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Green revolution in cement industry

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Nobody could have imagined of creating building materials made of crop residues and industrial by-products. But GreenJams have revolutionised the way building materials are being manufactured. Tarun Jami, the Founder of GreenJams, spent five years studying hempcrete academically to equip himself with the technical skills to create a carbon-negative product, and after a lot of trials and tribulations, he invented Agrocrete–a carbon-negative building material comprising of crop residues and a lime-based binder. While Agrocrete is a scientific anomaly, the most amazing aspect about it is that it augments farmers??income, keeps the air clean, and generates rural employment. It is carbon-negative and helps reverse climate change too.

??reen??and ??nvironmentally efficient??products have become the buzzwords today. The Indian cement and construction industry is working effectively towards reducing carbon footprints and meeting sustainability targets. Calcination and clinker-making process are the biggest contributors to CO2 emission. About 7-8 per cent of global carbon emissions come from clinker manufacturing alone. Materials like fly ash bricks, AAC blocks, and any other novel building materials use clinker-based cement.

Cemet production is a significant source of global carbon dioxide (CO2) emissions. About 7-8 per cent of global carbon emissions come from clinker manufacturing alone. So, what is the solution? GreenJams has an answer to this problem too. The company has come up with another innovative product called BINDR?? 100 per cent upcycled product that can help cement companies cut their carbon footprint by more than 80 per cent when compared to regular Portland cement.

Below are excerpts from the interview with Tarun Jami, the Founder of GreenJams.

How did you start your journey towards making a carbon-neutral building material for the construction industry?

Late during my undergrad days of studying civil engineering, I had come across the topic-what climate change is and the impact that construction activities have on it. Since then, I got conscious of what destruction construction would cause to our environment. Ever since I developed this conviction, I was on the lookout for technologies and materials that would help make construction less harmful to the environment.

Towards the end of my engineering, I had stumbled upon a building material called hempcrete. It was carbon-negative and was made of hemp, and it felt like I had discovered a wonderland. I suddenly realised that with this hempcrete, we could make construction better for the planet. Can you imagine that construction could help reverse climate change? That epiphany set me on a journey that took me this far.

Could you brief us about your innovative product BINDR– a low-carbon replacement of Portland cement? Does it qualify for all quality and strength tests? How is it better than Portland cement?

BINDR is a 100 per cent up-cycled replacement of Portland cement with a characteristic strength equivalent to 43 grade OPC. We aren?? yet claiming structural capabilities for BINDR since we haven?? yet proven its long-term durability. Being a 100 per cent upcycled product, we can cut its carbon footprint by more than 80 per cent when compared to regular Portland cement. At 0.1 kg CO2/kg, the embodied carbon can?? go lower than this at this price point.

Agrocrete is made from crop residue. You have changed the traditional processes. How did you think of such an innovative idea? How was the response in the market in the beginning?

Agrocrete came out of a lot of trials and tribulations. It emerged as a response to a much deeper societal problem in India. About 44 per cent of Delhi-NCR?? poor winter air quality is because of crop residue burning. Almost 100 million tonnes of crop residues are burnt annually in India, leading to almost 2 lakh crore of economic loss to the country. I almost crashed my car on my visit to Delhi in late 2019 because of the impact that poor air quality had on my health. While Agrocrete is a scientific anomaly, the most amazing aspect about it is the fact that it augments farmers??income, keeps the air clean, and generates rural employment. It is carbon-negative and helps reverse climate change too. In the beginning, the market response was very skeptical and it still is. I get questions on fire resistance, decay, and durability of the blocks, which are all great, by the way.

Were there any hurdles you faced? How did you overcome them?

There were so many hurdles we faced. The biggest hurdles were technical and financial. While we somehow managed to solve the financial hurdles, the technical ones were more difficult to overcome. I spent five years studying hempcrete academically to equip myself with the technical skills to create Agrocrete. In 2017 I had started my Ph.D. at CSIR-Central Building Research Institute (CSIR-CBRI), Roorkee.

How cost-effective is your Agrocrete product? Does it offer faster completion of a project? How? Could you tell us about the manufacturing process of Agrocrete material? What kind of technology was involved?

