Cement Energy & Environment

42 Digital and Thermal Innovations in Kiln–Cooler Operations for Sustainable Clinker Production Dr S. B. Hegde Former President – Manufacturing (Cement Industry) and Professor, Department of Civil Engineering, Jain College of Engineering and Technology, Hubballi, Karnataka, India, and Visiting Professor Pennsylvania State University, USA ABSTRACT The Indian cement industry is undergoing a major transformation, driven by digital technologies and thermal innovations that redefine the efficiency and sustainability of clinker production. This article critically examines how advanced kiln automation, model predictive control (MPC), waste-heat recovery (WHR) and alternative fuels are reshaping modern operations. Drawing from recent data from five large Indian plants and selected international benchmarks, it discusses how thecombinationof data-drivencontrol, exergy optimization, and CO 2 reduction can deliver high clinkerqualityatreducedspecificheatconsumption. These developments demonstrate that sustainability and process excellence are converging into one operational goal. 1. INTRODUCTION Cement manufacturing remains one of the most energy-intensive and carbon-emitting industrial processes, contributing approximately 8% of global CO 2 emissions. India, producing over 400 million tonnes annually, is both a leader in volume and innovation. Fuel and power account for 35– 40% of cement production costs, making process efficiency an economic as well as environmental priority. Modern Indian plants are now operating large rotary kilns (6,000–12,000 t/day) with advanced process control and heat recovery systems. Digitalization—through MPC, AI, and IoT sensors—has made real-time optimization possible. Thermal innovations such as preheater redesign, low-pressure coolersand improved insulation have further reduced energy losses. The target for Indian integrated plants is to bring down specific heat consumption from