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Designing Green Cement Plants

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SP Deolakar explains the concept of greenhouse gases, talks of sustainable development and how all these issues should be handled with respect to the manufacture of cement, in his new book Designing Green Cement Plants.Pradeep Kapoor reviews the book.

In recent years, a lot of attention is being focused on manufacturing cement in an even more environment friendly manner. Efforts are being made for reducing the adverse effects of greenhouse gases, particularly carbon dioxide, and for ensuring development in a sustainable manner. In the years to come, this issue is likely to attract a lot more attention from the policy makers and the general populace, too. It will become practically impossible to construct new cement plants or to operate existing plants unless they meet the civil society’s requirements of sustainable development and low generation of greenhouse gases. Designers, manufacturers and operators of cement plants will have to understand this subject and its implications, and equip themselves to fulfill the requirements of the emerging statutory regulations and the requirements of civil society.

Keeping this requirement in mind, SP Deolalkar’s Designing Green Cement Plants is a timely and welcome publication, which brings under one cover, all the relevant issues associated with this very important and very sensitive subject.

The author has explained the concept of greenhouse gases, of sustainable development and how all these issues should be handled with respect to the manufacture of cement, in a most coherent manner…

The book is divided into eleven sections, with each section having a number of chapters. Each section deals with a particular aspect of a green cement plant and the various chapters of each section go into sufficient details to enable the reader to fully understand the subject. ASII- relevant issues like blended cements, raw materials, alternate fuels, waste heat recovery systems, cement substitutes, etc, have all been covered. The book also contains chapters on capital costs and costs of production associated with green cement plants. An interesting chapter is on Carbon Capture and Storage System in which the author discusses future possibilities anchored in technologies already developed or under development. It is evident that with the passage of time, regulatory requirements would become increasingly stiff and such futuristic technologies would become integral part of cement plants.

The author, SP Deolalkar, has spent his entire professional life designing, manufacturing, installing and operating cement plants. The wealth of knowledge, experience and expertise that he has garnered in a lifetime has been distilled into this brilliantly produced and eminently readable book. Actually, this is a must read book for anybody connected with designing, manufacturing, operating modern cement plants anywhere in the world. It is a worthy successor to the author’s first book, Handbook for Designing Cement Plants.

Book reviewed by: Pradeep Kapoor, Former Managing Director & CEO, FL Smidth. Former Vice Chairman/Managing Director/CEO, ABG Cement.

About the author

Deolalkar is a first class graduate in Mech. and Elect. Engineering. He is also a Graduate of the British Institute of Management. He joined the Associated Cement Companies, in 1956 and has been associated with the cement industry ever since, a long innings of over 50 years. He has had firsthand working experience in cement plants, in the operation, erection and commissioning of new plants. He later worked with ACC-Vickers-Babcock, a subsidiary of ACC engaged in manufacture of Babcock boilers and cement machinery. Since 1986, Deolalkar has been working as a consultant, first as a Chief Executive of Bhagwati Priya Consulting Engineers , and later for Deolalkar Consultants, a proprietary consultancy company in Hyderabad. Deolalkar was associated with a number of institutions related to the cement industry at the national level like the Bureau of Indian Standards (earlier known as ISI), National Committee for Science and Technology and National Council for Cement and Building Materials. He was a member of the Research Advisory Committee of the NCCBM. In 2008, he wrote his first book Handbook for Designing Cement Plants. It was well received by the cement industry. His second book, Nomograms for Design and Operation of Cement Plants was a sequel to his first book and is complementary to it.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

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Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.

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