Refractory Industry's Role in Driving Infrastructure Growth

Parmod Sagar, Chairman & Managing Director - India, President - India, West Asia, and Africa at RHI Magnesita, in a recent interview with Industry Outlook, discussed how the Indian refractory industry is adopting advanced technologies like AI, IoT, and smart manufacturing techniques, while integrating these innovations with traditional practices. He emphasized balancing efficiency, sustainability, and durability, as well as addressing workforce upskilling and aligning with Industry 4.0. With over 30 years of experience in the steel and refractory industries, Parmod Sagar is skilled in technical marketing and leadership, driving innovation at RHI Magnesita. He also serves as the President of the World Refractories Association.

The Indian refractory industry is increasingly adopting AI and IoT to enhance efficiency. How are companies balancing these advancements with traditional processes, and which digital tools are most impactful?

The Indian refractory industry is at a pivotal moment, balancing technological innovation with time-tested processes. AI tools are available for the industry to integrate into their operations while maintaining the foundational principles of refractory production. Traditional methods remain essential for quality assurance and material integrity, but they are now complemented by predictive analytics, process automation, and data-driven decision-making.

Automated Process Optimisation (APO) systems are one tool through which an enormous amount of data is collected for steel production steps. These tools enable precise real-time monitoring, improve process efficiency, and reduce material wastage. Additionally, AI-powered predictive maintenance enhances equipment reliability, minimizes downtime, and extends the lifespan of refractory materials. By balancing tradition with innovation, the industry fosters a future-ready, efficient, and resilient production ecosystem.

With the rise of Industry 4.0, how are Indian refractory manufacturers incorporating smart manufacturing techniques to optimize material performance and production processes?

Industry 4.0 is driving a significant transformation in the manufacturing landscape. Companies are embedding smart manufacturing techniques like robotics, process automation, and real-time data analytics into production workflows. RHI Magnesita, for instance, is supporting the steel and cement industry with advanced technology solutions like Lining Evaluation Scan for the cement industry and Robotics Technology’ for the steel industry, revolutionizing key processes such as ladle handling and slag management. By providing accurate assessments within around four hours after scanning, LES significantly enhances the precision and efficiency of evaluating the remaining lining thickness of rotary kilns.

As demand for durable refractories rises, what innovations are being implemented to improve their lifespan, and how are they integrated into production?

Refractory products and solutions are engineered to withstand temperatures exceeding 1200 degrees Celsius, critical for industries like steel, cement, and glass. High-grade Magnesia and Alumina-based bricks and mixes are designed to offer superior thermal resistance and mechanical strength. For instance, RHIM’s state-of-the-art manufacturing facilities and rigorous quality control processes ensure that each product meets the highest industry standards. Ultimately, our refractories perform well under pressure and support the structural integrity of infrastructure, thereby contributing to the overall efficiency of high-temperature operations. Furthermore, to meet the rising demand for durable refractories, the industry is prioritizing materials engineering and digital innovation. Solutions like the SX3 Slide Gate System and INTERSTOP® Flow Control Technology optimize the flow of molten steel and reduce wear and tear on refractory linings. The integration of these advanced technologies extends the lifespan of refractories in harsh operating environments.

How is the Indian refractory industry addressing the need for real-time monitoring and data analytics to ensure the quality and reliability of refractory products in a digitalized production environment?

Real-time monitoring and data analytics are gaining pace to ensure product quality and reliability. Refractory companies offer integrated smart sensors, connected devices, and cloud-based platforms to achieve end-to-end visibility of production processes. For example, the EMLI LadleSlag sensor allows real-time slag detection, which enables precise control over molten steel production.

Digital twins and APO systems are also being used to stimulate production scenarios and predict material’s performance. This approach allows the manufacturers to identify potential defects and their rectification before they impact production. Moreover, cross-functional safety audits and site inspections are now supported by data-driven insights, leading to safer operations and higher product reliability. Such initiatives not only boost operational excellence but also align with customer expectations for consistent product quality.

With automation in steel and cement, what steps is the refractory industry taking to provide technical support and close skill gaps?

As automation becomes more prevalent in steel and cement, the refractory industry prioritizes workforce upskilling and technical support. RHI Magnesita is leading this effort through dedicated training programs and cross-functional audits. Employees at customer sites are trained in the operation of robotic cells, AI-enabled sensors, and predictive maintenance tools, ensuring a smooth transition to Industry 4.0 workflows.

By fostering a culture of continuous learning, the industry is enabling a future-ready workforce that can seamlessly adapt to automation-driven changes.

Looking ahead, what trends do you see shaping the future of the Indian refractory industry in terms of innovation, sustainability, and alignment with Industry 4.0 objectives?

Innovation, sustainability, and digital transformation have become increasingly significant not only for the refractory industry but for the overall manufacturing sector. This includes the adoption of AI, robotics, and predictive analytics to achieve leaner, more innovative, and more sustainable manufacturing operations. 

Sustainability is another critical focus area. The industry is developing eco-friendly refractory materials and using AI to optimize material usage and reduce waste. For instance, RHI Magnesita has developed proprietary technology for increasing the use of secondary raw materials with no loss in refractory performance. This helps in the customer’s decarbonization journey, reduces customer waste, and eliminates CO2 emissions that would otherwise be released in the mining and processing of new raw materials.