dual layer dip tube

– Quench air inlet flap valve

– Control scheme for maximum stability

– Special lining design in transition pipe section

– Constant force support system

– Multiple layout possibilities

While the fundamental principles of a bypass system have not changed, state-of-the-art technology and design tools have been incorporated to improve bypass efficiency and maximise reliability. Most projects today will at least have the space for a future small chloride bypass (less than 10%) with respect to use of alternative fuels and materials.

Conclusion

The co-processing of waste as AFR disposes the waste completely and thereby eliminates the societal concerns associated with it. In Indian cement industry, if these initiatives could increase thermal substitution to the level of European countries, the cement industry can reduce its GHG emission by a significant amount, impacting the overall country?? GHG emission.

The type of fuel used in cement production is subject to the constraints imposed by its effects on cement quality, refractory life, emissions to the atmosphere, etc. and hence requires proper study and planning by specialists before implementation.

To reduce fuel cost in cement industry, globally, waste materials and low-grade fuels are co processed extensively as alternative fuels or energy sources. India still has a long way to go in ensuring greater substitution of AFRs, resulting in sizable conservation of natural materials and fossil fuels and to make the most out of the technology available for the same.

Author:

Gopika Krishnakumar

Product Line Manager

Cement Industry/Pyro Technology

FLSmidth

Concrete

Smart Cement Plants

Published

4 months ago

August 23, 2024

Roshna

By integrating advanced technologies like IoT and AI, cement plants are transforming into highly efficient and interconnected systems. ICR explores how these innovations enable real-time monitoring and predictive maintenance, significantly reducing downtime and operational costs.

The cement industry, traditionally known for its reliance on heavy machinery and manual processes, is undergoing a significant digital transformation. This shift is driven by advancements in technology that promise to enhance efficiency, reduce costs, and improve overall production quality. Key trends include the adoption of the Internet of Things (IoT), which enables real-time monitoring and control of production processes through interconnected devices. Artificial Intelligence (AI) and Machine Learning (ML) are being utilised to optimise operations, predict maintenance needs, and minimise downtime by analysing vast amounts of data. Additionally, the integration of Big Data analytics allows for more informed decision-making by providing insights into production trends and potential areas for improvement.
“One of the key advantages of integrating data across our systems is the ability to have a more transparent, agile, and integrated supply and logistics chain. With the implementation of Oracle Logistics Management Solution, we have been able to overcome challenges related to consignment locations and truck movements, providing real-time visibility into our operations. This has also led to operational efficiency improvements and the ability to predict consignment delivery times, which we share with our customers, enhancing their experience” says Arun Shukla, President and Director, JK Lakshmi Cement.
According to BlueWeave Consultancy, during the forecast period between 2023 and 2029, the size of India cement market is projected to grow at a CAGR of 9.05 per cent reaching a value of US$ 49.24 billion by 2029. Major growth drivers for the India cement market include the growing need from construction and infrastructure sectors and rising governmental initiatives and investments in expansive infrastructure ventures encompassing highways, railways, airports, and public edifices.

Importance of Digitalisation
Digitalisation in cement manufacturing is crucial for several reasons:

Enhanced efficiency: Digital tools streamline production processes, reducing waste and improving the precision of operations. This leads to higher output and better resource utilisation.
Predictive maintenance: By leveraging AI and IoT, cement plants can predict equipment failures before they occur, minimising unplanned downtime and extending the lifespan of machinery.
Energy optimisation: Digital technologies enable the monitoring and optimisation of energy consumption, leading to significant cost savings and a reduced carbon footprint.

This aligns with global sustainability goals and regulatory requirements.

Quality control: Advanced sensors and data analytics ensure consistent product quality by closely monitoring and adjusting the production parameters in real time.
Safety improvements: Automation and robotics reduce the need for human intervention in hazardous environments, enhancing worker safety and reducing the risk of accidents.
Competitive advantage: Companies that embrace digitalisation can respond more quickly to market changes, innovate faster, and provide better customer service, giving them a competitive edge in the industry.
Digital transformation is reshaping the cement industry by driving efficiency, enhancing product quality, and promoting sustainability. As the industry continues to evolve, the adoption of digital technologies will be essential for maintaining competitiveness and achieving long-term success.

