This book captures the path of digital transformation that the cement enterprises are adopting progressively to elevate themselves to ‘Industry 4.0’ level. Digital innovations-based Internet of Things (IoT) and Artificial Intelligence (AI) are pertinent technologies for the cement enterprises as the manufacturing processes operate at very large scales with multiple inputs, outputs, and variables, resulting in the essentiality of big data management. Featuring contributions from cement industries worldwide, it covers various aspects of cement manufacturing from IoT, machine learning and data analytics perspective. It further discusses implementation of digital solutions in cement process and plants through case studies.
- Present an up-to-date, consolidated view on modern cement manufacturing technology, applying new systems.
- Provides narration of complexity and variables in modern cement plants and processes.
- Discusses evolution of automation and computerization for the manufacturing processes.
- Covers application of ERP techniques to cement enterprises.
- Includes data-driven approaches for energy, environment, and quality management.
This book aims at researchers and industry professionals involved in cement manufacturing, cement machinery and system suppliers, chemical engineering, process engineering, industrial engineering, and chemistry.
Table of Contents
Chapter 1: Contemporary Cement Plants: Scale, Complexity, and Operational Variables
Anjan Kumar Chatterjee
Chapter 2: Transforming Cement Manufacturing Through Application of AI Techniques - an Overview
Chapter 3: Process Automation to Autonomous Process in Cement Manufacturing – Basics of Transformational Approach
Anjan Kumar Chatterjee
Chapter 4: Electrical Systems for Sustainable Production in Cement Plants: a Perspective View
Peddana Shirumalla and Anjan Kumar Chatterjee
Chapter 5: Data-driven Thermal Energy Management Including Alternative Fuels and Raw Materials Use for Sustainable Cement Manufacturing
Ashok Dembla and Mathias Mersmann
Chapter 6: Control of Cement Composition and Quality – Potential Application of AI Techniques
Mohsen Ben Haha, Maciaj Zajac, Markus Arndt, Jan Skocek
Chapter 7: Asset Performance Monitoring and Maintenance Management in Cement Manufacturing
P.V. Kiran Ananth, K. Muralikrishnan and Anjan Kumar Chatterjee
Chapter 8: Digital Twin and Its Variants for Advancing Digitalization in Cement Manufacturing
Anjan kumar Chatterjee
Chapter 9: Developments in Application of Sensors to Sustainable Manufacturing of Cement
Kamal Kumar, Anupam, and Anjan Kumar Chatterjee
Chapter 10: Integrated Enterprise Resource Planning (IERP) in Sustainable Cement Production.
Chapter 11: Implementation of digital solutions in cement process and plants
Sriram Seshadri, Jeyamurugan Kandasamy, and Manikandan Rajendran
Chapter 12: Technological Forecasting for Commercializing Novel Low-Carbon Cement and Concrete Formulations
Anjan Kumar Chatterjee is a Materials Scientist and has spent almost five decades in the cement and concrete industry as a research Scientist and a corporate executive. He holds a doctorate degree from the Moscow State University, Russia, based on his research studies on electro-re-melting slags at the Baikov Institute of Metallurgy in Moscow. He also carried out research work at the Building Research Establishment in the United Kingdom. His professional activities encompassed the cement manufacturing process, blended and special-purpose cements, refractory products, ready-mixed concrete production, cement and concrete materials science and chemistry. He is an alumnus of Presidency College (now a university) in Kolkata.
Dr. Chatterjee started his career as a faculty member of the Materials Science Center of Indian Institute of Technology, Kharagpur, India, and later moved to Cement Research Institute of India (now National Council of Cement and Building Materials), New Delhi, and then to Associated Cement Companies Limited (now ACC Limited), Mumbai, from where he retired as its Whole-time Executive Director. During his tenure in ACC, he was responsible for the company’s R & D, new cement projects, and all diversified business activities. In the post-retirement period, he has been engaged in providing technical support services to the cement, concrete and mineral industries in India and abroad in various capacities. In addition, Dr. Chatterjee has been on various international assignments with UNIDO and other organizations. He continues to be the Chairman of Conmat Technologies Private Limited, a service-oriented outfit, in Kolkata.
Dr. Chatterjee is a fellow of the Indian National Academy of Engineering, Indian Concrete Institute, and Indian Ceramic Institute. He is on the editorial boards of international journals such as ‘Cement and Concrete Research’ and ‘Cement Wapno Beton’. He has continued to be a member of the steering committee of International Congress on the Chemistry of Cement for the last four decades. He has been conferred lifetime achievement awards by the Indian Concrete Institute, Association of Consulting Civil Engineers, Confederation of Indian Industries, and Cement Manufacturers Association of India. Amongst his numerous publications the most note-worthy is the book on ‘Cement Production Technology: Principles and Practice’, published by the CRC Press of Taylor & Francis Group. He has many awards to his credit.
Essential reference read unravelling the cement industry’s digital transformation
A new publication providing an in-depth exploration of the digital transformation of cement production with practical insights for its application has been launched. Edited by Anjan Kumar Chatterjee and published by CRC Press, Taylor & Francis Group, Intelligent and Sustainable Cement Production - Transforming to Industry 4.0 Standards is the perfect place to start in terms of understanding the potential for and means of the digital transformation of cement manufacturing technology.
According to Dr Anjan Chatterjee, a renowned cement research scientist and corporate executive with over five decades’ experience in the Indian cement sector, a typical cement plant generates around 1bn data samples per year. Through the proper application of digital technologies, cement plants can transform their operational efficiency and, above all, operate sustainably.
The digital transformation of the cement industry, Dr Chatterjee argues, is imperative if the industry is to increase output in line with world population needs, while remaining environmentally sustainable, which is to say limiting carbon emissions and other gaseous emissions while maximising resource conservation. “A paradigm shift is foreseen in the cement industry to make it intelligent and sustainable, which can only happen through digitalisation toward Industry 4.0,” he adds.
Over 12 chapters, this essential reference explores the digital transformation of the cement industry along the journey to Industry 4.0, from cloud computing and storage to big data analytics, machine learning (ML) and other technologies deploying artificial intelligence (AI). Advances in digital twin technology and, ultimately, fully autonomous plants, is the ultimate goal – “but what is essential to achieve is sustainability and lower material footprint and significantly reduced carbon footprint,” says Dr Chatterjee.
The contributions are practical and well informed, often drawing on direct experience of practitioners, including Holcim (Switzerland) and HeidelbergCement (Germany), and knowledge experts from equipment suppliers, including FLSmidth (Denmark) and KHD (Germany). It goes beyond the promotional announcements of cement producers and equipment suppliers to explore, systematically and in some depth, the cement industry’s progress towards digital transformation.
Digital transformation will see cement plants data-driven, predictive and autonomous. This phase of industrial development is not an option but a requirement for the industry if it is to meet the demands of environmental sustainability, ensuring maximum efficiency, minimum pollution, and adequate resource conservation. “All in all,” concludes Dr Chatterjee, “the intelligent and sustainable production of cement is not a distant goal. The cement sector must achieve this objective sooner than later.”