Agrocrete helps reduce the cost of construction by almost 50 per cent in comparison to red bricks. The larger block sizes enabled by the significantly lesser weight help make it easy to work with for the masons. We are able to reduce the mortar joints by more than 60 per cent and the plaster requirements by almost 50 per cent because of the cleaner finish. The construction speed is up by almost 2.5X. Agrocrete manufacturing is a completely zero-emissions process. We utilise a patent-pending advanced alkali activation chemical technology. We do not use any furnaces and use latent chemical reactions to achieve strength.

Calcination and clinker-making process are the biggest contributors to CO2 emission. Please share your thoughts on how you can make a difference in this space.

About 7-8 per cent of global carbon emissions come from clinker manufacturing alone. Any reduction in clinker production is beneficial for the planet and humankind. Also, fly ash bricks, AAC blocks, and any other novel building materials use clinker-based cement which contribute a significant sum to the products??embodied carbon. BINDR could potentially be used to make all these products. Furthermore, by making mortars for block work and plastering, we can reduce the carbon footprint of buildings.

Tell us about the office space that you converted into a manufacturing unit at Roorkee

We built our manufacturing unit from scratch in Roorkee. We built this 1100 sq. ft. industrial building in four days flat at a cost of only Rs 200 /sq. ft. We were able to capture a total of 3.1 tons of carbon dioxide, making it carbon negative. We were able to achieve a 30 percent lesser cost of construction as compared to red bricks by reducing the mortar joints and construction time by 60 per cent. Our Roorkee manufacturing facility was built at Rs 2 lakh, which would have otherwise cost about Rs 5 lakh if we had built it using red bricks. We were able to reduce the mortar joints by more than 60 per cent and increased construction pace by 2.5x and consequently reduced labour costs.

Could you tell us about the ongoing projects and the cost and material involved in it? Any business expansion plans?

We are currently working on supplying Agrocrete hollow and solid blocks and BINDR to multiple residential projects in Punjab, Haryana, Uttarakhand, Delhi-NCR, and Uttar Pradesh. These are individual residences being built by private clients for themselves and the total number of Agrocrete hollow and solid blocks we are supplying are almost 1,00,000 units and BINDR will be about 200 bags.

We are currently in the process of setting up a brand new 2,000 blocks per day manufacturing facility in Visakhapatnam, Andhra Pradesh. The facility is expected to be operational in the next two to three months. We have received an overwhelming number of enquiries since July 13, 2021 from Karnataka, Maharashtra and Telangana and are looking for franchising partners who could set up the Agrocrete blocks manufacturing facilities in these markets.

A lot of well-established brands claim to be ??/strong>green??and ??nvironmentally efficient?? Your thoughts on this? Do you think the Indian cement & construction industry is on the right path towards sustainability?

The problem with the industry is that the benchmarks for ??reen??are getting higher and higher. Also, many products are greenwashed and do not consider lifecycle environmental impacts. With greenwashing becoming rampant, consumers and competitors are going to ask more difficult questions that manufacturers will have to be ready for. The Indian cement industry specifically is one of the greenest in the world. The average embodied carbon of Indian cement is much lower than the global average. With many companies committing to becoming carbon-neutral or even carbon-negative, I think we are on the right path towards sustainability. But it?? also time to now shift focus towards biodiversity and similar pursuits.

What are your plans in terms of adding more to product portfolio, investments, research, and development?

We have always been focused on research and development. Our team is capable, fast, and enterprising enough to develop new products that satisfy customer demands. In fact, our Agrocrete Plaster was created in response to a customer?? request. We are also looking to launch a range of carbon-negative home d?cor products under a new brand name called Sanscrete. It could potentially be the world?? first carbon-negative home d?cor brand. Sanscrete will focus on objects for home d?cor, and corporate and wedding gifting. We are currently looking to raise our first seed round and are inviting angel investors and HNIs to come to speak to us.

– Megha Rai

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Concrete

India’s Steel Imports Drop 34 Per Cent, Exports Rise 25 Per Cent In April–October

Consumption grows despite weak prices and subdued demand

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India’s finished steel imports fell 34.1 per cent year-on-year to 2.5 million tonnes in the first seven months of the financial year, according to government data. Despite the decline, the world’s second-largest crude steel producer remained a net importer of finished steel during the April–October period. The fall in imports came alongside a 7.4 per cent rise in domestic consumption, which reached 92.2 million tonnes.