Key technologies driving digitalisation
The digital transformation of the cement industry is powered by a suite of advanced technologies that enhance efficiency, improve product quality, and drive sustainability. Here are some of the key technologies making a significant impact:
IoT refers to a network of interconnected devices that communicate and exchange data in real time. In the cement industry, IoT applications are revolutionising operations by enabling real-time monitoring and control of production processes. Sensors embedded in equipment collect data on various parameters such as temperature, pressure, and vibration. This data is then transmitted to a central system where it is analysed to optimise performance. For instance, IoT-enabled predictive maintenance systems can detect anomalies and predict equipment failures before they occur, minimising downtime and reducing maintenance costs. Additionally, IoT helps in energy management by monitoring consumption patterns and identifying opportunities for energy savings.
AI and ML in process optimisation are pivotal in enhancing process optimisation in the cement industry. AI algorithms analyse vast amounts of data generated from production processes to identify patterns and insights that human operators might overlook. ML models continuously learn from this data, improving their accuracy and effectiveness over time. These technologies enable real-time adjustments to production parameters, ensuring optimal performance and product quality. For example, AI-driven systems can automatically adjust the
mix of raw materials to produce cement with consistent properties, reducing waste and improving efficiency. AI and ML also play a crucial role in predictive maintenance, forecasting potential issues based on historical data and preventing costly equipment failures.
Tushar Kulkarni, Head – Solutions, Innomotics India, says, “Adoption of artificial intelligence (AI) will significantly help cement plants in their efforts towards innovation, efficiency and sustainability goals through improved process optimisation 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,” he adds.
Big Data analytics involves processing and analysing large volumes of data to extract meaningful insights. In the cement industry, Big Data analytics is used for predictive maintenance and strategic decision-making. By analysing data from various sources such as sensors, machinery logs, and production records, companies can predict equipment failures and schedule maintenance activities proactively. This approach minimises unplanned downtime and extends the lifespan of critical assets. Furthermore, Big Data analytics helps in optimising supply chain management, inventory control, and production planning by providing actionable insights into trends and patterns. Decision-makers can leverage these insights to make informed choices that enhance operational efficiency and competitiveness.
Arun Attri, Chief Information Officer, Wonder Cement, says, “The advantages of data integration are substantial. By leveraging integrated data,
we build a single source of truth, we can identify patterns, optimise processes, and implement strategic initiatives that drive overall business growth. This approach not only enhances operational efficiency but also strengthens our relationships with all stakeholders by providing a clear and consistent view of our operations.”
“By establishing a single source of truth, we ensure that all stakeholders, both internal and external, have access to consistent and accurate data. This unified data repository enhances visibility into our operations, improves decision-making, and enables comprehensive analyses. For internal stakeholders, such as our production, quality and maintenance teams, this means having reliable data to optimise processes and schedule maintenance effectively. For external stakeholders, including suppliers and customers, it ensures transparency and trust, as they can rely on the accuracy of the information provided,” he adds.
Cloud computing offers a scalable and flexible solution for data storage and access, playing a vital role in the digitalisation of the cement industry. By storing data in the cloud, companies can easily access and share information across different locations and departments. Cloud-based platforms facilitate real-time collaboration and data sharing, enabling seamless integration of various digital tools and systems. Additionally, cloud computing provides robust data security and backup solutions, ensuring that critical information is protected and can be recovered in case of data loss. The scalability of cloud services allows cement manufacturers to handle the increasing volume of data generated by IoT devices and other digital technologies, supporting their growth and innovation initiatives.

