Pioneering the global cement industry

This is the second instalment of an article by Dr S B Hegde. The first part can be found here.

Global advancements: Electrifying kiln technology for sustainable cement production

On the global stage, the initiative to electrify kiln technology in the cement industry is gaining momentum, ushering in a new era of efficiency and sustainability. This ambitious move is not just about reducing carbon footprints; it is a transformative step that is opening new horizons and setting the stage for a more sustainable future in cement production.

Current global initiatives:

Several leading cement manufacturers around the world have embraced the electrification of kiln technology, recognising its potential to revolutionise traditional manufacturing processes. As of the latest data, the global cement industry contributes to approximately 8% of total carbon dioxide emissions. Electrification is emerging as a key strategy to address this environmental challenge.

Investments and impact:

Global investments in electrifying kiln technology are substantial, reflecting a commitment to sustainable practices. For instance, a major cement plant in Europe has invested over €80 million (approximately US$90 million) in retrofitting its kilns with advanced electric heating systems. This investment is projected to lead to a 30% reduction in carbon emissions from the kiln operations.

Technology adoption and innovations:

Cutting-edge electric heating elements and control systems are being implemented globally to replace traditional fuel-based kiln technologies. These innovations not only facilitate a significant reduction in greenhouse gas (GHG) emissions but also offer enhanced temperature control and efficiency, thereby improving overall production quality.

Collaborations and knowledge exchange:

The global cement industry is witnessing collaborative efforts between manufacturers, technology providers, and research institutions to accelerate the adoption of electrification technologies. Knowledge exchange platforms and industry collaborations are contributing to a collective understanding of best practices and challenges associated with the electrification transition.

Environmental impact:

The environmental impact of electrifying kiln technology is substantial. By reducing reliance on fossil fuels, the cement industry can significantly lower its carbon footprint. The precise control afforded by electric heating systems also contributes to a more energy-efficient and environmentally friendly production process.

Regulatory drivers:

Governments and regulatory bodies worldwide are increasingly recognising the importance of sustainable industrial practices. Incentives, policies, and regulations supporting the adoption of clean technologies are serving as catalysts for the global cement industry to prioritise electrification in kiln operations.

Future trajectory:

As the global cement industry continues its journey toward electrification, the future trajectory looks promising. Anticipated advancements in technology, increased investments, and collaborative research efforts are expected to drive widespread adoption. This not only benefits individual cement plants but also contributes to the industry's collective efforts in mitigating climate change.

Robust electrification in Indian cement plants

In the Indian cement industry, a paradigm shift is underway with a strategic focus on robust electrification. This transformative initiative involves the electrification of kiln technology, a move that not only reduces the industry's carbon footprint but also opens new horizons in efficient and sustainable cement production.

Current status:

As of now, several prominent Indian cement plants are actively engaged in transitioning their kiln technology from conventional fossil fuel-based systems to electrified alternatives. The aim is to achieve a substantial reduction in GHG emissions associated with traditional cement manufacturing processes.

Investments:

The investments made in the electrification of kiln technology are both substantial and indicative of the industry's commitment to sustainability. To provide a concrete example, a leading cement manufacturer in India has allocated over Rs. 1.5 billion (approximately US$20 million) to implement electrified kiln technology. This investment is anticipated to result in an immediate 25% reduction in carbon emissions from the kiln operation.

Technology implementation:

Electrification of kiln technology involves the integration of electrically-powered heating systems in lieu of traditional fuel-fired methods. Advanced electrical heating elements are employed to achieve the high temperatures required for the cement manufacturing process, eliminating the reliance on fossil fuels and significantly reducing emissions.

Efficiency gains:

Beyond the environmental benefits, the electrification of kiln technology is poised to enhance operational efficiency in cement plants. The precision and controllability of electric heating systems allow for better temperature management, leading to improved product quality and energy efficiency.

Renewable energy integration:

In conjunction with electrification, many Indian cement plants are exploring the integration of renewable energy sources to power their operations. Solar and wind energy installations are being considered to meet the electricity demand of electrified kilns, further reducing the carbon intensity of the cement production process.

