AI Transforms Cement Production: Faster Quality Checks, Lower Carbon Emissions.

New Delhi: Cement is the most widely used construction material in the world, forming over 90% of our built environment. While crucial for urban development and affordable housing, cement production is highly carbon-intensive, contributing roughly 8% of global CO₂ emissions. Producing just one tonne of cement releases about 0.66 tonnes of CO₂—the equivalent of driving a car from Paris to Istanbul.

Now, researchers at IIT Delhi have developed a cutting-edge AI solution that can predict the quality of cement clinker in a fraction of a second, replacing traditional X-ray methods that take hours. Led by PhD scholar Sheikh Junaid Fayaz under Prof. N.M. Anoop Krishnan, the AI models are 88% more accurate than previous industrial-scale approaches.

“Traditional X-ray checks can take up to four hours, but our AI predicts quality in just 1/100th of a second. This allows cement plants to adjust production in real time, reducing waste and energy use,” said Prof. Krishnan. Fayaz added, “Our AI not only boosts efficiency but also advances sustainability in cement manufacturing, which is critical for cutting the industry’s carbon footprint.”

The models have already caught the attention of several global cement plants and could pave the way for smart AI-driven factories worldwide. The study, Industrial-scale prediction of cement clinker phases using machine learning, was published in Communications Engineering.

This breakthrough is also an exciting opportunity for deep-tech startups and angel investors. AI-powered solutions like this can make traditional industries smarter, greener, and more cost-effective, creating huge market potential in the construction and manufacturing sectors.

The project involved international collaboration, including Prof. Shashank Bishnoi (IIT Delhi) and researchers from Politecnico di Milano, Italy, highlighting the global push for sustainable industrial innovation.