South Korea emerged as India’s largest source of finished steel imports, supplying 1.4 million tonnes. It was followed by China, Japan and Russia. Although total imports declined sharply, the figures show a continued inflow of foreign steel into the Indian market.

Domestic production remained strong. Finished steel output stood at 91.6 million tonnes for April–October, while crude steel production reached 95.7 million tonnes, underscoring the scale and resilience of India’s steel industry despite external competition.

In contrast to the fall in imports, India’s finished steel exports jumped 25.3 per cent year-on-year to 3.5 million tonnes. Europe was a major destination, with Italy and Belgium leading as top importers of Indian steel, followed by Spain. This highlights the growing global competitiveness of Indian steel in select markets.

The government noted that domestic steel prices have come under pressure due to weak demand and high supply. Trading activity also remained subdued during the festival season. This challenging environment has been particularly difficult for smaller steel producers, as previously reported.

Overall, the combination of declining imports, rising exports and increasing domestic consumption reflects the complex landscape of the Indian steel sector as it navigates muted internal demand and evolving international trade dynamics.

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Concrete

JK Lakshmi Cement Plans Rs 18.16 Billion Expansion

Firm to boost clinker and grinding capacity in Chhattisgarh

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JK Lakshmi Cement announced on Tuesday that it will invest Rs 18.16 billion to expand its manufacturing operations in Chhattisgarh. The company intends to raise its clinker production capacity by 2.31 million tonnes per annum (MTPA) and its cement grinding capacity by 1.2 MTPA, supported by this proposed investment.

The Memorandum of Understanding for the expansion was signed during the Chhattisgarh Investor Connect event in New Delhi, in the presence of Chief Minister Vishnu Deo Sai. The added capacity will enhance the company’s ability to serve the rapidly growing markets of Eastern and Central India, where demand for building materials remains robust.

The move supports JK Lakshmi Cement’s broader goal of increasing its total capacity to around 30 MTPA in the coming years. Deputy Managing Director Shrivats Singhania said the expansion marks a significant step in the company’s next phase of growth, adding that Chhattisgarh has long been central to its manufacturing strategy.

Over the past decade, JK Lakshmi Cement has contributed to strengthening Chhattisgarh’s industrial landscape since establishing its integrated plant in Durg in 2015. The company has implemented multiple initiatives, including a manufacturing facility with 1.8 MTPA of clinker capacity and 2.7 MTPA of cement capacity, operational upgrades with energy-efficient technology and automation, and logistics improvements through enhanced rail connectivity.

Chhattisgarh continues to show strong economic momentum, making it one of the most promising markets for cement demand, said Arun Shukla, President and Director at JK Lakshmi Cement. The company’s shares closed 0.28 per cent higher at Rs 782.10 on the BSE.

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Balancing Rapid Economic Growth and Climate Action

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Dr Yogendra Kanitkar, VP R&D, and Dr Shirish Kumar Sharma, Assistant Manager R&D, Pi Green Innovations, look at India’s cement industry as it stands at the crossroads of infrastructure expansion and urgent decarbonisation.