Digital twin technology
Digital twin technology involves creating a virtual replica of a physical asset, process, or system. This digital counterpart is continuously updated with real-time data from sensors and other sources, mirroring the physical entity’s performance, behaviour and condition. In the cement industry, digital twins
offer numerous benefits. They enable real-time monitoring and analysis, allowing operators to visualise and understand complex processes in detail. This enhanced visibility helps in optimising production, improving efficiency, and reducing downtime. Digital twins also facilitate predictive maintenance by simulating various scenarios and identifying potential issues before they occur, thereby extending the lifespan of equipment and minimising maintenance costs. Moreover, they support data-driven decision-making by providing comprehensive insights into operations, leading to better resource management and increased productivity.
Tarun Mishra, Founder and CEO, Covacsis, explains, “Different plant data reside within the walls of individual plants. Comparing micro economic performance across plants is impossible. Covacsis’ IPF is designed to aggregate multiple plant’s data at unified enterprise datalike (historian) which then further used for relative baselining and relative performance analysis across same and similar asset base or product or processes.”
“Data plays the most important role in any algorithm. Big data and fast data are only adding to the logistics performance of any algorithm and platform. Covacsis is a decade old and most mature platform in the world. Covacsis’ SaaS infrastructure is already handling more than 350 billion of cement process and operation data on a daily basis with a compounding daily growth rate of 1 per cent. This provides a significant advantage to Covacsis towards building algorithms and ensuring the value efficacy of these algorithms for the industry,” he elaborates.
The implementation of digital twins in cement plants involves several steps. First, detailed models of the plant’s equipment, processes, and systems are created using data from various sources such as sensors, historical records, and engineering specifications. These models are then integrated into a digital platform that continuously collects and analyses real-time data from the physical plant. For instance, a digital twin of a cement kiln can monitor temperature, pressure, and other critical parameters, allowing operators to optimise the combustion process and improve energy efficiency.
Similarly, digital twins of grinding mills can help in adjusting operational parameters to achieve optimal particle size distribution and improve cement quality. The integration of digital twins with other digital technologies such as IoT, AI and Big Data analytics enhances their capabilities, providing a comprehensive and dynamic view of the entire production process. As a result, cement plants can achieve significant improvements in operational efficiency, product quality and sustainability.

Automation in cement production
Automation plays a pivotal role in enhancing productivity within the cement industry by streamlining operations and reducing the reliance on manual labor. Automated systems and machinery can perform repetitive and complex tasks with higher precision and consistency than human workers. This leads to significant improvements in operational efficiency and throughput. For instance, automated material handling systems can manage the movement and storage of raw materials and finished products more effectively, minimising delays and reducing handling costs.
Automated process control systems enable real-time monitoring and adjustments of production parameters, ensuring optimal performance and reducing waste. Additionally, automation helps in maintaining consistent product quality by minimising human errors and variations in the manufacturing process. Overall, the integration of automation technologies results in faster production cycles, lower operational costs, and increased competitiveness in the market.
The introduction of automation in the cement industry has a profound impact on workforce skills and safety. As automation takes over routine and hazardous tasks, the demand for manual labour decreases, and the focus shifts to more technical and supervisory roles. Workers are required to develop new skills in operating and maintaining automated systems, as well as in data analysis and problem-solving. This shift necessitates continuous training and upskilling to ensure the workforce can effectively manage and leverage advanced technologies.
On the safety front, automation significantly enhances worker safety by reducing their exposure to dangerous environments and tasks. Automated systems can handle heavy lifting, high-temperature processes, and exposure to harmful dust and chemicals, thereby minimising the risk of accidents and occupational health issues. As a result, automation not only boosts productivity but also contributes to a safer and more skilled workforce, fostering a more sustainable and resilient industry.

