Comprehensive Emissions & Process Monitoring for Cement Plants. Replace 6-8 traditional CEMS systems with one intelligent solution. AI-powered multi-gas detection from ppb to 25% CO₂ - built for extreme kiln environments.
India produces 380+ million tonnes of cement annually - the world's 2nd largest producer with strict emission regulations
CO₂ accounts for 8% of global emissions. NOx, SO₂, Mercury require continuous monitoring.
CPCB, MoEF&CC, EU IED, EPA standards with heavy fines for violations.
30-40% of operational costs. Kilns operate at 1,400-1,500°C continuously.
Variable raw materials affect efficiency. Real-time optimization needed.
H₂S, CO, VOCs require continuous monitoring for personnel protection.
$50-150/ton production cost. Every efficiency gain matters.
PM10/PM2.5 health impacts, community concerns, regulatory fines.
Waste co-incineration requires HCl, HF, dioxin monitoring.
Real-time process measurement with unprecedented accuracy - the key to unlocking massive savings
Result: Traditional CEMS are compliance tools, not process optimization tools. You can't optimize what you can't measure accurately in real-time.
| Parameter | Traditional CEMS | CEMS 5.0 Pro+ with NANOZ |
|---|---|---|
| System Accuracy | ±5-10% (combined) | ±0.1% (integrated) |
| Response Time | 15-30 minutes | <1 second |
| Measurement Method | Extractive (sample lines) | In-situ (direct) |
| Number of Devices | 6-8 separate units | 1 integrated system |
| Calibration Frequency | Weekly/Monthly per device | AI self-calibrating |
| Drift Compensation | Manual adjustment | Zero-drift FTIR + AI |
| Cross-Sensitivity | Major interference issues | AI auto-compensation |
| Process Optimization | Not possible | Real-time control |
| Data for AI/ML | Too slow, inaccurate | Perfect for ML models |
With ±10% accuracy, you can't fine-tune air/fuel ratio. You run rich (wasting fuel) or lean (damaging refractory).
With ±0.1% accuracy, you optimize combustion in real-time, saving 2-5% fuel = ₹1.2.5 Crore/year.
Traditional CEMS show you what happened 15-30 minutes ago. That's historical data, not process control.
With <1 second response, you see changes as they happen. AI predicts issues before they occur = 67% less downtime.
Co-incineration requires precise HCl, HF, Mercury monitoring. Traditional systems can't react fast enough to variable waste composition.
With real-time monitoring, you safely increase alt fuel ratio by 20-40% = massive fuel cost savings.
Carbon markets require verified, auditable CO₂ data. ±10% accuracy means ±10% uncertainty in your credits.
With ±0.1% accuracy, your CO₂ reduction claims are bulletproof. Full value for 216K-432K tonnes CO₂ saved.
Bottom Line: Traditional CEMS tell you if you're compliant.
CEMS 5.0 Pro+ tells you how to optimize your entire plant in real-time.
One system replaces 6-8 traditional monitoring devices
Complete coverage from raw material to dispatch
Complete 5-year total cost of ownership comparison
For a typical 10,000 tonnes/day cement plant (Indian standard)
CEMS 5.0 Pro+ optimization reduces cement plant emissions significantly - contributing to ESG goals and carbon credits
IN India Context: With 380+ million tonnes annual cement production and the Carbon Credit Trading Scheme (CCTS) launching, reducing emissions is not just environmental responsibility - it's a significant revenue opportunity.
Our sensors enable comprehensive plant-wide control - unlocking additional savings through holistic process optimization
All monitoring points connected through one AI-powered platform Real-time optimization across the entire production chain
Built-in compliance with Indian regulatory requirements - automatic reporting to CPCB, SPCB and MoEF&CC
Real-time data integration
Continuous data upload every 15 minutes to CPCB online portal as per OCEMS guidelines
Daily, monthly, quarterly reports in prescribed format - zero manual effort
Encrypted transmission with audit trail - meets CPCB data integrity requirements
Automatic notification to authorities and plant management when limits approached
Central Pollution Control Board
State Pollution Control Boards
Ministry of Environment
Ambient Air Quality System
Combined impact of CEMS 5.0 Pro+ with NANOZ for a typical 10,000 t/day cement plant (Indian standard)
| Category | Source | USD/Year | INR/Year |
|---|---|---|---|
| Energy Reduction | Kiln optimization 2-5% | $120K - $300K | ₹1Cr - ₹2.5Cr |
| Process Efficiency | Capacity +1-3%, quality | $800K - $2.4M | ₹6.7Cr - ₹20Cr |
| Maintenance & Labor | -58% maintenance, -75% audit time | $170K - $280K | ₹1.4Cr - ₹2.3Cr |
| Plant Integration | Cross-process synergies | $860K - $1.76M | ₹7.2Cr - ₹14.7Cr |
| Risk Mitigation | Avoided fines, shutdowns | $100K - $1M | ₹83L - ₹8.3Cr |
| Carbon Credits (CCTS) | India CCTS @ ₹900/tonne | $2.3M - $4.7M | ₹19.4Cr - ₹38.9Cr |
| TOTAL ANNUAL SAVINGS (incl. Carbon Credits) | $4.5M - $11.1M | ₹37.5Cr - ₹92.5Cr | |
| Source | Mechanism | Reduction % | Tonnes CO₂/Year |
|---|---|---|---|
| Kiln Optimization | AI-powered combustion control | 3-7% | 81,000 - 189,000 |
| Process Integration | Cross-process synergies | 2-3% | 54,000 - 81,000 |
| ️ Heat Recovery | Clinker cooler optimization | 1-2% | 27,000 - 54,000 |
| ️ Alternative Fuels | Safe co-incineration increase | 2-4% | 54,000 - 108,000 |
| TOTAL CO₂ REDUCTION | 8-16% | 216,000 - 432,000 | |
Calculations based on typical 10,000 t/day cement plant (Indian standard) with 300 operating days/year producing ~3 million tonnes cement annually. Carbon credit values based on India CCTS compliance rate of ₹900/tonne CO₂ (expected starting price 2026). CCTS prices projected to increase to ₹1,500-2,000/tonne by 2030. Actual results may vary based on plant configuration, existing systems, raw material quality, and local energy costs. Contact us for a customized assessment of your facility.
LafargeHolcim Partner Plant | 8,000 Tonnes/Day Capacity
12 monitoring points across entire facility
Aging CEMS infrastructure, high maintenance costs, increasing EPA pressure, frequent calibration requirements
Complete CEMS 5.0 Pro+ with NANOZ system with NANOZ MoxAi, 12 monitoring points, AI-powered analytics, cloud reporting
Full compliance with Indian and international emission regulations
Central Pollution Control Board standards for cement industry emissions
Ministry of Environment, Forest and Climate Change regulations
Industrial Emissions Directive Annex VI BAT-AELs
Environmental Protection Agency MACT standards
Quality assurance of automated measuring systems
UK Environment Agency monitoring certification
German technical inspection certification
Accredited calibration laboratory (SCS 0046)