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We will certainly consider going for Greenco rating in future

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Anil Kumar Pillai, Chief Executive Officer, JSW Cement.
We are one among the best in class cement industries in India having lower specific energy consumption, dust emission, water consumption, GHG emission, and zero effluent discharge outside the premises, says Anil Kumar Pillai, Chief Executive Officer, JSW Cement. Excerpts from the interview…

How do you look at the sustainability issues in the cement industry?
Cement industry fundamentally is an energy intensive operation and not at all environmentally friendly by nature. Furthermore, it consumes large amounts of non-renewable raw materials and generates substantial amounts of carbon dioxide and environmental particulate matter in the process. It is estimated that 5-6 per cent of all carbon dioxide greenhouse gases generated by human activities originate from cement production alone.

Cement industry has to place the sustainability of the planet and the welfare of future generations high on their agenda before profit making only, and step up to their environmental responsibility. It is simply too important an industrial sector for mankind to go without, and it is possible with current technology and will power to operate in both a sustainable as well as economically profitable way. In order to minimize the impact of all of the above-mentioned issues, it is clear that the cement and construction industry will have to adapt to remain sustainable and in the process, adopt a number of innovative and new practices.

What are the possible ways to increase sustainability in the cement industry?
Few of the possible ways to increase sustainability in cement production could be:

  • Use of latest technology equipment/technology up gradation for older plants
  • Waste heat recovery boilers should be installed to generate power from waste hot gases
  • Use of alternative raw materials (industrial by products and wastes) from those currently employed
  • Use of fluxes to lower the burning temperature in cement kiln to lower the energy consumption
  • Use of chemical gypsum to the optimum level so that mineral gypsum may be conserved
  • Use of grinding aids to reduce electrical energy consumption for cement grinding
  • Production of blended cements such as PPC, PSC, limestone blended cement etc.

However, judging from the possibilities to improve sustainability by optimizing the raw material supply, adopting latest energy efficient technologies, optimizing the production process, substituting alternative fuels and raw materials, and finally blending the final product with suitable admixtures, it seems that the emphasis of most cement producers is still focused on selected parts of these different possibilities, especially the final substitution of cement by various mineral admixtures. It is therefore imperative for the cement producers to adapt fast enough and to a sufficient degree to exploiting all the possible options to reduce their environmental footprint.

Brief us on the steps initiated by JSW to reduce the carbon footprint.

AFR: Use of pet coke, carbon black from tyre chips, and waste from JSW Steel etc, are being used to conserve fossil fuels.

Renewable energy: Feasibility study in progress to install solar power system and wind mill installation at cement mill dust collector fan outlet WHR systems: We have planned to install 9 MW WHRPP to recover the waste heat generated from preheater and clinker cooler. This will help us to reduce our carbon footprint to a large extent.

Water positive: We are a water positive unit; i.e. our total water recharge exceeds the groundwater withdrawal. However, we will further reduce our specific water consumption by utilizing more slag on one hand while improving the process and equipment efficiency with respect to water consumption.

Logistics: Gradual increase in rail movement (inward and outward)

What is your goal of reducing carbon footprint by 2020?
We plan a 20 per cent reduction from the present level.

Which are the key levers you have identified to reduce the carbon footprint?

  • Reduction in special thermal and electrical energy consumption through process optimization
  • Increase in addition of slag content in PSC
  • Increase in production of PSC and GGBS
  • Increase in rail movement (inward and outward)
  • Maximum utilisation of industrial waste generated at JSW Steel (slag, raw material supplement such as flue dust, Corex sludge etc.)
  • Maximum utilisation of chemical gypsum by replacing imported mineral gypsum Installation of waste heat recovery power plant in the existing kiln
  • Use of renewable energy
  • Benchmarking with best-in-class and global players
  • Carbon footprint estimation in line with CSI/WBCSD protocol by an external and recognised agency
  • Energy audit of the entire facility by accredited energy auditors in order to pinpoint areas for reduction in energy consumption
  • Increased production and sale of PSC with corresponding reduction in OPC supplies
  • Increase in slag addition in PSC to optimum level
  • Sale of GGBS to RMC units and construction industries
  • Process optimization, minor modifications and debottlenecking with a view to improving overall plant energy performance

How green is your operation, from mining to production and dispatch of cement?
Since out plant is designed for PSC and GGBS production, we are far greener than OPC and PPC producing industries. The key ?Green areas? are highlighted below:

  • Reduced material extraction (tonne of limestone/tonne of cement) from the quarries thus reduced loss to natural landscaping compared to OPC/PPC producing cement plants
  • Controlled blasting technique is used to reduce dust, noise, vibration and fly rock generation
  • Optimum utilisation of subgrade limestone
  • Entire top soil generated from mines is used for greenbelt development
  • Use of flue dust (waste from steel plant) in place of iron ore to supplement Fe2O3 in raw mix
  • Most energy efficient grinding mills (Combi Roller Press) installed
  • Six-stage pre-heater system with inline calciner
  • Low SOx and NOx generation from pyro-processing. (Inline calciner and low NOx burner provided)
  • All pollution control equipment (bag house and bag filters) are designed to control dust emission below 30 mg/Nm3
  • Extensive utilisation of industrial wastes such as slag, pet coke, raw mix additives etc.
  • 65 per cent of the total gypsum we use in cement manufacturing is chemical gypsum sourced from fertiliser industries
  • Production of environment-friendly products by using blast furnace slag ? PSC, GGBS and slag sand
  • We are supplying GGBS directly to RMC plants to help them reduce their own carbon foot prints. In this way, we are indirectly contributing to GHG emission reduction.

Brief us on the equipment used in your plants.
We have installed high-efficiency bag houses designed to control dust emission below 10 mg/Nm3 in all sections viz, kiln and raw mill, clinker cooler, coal mill, cement and slag mills etc. These bag houses are designed to operate at about 99.9 per cent efficiency.

How many of your plants are Greenco rated?
So far none of our plants is Greenco rated. However, in future we will certainly consider going for Greenco rating.

Where does the company see itself five years down the line?
The company in the next five years clearly looks at being one of the strongest players in the cement category having a wide spread distribution network and strong brand.

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Concrete

India donates 225t of cement for Myanmar earthquake relief

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On 23 May 2025, the Indian Navy ship UMS Myitkyina arrived at Thilawa (MITT) port carrying 225 tonnes of cement provided by the Indian government to aid post-earthquake rebuilding efforts in Myanmar. As reported by the Global Light of Myanmar, a formal handover of 4500 50kg cement bags took place that afternoon. The Yangon Region authorities managed the loading of the cement onto trucks for distribution to the earthquake-affected zones.

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Concrete

Reclamation of Used Oil for a Greener Future

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In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.

The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.

The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.

Circular economy in lubricants
In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt, and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.

Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.

Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)

The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.

On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:

  • Kinematic Viscosity
  • Flash Point
  • Total Acid Number
  • Moisture / Water Content
  • Oil Cleanliness
  • Elemental Analysis (Particulates, Additives and Contaminants)
  • Insoluble

The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.

Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.

About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

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Concrete

Charting the Green Path

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The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.

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