Cement, Energy and Environment

Abstract The cement industry has seen significant technological advancements in the areas of quality assurance, process control, and production, driving improvements in efficiency, sustainability, and profitability. This article explores critical innovations such as online free lime analyzers, online degree of calcination systems, and advanced gas analyzers, which have revolutionized the ability of cement plants to maintain consistent quality and reduce emissions. The paper also focuses into the role of automation and data analytics in kiln operations, including predictive maintenance and self-operating action software, providing global and Indian case studies to highlight both successes and challenges. Drones, artificial intelligence (AI), and cyber-physical systems are also discussed for their emerging roles in enhancing plant safety, monitoring, and process optimization. While these systems offer substantial benefits, such as improved energy efficiency and reduced CO emissions, their success is contingent on having a competent workforce capable of managing advanced technologies. The article critically examines the failures and limitations of certain systems, emphasizing the importance of technical The cement industry’s push towards efficiency and sustainability has led to the adoption of increasingly sophisticated technologies. However, the successful implementation of these systems is not guaranteed by investment alone. Advanced systems like online analyzers, automated control systems, and emission monitoring technologies require not only financial investment but also skilled and knowledgeable engineers who can operate, interpret, and maintain these technologies effectively. Without the right technical Introduction competence and proper implementation. Additionally, the paper explores the industry's growing focus on cybersecurity, addressing potential threats to operational technology (OT) systems and the need for robust protections. Lastly, in light of India's commitments under the Paris Agreement, the paper discusses the way forward for the Indian cement industry, including strategies for achieving sustainability and meeting regulatory requirements from the Central Pollution Control Board (CPCB) Dr S B Hegde Ex President – Manufacturing (Cement Industry), Professor, Department of Civil Engineering, Jain College of Engineering and Technology, Hubli, India and Visiting Professor, Pennsylvania State University, United States of America Technological Innovations Driving Quality, Efficiency and Sustainability in Cement Manufacturing 07