The cement industry plays an indispensable role in India’s infrastructure development and economic growth. As the world’s second-largest cement producer after China, India accounts for more than 8 per cent of global cement production, with an output of around 418 million tonnes in 2023–24. It contributes roughly 11 per cent to the input costs of the construction sector, sustains over one million direct jobs, and generates an estimated 20,000 additional downstream jobs for every million tonnes produced. This scale makes cement a critical backbone of the nation’s development. Yet, this vitality comes with a steep environmental price, as cement production contributes nearly 7 per cent of India’s total carbon dioxide (CO2) emissions.
On a global scale, the sector accounts for 8 per cent of anthropogenic CO2 emissions, a figure that underscores the urgency of balancing rapid growth with climate responsibility. A unique challenge lies in the dual nature of cement-related emissions: about 60 per cent stem from calcination of limestone in kilns, while the remaining 40 per cent arise from the combustion of fossil fuels to generate the extreme heat of 1,450°C required for clinker production (TERI 2023; GCCA).
This dilemma is compounded by India’s relatively low per capita consumption of cement at about 300kg per year, compared to the global average of 540kg. The data reveals substantial growth potential as India continues to urbanise and industrialise, yet this projected rise in consumption will inevitably add to greenhouse gas emissions unless urgent measures are taken. The sector is also uniquely constrained by being a high-volume, low-margin business with high capital intensity, leaving limited room to absorb additional costs for decarbonisation technologies.
India has nonetheless made notable progress in improving the carbon efficiency of its cement industry. Between 1996 and 2010, the sector reduced its emissions intensity from 1.12 tonnes of CO2 per ton of cement to 0.719 tonnes—making it one of the most energy-efficient globally. Today, Indian cement plants reach thermal efficiency levels of around 725 kcal/kg of clinker and electrical consumption near 75 kWh per tonne of cement, broadly in line with best global practice (World Cement 2025). However, absolute emissions continue to rise with increasing demand, with the sector emitting around 177 MtCO2 in 2023, about 6 per cent of India’s total fossil fuel and industrial emissions. Without decisive interventions, projections suggest that cement manufacturing emissions in India could rise by 250–500 per cent by mid-century, depending on demand growth (Statista; CEEW).
Recognising this threat, the Government of India has brought the sector under compliance obligations of the Carbon Credit Trading Scheme (CCTS). Cement is one of the designated obligated entities, tasked with meeting aggressive reduction targets over the next two financial years, effectively binding companies to measurable progress toward decarbonisation and creating compliance-driven demand for carbon reduction and trading credits (NITI 2025).
The industry has responded by deploying incremental decarbonisation measures focused on energy efficiency, alternative fuels, and material substitutions. Process optimisation using AI-driven controls and waste heat recovery systems has made many plants among the most efficient worldwide, typically reducing fuel use by 3–8 per cent and cutting emissions by up to 9 per cent. Trials are exploring kiln firing with greener fuels such as hydrogen and natural gas. Limited blends of hydrogen up to 20 per cent are technically feasible, though economics remain unfavourable at present.
Efforts to electrify kilns are gaining international attention. For instance, proprietary technologies have demonstrated the potential of electrified kilns that can reach 1,700°C using renewable electricity, a transformative technology still at the pilot stage. Meanwhile, given that cement manufacturing is also a highly power-intensive industry, several firms are shifting electric grinding operations to renewable energy.
Material substitution represents another key decarbonisation pathway. Blended cements using industrial by-products like fly ash and ground granulated blast furnace slag (GGBS) can significantly reduce the clinker factor, which currently constitutes about 65 per cent in India. GGBS can replace up to 85 per cent of clinker in specific cement grades, though its future availability may fall as steel plants decarbonise and reduce slag generation. Fly ash from coal-fired power stations remains widely used as a low-carbon substitute, but its supply too will shrink as India expands renewable power. Alternative fuels—ranging from biomass to solid waste—further allow reductions in fossil energy dependency, abating up to 24 per cent of emissions according to pilot projects (TERI; CEEW).
Beyond these, Carbon Capture, Utilisation, and Storage (CCUS) technologies are emerging as a critical lever for achieving deep emission cuts, particularly since process emissions are chemically unavoidable. Post-combustion amine scrubbing using solvents like monoethanolamine (MEA) remains the most mature option, with capture efficiencies between 90–99 per cent demonstrated at pilot scale. However, drawbacks include energy penalties that require 15–30 per cent of plant output for solvent regeneration, as well as costs for retrofitting and long-term corrosion management (Heidelberg Materials 2025). Oxyfuel combustion has been tested internationally, producing concentrated CO2-laden flue gas, though the high cost of pure oxygen production impedes deployment in India.
Calcium looping offers another promising pathway, where calcium oxide sorbents absorb CO2 and can be regenerated, but challenges of sorbent degradation and high calcination energy requirements remain barriers (DNV 2024). Experimental approaches like membrane separation and mineral carbonation are advancing in India, with startups piloting systems to mineralise flue gas streams at captive power plants. Besides point-source capture, innovations such as CO2 curing of concrete blocks already show promise, enhancing strength and reducing lifecycle emissions.
Despite progress, several systemic obstacles hinder the mass deployment of CCUS in India’s cement industry. Technology readiness remains a fundamental issue: apart from MEA-based capture, most technologies are not commercially mature in high-volume cement plants. Furthermore, CCUS is costly. Studies by CEEW estimate that achieving net-zero cement in India would require around US$ 334 billion in capital investments and US$ 3 billion annually in operating costs by 2050, potentially raising cement prices between 19–107 per cent. This is particularly problematic for an industry where companies frequently operate at capacity utilisations of only 65–70 per cent and remain locked in fierce price competition (SOIC; CEEW).
Building out transport and storage infrastructure compounds the difficulty, since many cement plants lie far from suitable geological CO2 storage sites. Moreover, retrofitting capture plants onto operational cement production lines adds technical integration struggles, as capture systems must function reliably under the high-particulate and high-temperature environment of cement kilns.
Overcoming these hurdles requires a multi-pronged approach rooted in policy, finance, and global cooperation. Policy support is vital to bridge the cost gap through instruments like production-linked incentives, preferential green cement procurement, tax credits, and carbon pricing mechanisms. Strategic planning to develop shared CO2 transport and storage infrastructure, ideally in industrial clusters, would significantly lower costs and risks. International coordination can also accelerate adoption.
The Global Cement and Concrete Association’s net-zero roadmap provides a collaborative template, while North–South technology transfer offers developing countries access to proven technologies. Financing mechanisms such as blended finance, green bonds tailored for cement decarbonisation and multilateral risk guarantees will reduce capital barriers.
An integrated value-chain approach will be critical. Coordinated development of industrial clusters allows multiple emitters—cement, steel, and chemicals—to share common CO2 infrastructure, enabling economies of scale and lowering unit capture costs. Public–private partnerships can further pool resources to build this ecosystem. Ultimately, decarbonisation is neither optional nor niche for Indian cement. It is an imperative driven by India’s growth trajectory, environmental sustainability commitments, and changing global markets where carbon intensity will define trade competitiveness.
With compliance obligations already mandated under CCTS, the cement industry must accelerate decarbonisation rapidly over the next two years to meet binding reduction targets. The challenge is to balance industrial development with ambitious climate goals, securing both economic resilience and ecological sustainability. The pathway forward depends on decisive governmental support, cross-sectoral innovation, global solidarity, and forward-looking corporate action. The industry’s future lies in reframing decarbonisation not as a burden but as an investment in competitiveness, climate alignment and social responsibility.

