Economy & Market

Green sustainability in cement

Published

11 years ago

April 30, 2015

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Aryabrat Ghosh observes that 2020 will be a year of green sustainability for cement industry where the ground work has already started.

Cement industry is one of the two primary industrial producers of carbon dioxide (CO2), creating up to 5 per cent of worldwide man-made emissions of this gas, of which 50 per cent is from the chemical process and 40 per cent from burning fuel. The CO2 produced for the manufacture of one tonne of structural concrete (using ~14 per cent cement) is estimated at 410 kg/cu m (~180 kg/tonne at a density of 2.3 g/cu cm) (reduced to 290 kg/cu m with 30 per cent fly ash replacement of cement). The CO2 emission from concrete production is directly proportional to the cement content used in the concrete mix; 900 kg of CO2 are emitted for the fabrication of every tonne of cement. Cement manufacturer contributes greenhouse gases both directly through the production of CO2 when calcium carbonate is thermally decomposed, producing lime and CO2 and also through the use of energy, particularly from the combustion of fossil fuels.

One reason why the carbon emissions are so high is because cement has to be heated to very high temperatures in order to form clinker. A major culprit of this is alite (Ca3SiO5), a mineral in concrete that cures within hours of pouring and is therefore responsible for much of its initial strength. However, alite also has to be heated to 1,500?C in the clinker-forming process.

Some research suggests that alite can be replaced by a different mineral, such as belite (Ca2SiO4). Belite is also a mineral already used in concrete. It has a roasting temperature of 1,200?C, which is significantly lower than that of alite. Furthermore, belite is actually stronger once concrete cures. However, belite takes on the order of days or months to set completely, which leaves concrete weak for an unacceptably long period of time.

Current research is focusing on finding possible impurity additives, like magnesium, that might speed up the curing process. It is also worthwhile to consider that belite takes more energy to grind, which may make its full life impact similar to or even higher than alite.

Another approach has been the partial replacement of conventional clinker with such alternatives as fly ash, bottom ash, and slag, all of which are by-products of other industries that would otherwise end up in landfills. Fly ash and bottom ash come from thermoelectric power plants, while slag is a waste from blast furnaces in the ironworks industry. These materials are slowly gaining popularity as additives, especially since they can potentially increase strength, decrease density, and prolong durability of concrete.

The main obstacle to wider implementation of fly ash and slag may be largely due to the risk of construction with new technology that has not been exposed to long field testing. Until a carbon tax is implemented, companies are unwilling to take the chance with new concrete mix recipes even if this reduces carbon emissions.

In India, typical usage of fly ash in PPC type of cement may range from 23 per cent to 26 per cent (average) whereas Bureau of Indian Standard (BIS) has allowed the limit till 35 per cent (in coming years the limit may exceed to 40 per cent), so there is a huge scope to increase fly ash. Chryso in India brings the solution (performance enhancers) to help reduce the issues given above like solutions to increase fly ash/slag content in PPC and PSC type of cement or to save energy by solutions like grinding aid for all type of cements (PPC/PSC/OPC) and also raw meal. With the help of its R&D centre in Turbhe, Navi Mumbai, the discussions has already started with many big cement groups to come up with solutions for the future where we are talking about complex type of cement product (addition of fly ash/slag/limestone in one type of cement) and increase of fly ash (to 40 per cent).

To summarise, one can say that 2020 will also be a year of green sustainability for cement industry where the ground work has already started.

Concrete

Wonder Cement appoints Mahesh Singh as VP Corporate Brand Communication

Published

6 days ago

October 9, 2026

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Singh brings 20+ years of brand and marketing experience, and will lead integrated corporate brand communication initiatives at Wonder Cement

New Delhi

Wonder Cement, a leading cement manufacturer, has appointed Mahesh Singh as Vice President – Corporate Brand Communication. In his new role, he will oversee corporate brand strategy and communication, including digital and performance marketing, public relations, trade, events, exhibitions, sports and experiential marketing.

Singh brings over two decades of experience across marketing and communications, with roles spanning the automotive industry, agencies and entrepreneurship. He spent more than a decade with Honda Motorcycle & Scooter India, working across integrated communication, media, digital, retail and consumer engagement. His stint also included helping build the company’s digital marketing capabilities.

He moved to dentsu X India as Vice President – Strategy & Planning, working across categories such as automotive, auto components, electric vehicles, FMCG, consumer electronics, BFSI, apparel and brand consulting. His responsibilities included media and marketing strategy, product launches, content, performance marketing and consumer activations.

Singh subsequently took an entrepreneurial route with Radiant Brands before joining Shriram Ltd (SPR Autotech) as Head – Marketing & Communications. There, his remit included brand and corporate strategy, communications, PR and ORM, retail identity, loyalty programmes and events.

At Wonder Cement, Singh will be responsible for bringing together the company’s corporate brand communication initiatives across digital, performance marketing, PR, trade, sports and experiential platforms. The role will focus on creating an integrated approach to communication across consumers, trade partners and other key stakeholders.

The appointment brings to Wonder Cement a marketer whose career has spanned the brand, agency and entrepreneurial sides of the communications ecosystem.