Energy efficiency and sustainability
Digital tools are revolutionising the way energy consumption is monitored and optimised in the cement industry. Advanced sensors and IoT devices continuously collect data on energy usage across different stages of the manufacturing process. This real-time data is analysed using AI and machine learning algorithms to identify patterns, inefficiencies, and opportunities for energy savings. Energy management systems (EMS) integrate these digital tools to provide a comprehensive overview of energy consumption, allowing operators to make informed decisions to reduce energy waste. For instance, predictive analytics can forecast energy demands and optimise the operation of high-energy equipment, such as kilns and grinders, to align with periods of lower energy costs. Additionally, automated control systems can adjust operational parameters to maintain optimal energy efficiency, thereby reducing the overall energy footprint of the plant.
McKinsey & Company for the cement industry analyse that pursuing digitisation and sustainability levers are key to significantly boosting productivity and efficiency of a typical cement plant. The result is a margin gain of $4 to $9 per tonne of cement, which would shift a traditional plant to the top quartile of the cost curve for plants with similar technologies.
Digital technologies are also instrumental in driving sustainable practices within the cement industry. By providing precise control over production processes, digital tools help in minimising raw material wastage and reducing emissions. For example, advanced process control (APC) systems optimise the combustion process in kilns, leading to more efficient fuel use and lower carbon dioxide emissions. Digital twins, which create virtual replicas of physical assets, enable detailed simulations and scenario analyses, allowing companies to explore and implement more sustainable production methods. Furthermore, the integration of renewable energy sources,
such as solar and wind power, is facilitated by digital technologies that manage and balance energy loads effectively.
Digital platforms also support the implementation of circular economy practices, such as the use of alternative fuels and raw materials, by tracking and optimising their utilisation throughout the production cycle. Overall, digital technologies empower the cement industry to achieve significant advancements in energy efficiency and sustainability, contributing to environmental conservation and compliance with global sustainability standards.

Future of digitalisation
The cement industry is on the brink of a significant transformation driven by emerging technologies. Innovations such as artificial intelligence (AI), machine learning (ML), advanced robotics, and blockchain are poised to revolutionise various aspects of cement production and supply chain management. AI and ML will enable more sophisticated predictive maintenance and process optimisation, reducing downtime and increasing efficiency. Advanced robotics will automate more complex and hazardous tasks, further enhancing productivity and worker safety. Blockchain technology offers potential benefits in enhancing transparency and traceability in the supply chain, ensuring the integrity of product quality and compliance with environmental regulations. These emerging technologies will collectively contribute to a more efficient, reliable, and sustainable cement industry.
Smart cement plants represent the future of the industry, where digital technologies are fully integrated to create highly automated and interconnected production environments. In these plants, IoT devices, digital twins and AI-driven systems will work together seamlessly to monitor, control and optimise every aspect of the manufacturing process. Real-time data from sensors will feed into advanced analytics platforms, enabling instant adjustments to maintain optimal performance. Digital twins will allow operators to simulate and test changes in a virtual environment before implementing them in the physical plant, minimising risks and enhancing decision-making. Furthermore, smart cement plants will incorporate renewable energy sources and energy storage solutions, supported by intelligent energy management systems that ensure efficient and sustainable operations.
Over the next decade, the digital transformation of the cement industry is expected to accelerate, driven by continuous advancements in technology and increasing demands for sustainability. We can anticipate widespread adoption of AI and ML for real-time process optimisation and predictive maintenance, leading to significant reductions in operational costs and emissions. The use of digital twins will become standard practice, enabling more precise and flexible production planning and execution.
Enhanced connectivity and data sharing across the supply chain will improve efficiency, transparency, and collaboration among stakeholders. Additionally, the integration of renewable energy and advanced energy storage solutions will become more prevalent, supported by digital platforms that optimise energy usage and reduce environmental impact. As the industry embraces these digital innovations, we will see a new era of smart, sustainable, and highly efficient cement manufacturing, positioning it to meet the challenges and opportunities of the future.