Government support:

The Indian government's push for sustainable industrial practices aligns with the cement industry's electrification efforts. Incentives, subsidies, and favourable policies supporting the adoption of clean technologies play a crucial role in encouraging cement manufacturers to embrace electrification.

The future landscape:

Looking ahead, electrification is poised to become a cornerstone of sustainable cement production in India. Continued investments, technology advancements, and industry collaborations are expected to drive widespread adoption, reshaping the sector's environmental impact and bolstering India's position in sustainable manufacturing.

Hydrogen revolution in cement production

The global cement industry is undergoing a transformative phase by embracing the hydrogen revolution as a beacon of sustainable energy. This paradigm shift involves the incorporation of green hydrogen as a clean energy source, not only reducing environmental impact but also establishing new benchmarks for responsible energy use in cement production.

Global status:

Globally, several leading cement manufacturers have initiated pilot projects and full-scale implementations of hydrogen-based technologies in cement production. As of the latest data, the cement industry accounts for approximately 7% of global carbon dioxide emissions, making the adoption of green hydrogen crucial for achieving emission reduction targets.

In Germany, for instance, a prominent cement plant has invested over €40 million (approximately US$45 million) in a green hydrogen project. This initiative is expected to replace a significant portion of traditional fossil fuels, leading to a substantial reduction in carbon emissions.

Indian perspective:

In the Indian context, the hydrogen revolution is gaining momentum as the cement industry strives to align with the nation's commitment to sustainable development. While still in the early stages, pioneering cement plants in India are actively exploring the integration of green hydrogen into their production processes.

Current initiatives and investments in India:

An exemplary case is a major cement manufacturer in India investing Rs. 1.2 billion (approximately US$16 million) in a green hydrogen pilot project. This initiative aims to assess the feasibility of using green hydrogen as a primary fuel in cement kilns, with the potential to reduce carbon emissions by up to 30%.

Challenges and opportunities:

Despite the promising trajectory, challenges such as the cost of green hydrogen production and infrastructure development need to be addressed for widespread adoption. The Indian government's focus on promoting green hydrogen and the establishment of a National Hydrogen Mission indicate a conducive environment for overcoming these challenges.

Environmental impact:

The incorporation of green hydrogen into cement production offers a significant reduction in GHG emissions. As hydrogen combusts without producing carbon dioxide, it presents a cleaner alternative to traditional fossil fuels, aligning with global efforts to mitigate climate change.

Setting new standards:

By embracing the hydrogen revolution, the cement industry is not only reducing its environmental impact but also setting new standards for responsible energy use. This shift positions cement manufacturers as leaders in sustainable practices and reinforces their commitment to a low-carbon future.

Future trajectory:

The hydrogen revolution in cement production is poised to become a cornerstone of sustainable manufacturing globally and in India. Continued investments, collaborative research, and government support are expected to drive the widespread adoption of green hydrogen, ushering in a new era of responsible and environmentally conscious cement production.

The final part of this article will be available 22nd March.

About the author

Dr S B Hegde is a distinguished industrial leader renowned for his expertise in cement plant operations, optimisation, and the establishment of new plants. Currently guiding prominent cement companies in India and abroad, he focuses on achieving excellence in cement manufacturing, fostering product innovation, integrating hydrogen usage in cement kilns, and driving sustainability initiatives.

With a robust academic background, Dr Hegde has authored 182 research papers in national and international journals, showcasing his dedication to advancing industry knowledge. Additionally, he actively contributes to academia, participating in faculty development programmes. In an advisory role, he assists a think tank company in aiding the Government of India with research and policy formulation, particularly in the area of hydrogen usage. Dr Hegde's diverse contributions underscore his commitment to advancing the cement industry, academic pursuits, and shaping national-level policies.

Read the article online at: https://www.worldcement.com/the-americas/20032024/pioneering-the-global-cement-industry/