Wonder Cement, part of the RK Group, is a cement manufacturer with roots in Rajasthan and a focus on quality, trust and transparency. The company has grown to six manufacturing plants, and a cement capacity of 21.5 MTPA. With more than 2,000 employees and a network of over 5,000 dealers, its operations span manufacturing, distribution and customer engagement, with a focus on consistent product quality and efficient execution.

Concrete

JSW Cement commissions additional 1 MTPA grinding unit at Nagaur

Published

1 week ago

October 8, 2026

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With this commissioning, JSW Cement’s total cement grinding capacity has increased to 25.10 MTPA,
Mumbai

JSW Cement, one of India’s leading green cement producers and part of the diversified JSW Group, today announced the successful commissioning of an additional 1.00 MTPA cement grinding unit at Nagaur, Rajasthan. The commissioning marks another significant milestone in the Company’s growth strategy.

With this commissioning, JSW Cement’s total cement grinding capacity has increased to 25.10 MTPA, while its total clinker manufacturing capacity, including clinker capacity at its joint venture, JSW Cement FZC, stands at 9.74 MTPA.

JSW Cement had commenced operations in North India in March 2026 with the Nagaur Integrated Plant, comprising a 3.30 MTPA clinkerisation unit and 2.50 MTPA cement grinding unit. With the commissioning of the additional 1.00 MTPA cement grinding unit, the plant’s total cement grinding capacity has increased to 3.50 MTPA, enhancing the company’s ability to cater to the growing cement demand across Rajasthan, Haryana, Punjab and the National Capital Region (NCR). The expansion has been funded through a strategic mix of equity and long-term debt.

During the quarter ended 30th September 2026, JSW Cement has also commissioned the Alternate Fuel Handling System and the Waste Heat Recovery system (WHRS) at the Nagaur Integrated Plant.

Nilesh Narwekar, CEO, JSW Cement, said: “The commissioning of additional 1.00 MTPA grinding capacity at Nagaur is a key strategic priority for us and will accelerate JSW Cement’s expansion into North India. We look forward to servicing the growing needs of the region and contributing to the economic growth of Rajasthan, Haryana, Punjab and the NCR area. I am delighted to share that the company has commissioned this grinding unit within the expected timeline, showcasing our project execution capabilities. Further, the Alternate Fuel Handling System and the Waste Heat Recovery system (WHRS) are expected to substantially reduce our production costs going forward.”

Concrete

UltraTech becomes first Indian cement firm to cross 2 GW green energy

Published

1 week ago

October 7, 2026

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UltraTech Cement has crossed 2 GW of captive green energy capacity, with renewables and waste heat recovery meeting 48 per cent of its power needs.

Mumbai

UltraTech Cement Limited has surpassed 2 GW of installed green energy capacity for captive use, becoming the first cement company in India to achieve the milestone. The Aditya Birla Group company commissioned 116.55 MW of wind capacity at its Inter-State Transmission System-connected wind-solar hybrid project in Barmer, Rajasthan, along with 10 MW of Waste Heat Recovery System capacity at Sarlanagar Cement Works in Karnataka.

With these additions, UltraTech’s cumulative installed green energy capacity has reached 2,024 MW. This includes 1,580 MW of renewable energy capacity and 444 MW of waste heat recovery capacity, together meeting around 48 per cent of the company’s current power requirements.

The company said the milestone reflects the progress of its long-term energy transition strategy. In FY27 so far, nearly one-third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements, while five units have crossed 95 per cent.

K C Jhanwar, Managing Director, UltraTech Cement Limited, said, “Crossing the 2 GW green energy milestone is the result of a strategy we have pursued consistently over the past decade. Cement is an energy-intensive, hard-to-abate sector, and showing that reliability and growth can go hand in hand with a rapid shift to green energy sets a benchmark for the industry. With nearly half of our power needs now met through green energy, we are significantly less exposed to fossil fuel supply constraints and power price volatility. As we scale up renewables, waste heat recovery and battery storage across our operations, we are building an energy foundation for stable, long-term growth.”

UltraTech commissioned 430 MW of green energy capacity in FY26 and continues to expand its renewable energy and waste heat recovery portfolio.

The company is also progressively integrating Battery Energy Storage Systems across its operations to improve renewable energy utilisation and supply reliability.

In 2025, UltraTech operationalised what it described as India’s first on-site hybrid round-the-clock renewable energy project at Sewagram Cement Works in Gujarat. The project combines solar, wind and battery storage.

As part of its decarbonisation strategy, UltraTech said it has not invested in new captive thermal power capacity for either greenfield projects or brownfield expansions at its integrated units for more than a decade.

The company said its expanding green energy portfolio is helping reduce dependence on conventional grid electricity and fossil fuel-based power, while lowering exposure to fluctuations in coal and electricity prices.

UltraTech aims to increase green energy’s share in its total power mix to 85 per cent by 2030. As a member of RE100, it has also committed to meeting 100 per cent of its electricity requirement through renewable sources by 2050.

UltraTech Cement, the cement flagship of the Aditya Birla Group, has a total grey cement capacity of 210.1 MTPA and white cement and putty capacity of 3.5 MTPA. The company is also a signatory to the GCCA Climate Ambition 2050 and has committed to the GCCA Net Zero Concrete roadmap.