Conclusion
The digital transformation of the cement industry is poised to revolutionise traditional manufacturing processes, driving significant advancements in efficiency, sustainability, and competitiveness. Emerging technologies such as IoT, AI, ML advanced robotics, and blockchain are not only optimising energy consumption and improving operational efficiency but are also paving the way for more sustainable practices. The evolution towards smart cement plants, where digital tools are fully integrated, is set to redefine production environments with enhanced automation, real-time monitoring and advanced analytics.
Over the next decade, we can expect these technologies to become standard practice, leading to substantial reductions in costs and emissions, improved supply chain transparency, and greater adoption of renewable energy sources. As the industry embraces digitalisation, it will be better equipped to meet future challenges and seize new opportunities, ultimately contributing to a more sustainable and resilient
global economy.

– Kanika Mathur

Concrete

Advantages of data integration are substantial

Published

4 months ago

August 23, 2024

Roshna

Arun Attri, Chief Information Officer, Wonder Cement, discusses the digital transformation and advanced technologies used to enhance operational efficiency, sustainability and cybersecurity in their cement manufacturing processes.

How has the implementation of IT initiatives transformed your operations and processes in the cement industry?
We operate under the digital vision: To leverage digital to accelerate growth, build relationships and enhance consumer experience.
Our digital transformation initiatives have profoundly reshaped operations and processes at Wonder Cement. By integrating advanced technologies such as IoT, cloud computing and constructing a data lake house for data consolidation as a single source of truth, we have enabled seamless information flow between applications and developed real-time analytics. These advancements have streamlined our production processes, enhanced operational efficiency, and improved decision-making. Additionally, predictive analytics allows us to anticipate market trends and customer needs more accurately.

Can you discuss how your organisation is adopting Industry 4.0 technologies and the benefits you are experiencing?

Embracing Industry 4.0 technologies is truly transforming our operations and improving reliability. Here are the key benefits we are experiencing:

Real-time monitoring: IoT devices provide real-time data on equipment performance, enabling predictive maintenance and reducing downtime.
Process optimisation: AI and machine learning algorithms enhance process optimisation,
leading to increased efficiency and reduced operational costs.
Higher productivity: Improved monitoring and optimisation result in higher productivity and better product quality.
Enhanced sustainability: Better resource utilisation contributes to enhanced sustainability.

What specific automation technologies have you implemented, and how have they improved efficiency and productivity in your cement plants?
Automation technologies have revolutionised efficiency and productivity at our cement plants. Automated quality control systems ensure consistent product quality by continuously monitoring and adjusting production parameters. Robotic process automation (RPA) in administrative functions like inventory management and order processing has drastically reduced manual errors and boosted operational efficiency. These advancements enable us to uphold high standards of precision and reliability, optimise resource utilisation and minimise wastage.

How are predictive analytics and maintenance technologies being utilised in your operations to minimise downtime and optimise maintenance schedules?
Predictive analytics and maintenance technologies are pivotal in minimising downtime and optimising maintenance schedules at Wonder Cement. By analysing historical data and real-time sensor inputs, we proactively predict and address potential equipment failures. This approach has drastically reduced unplanned downtime, enhanced equipment reliability, and extended machinery lifespan. Our maintenance teams use these insights to schedule activities during planned shutdowns, ensuring minimal production disruption. This proactive strategy has led to substantial cost savings and significantly boosted overall plant efficiency.

What are the challenges and advantages of integrating data across various systems in your cement manufacturing process?
Integrating data across various systems in our cement manufacturing process presents both challenges and advantages. One of the primary challenges is ensuring data consistency and accuracy across different platforms. To address this, we have implemented robust data integration and validation frameworks that facilitate seamless data flow and synchronisation.
The advantages of data integration are substantial. By leveraging integrated data, we build a single source of truth, we can identify patterns, optimise processes, and implement strategic initiatives that drive overall business growth. This approach not only enhances operational efficiency but also strengthens our relationships with all stakeholders by providing a clear and consistent view of our operations.
By establishing a single source of truth, we ensure that all stakeholders, both internal and external, have access to consistent and accurate data. This unified data repository enhances visibility into our operations, improves decision-making, and enables comprehensive analyses. For internal stakeholders, such as our production, quality and maintenance teams, this means having reliable data to optimise processes and schedule maintenance effectively. For external stakeholders, including suppliers and customers, it ensures transparency and trust, as they can rely on the accuracy of the information provided.