References

  • Infomerics, “Indian Cement Industry Outlook 2024,” Nov 2024.
  • TERI & GCCA India, “Decarbonisation Roadmap for the Indian Cement Industry,” 2023.
  • UN Press Release, GA/EF/3516, “Global Resource Efficiency and Cement.”
  • World Cement, “India in Focus: Energy Efficiency Gains,” 2025.
  • Statista, “CO2 Emissions from Cement Manufacturing 2023.”
  • Heidelberg Materials, Press Release, June 18, 2025.
  • CaptureMap, “Cement Carbon Capture Technologies,” 2024.
  • DNV, “Emerging Carbon Capture Techniques in Cement Plants,” 2024.
  • LEILAC Project, News Releases, 2024–25.
  • PMC (NCBI), “Membrane-Based CO2 Capture in Cement Plants,” 2024.
  • Nature, “Carbon Capture Utilization in Cement and Concrete,” 2024.
  • ACS Industrial Engineering & Chemistry Research, “CCUS Integration in Cement Plants,” 2024.
  • CEEW, “How Can India Decarbonise for a Net-Zero Cement Industry?” (2025).
  • SOIC, “India’s Cement Industry Growth Story,” 2025.
  • MDPI, “Processes: Challenges for CCUS Deployment in Cement,” 2024.
  • NITI Aayog, “CCUS in Indian Cement Sector: Policy Gaps & Way Forward,” 2025.

ABOUT THE AUTHOR:
Dr Yogendra Kanitkar, Vice President R&D, Pi Green Innovations, drives sustainable change through advanced CCUS technologies and its pioneering NetZero Machine, delivering real decarbonisation solutions for hard-to-abate sectors.

Dr Shirish Kumar Sharma, Assitant Manager R&D, Pi Green Innovations, specialises in carbon capture, clean energy, and sustainable technologies to advance impactful CO2 reduction solutions.

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