How is digitalisation contributing to sustainability efforts and reducing the environmental impact of your cement production?
IT initiatives play a pivotal role in supporting our sustainability efforts and reducing the environmental impact of cement production at Wonder Cement. One of the key contributions of IT is the optimisation of energy consumption. Through advanced energy management systems, we continuously monitor and analyse energy usage across our operations. This allows us to identify areas of inefficiency and implement measures to reduce energy consumption, such as adjusting process parameters and utilising energy-efficient equipment.
Additionally, IT enables us to track and manage emissions more effectively. By integrating emission monitoring systems with our IT infrastructure, we can continuously measure and analyse emission levels, ensuring compliance with environmental regulations and identifying opportunities for reduction. For instance, real-time data on CO2 emissions allows us to adjust our production processes to minimise the carbon footprint.
IT initiatives also facilitate the implementation of circular economy practices. Through sophisticated waste management systems, we can monitor and optimise the use of alternative fuels and raw materials, reducing our reliance on traditional resources and minimising waste generation.

With the increasing digitisation of operations, what steps are you taking to ensure cybersecurity and protect sensitive data?
With the increasing digitisation of operations, ensuring cybersecurity and protecting sensitive data is paramount at Wonder Cement. We have implemented advanced technologies such as artificial intelligence and machine learning (AI/ML) for threat detection and response, and Secure Access Service Edge (SASE) to provide secure and efficient network access. Additionally, our Security Operations Centre (SOC) continuously monitors our digital infrastructure, utilising AI/ML to identify and mitigate potential threats in real-time. Comprehensive cybersecurity measures, including firewalls, intrusion detection systems, and regular security audits, further safeguard our systems. We also conduct regular training sessions for our employees to raise awareness about cybersecurity best practices and potential threats. By prioritising cybersecurity, we ensure the confidentiality, integrity, and availability of our critical data and systems, staying ahead of emerging cyber threats.

What future IT trends do you foresee having the most significant impact on the cement industry, and how is your organisation preparing to embrace these trends?
Looking ahead, we foresee several IT trends that will significantly impact the cement industry. These include the further integration of AI and machine learning for advanced process optimisation, the adoption of blockchain technology for transparent and secure supply chain management, and the expansion of IoT applications for enhanced monitoring and control. Additionally, the use of drones for site inspections, computer vision for quality control, generative AI for innovative design solutions, and robotics and RPA for automating repetitive tasks will bring substantial benefits. At Wonder Cement, we are actively preparing to embrace these trends by investing in research and development, collaborating with technology partners, and continuously upgrading our IT infrastructure. Our proactive approach ensures that we remain at the forefront of technological advancements, driving innovation and maintaining our competitive edge.

– Kanika Mathur

Concrete

WCA’s annual conference

Published

6 months ago

June 13, 2024

Roshna

At the World Cement Association’s annual conference the WCA Director, Emir Adiguzel addressed the global cement industry to outline the challenges and opportunities facing the global cement industry.

The conference held in Nanjing, had industry leaders, innovators and stakeholders in attendance to discuss the future of cement production and sustainability. The WCAA director emphasised on the cement industry’s stern commitment to sustainability; spoke about the global cement demand and market dynamics, projecting a period of stagnation from 2024-2030 with growth expected only in the Middle east, India and Africa; about the challenges and opportunities in carbon capture technology hat show promise but will need further development and substantial investment as well as about the strategic initiatives and collaboration within the industry in improving sustainability and operational performance.

Adiguzel concluded his address by highlighting the crucial point where the global cement industry stands by saying “Collaboration within the World Cement Association is essential for sharing knowledge and aligning on long-term objectives. Ensuring the industry’s resilience and adaptation to evolving market dynamics is crucial for the survival of independent cement producers”.