Concrete

Building a resilient future for all

Published

4 years ago

December 21, 2021

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Manoj Kumar Rustagi, EVP – Business Strategy & Capex Projects, Sustainability and R&D, JSW Cement Limited, talks about aligning efforts with sustainable development goals.

Manoj Kumar Rustagi, EVP – Business Strategy & Capex Projects, Sustainability and R&D, JSW Cement Limited, talks about aligning efforts with sustainable development goals.

Our business strategy has been based on the underlying concept of a circular economy across industries, making us a responsible corporate, and delivering superior quality products and building materials to our customers.

Our business model works on the principle of using industrial waste to manufacture superior quality cement or cementitious products in the most efficient and environment-friendly manner. We primarily focus on low-carbon products, utilisation of renewable energy, co-processing of waste materials in place of fossil fuels, deploying electric commercial vehicles, installation of Waste Heat Recovery System (WHRS), and other initiatives aligned with the low carbon economy and ecosystem.

During FY 2020-21, we have established our long-term targets for 2030, aligning to the sustainable development goals on various aspects related to climate change, biodiversity, water and waste-water, energy, circular economy, supply chain and air emissions.

Addressing climate change

We have undertaken definitive steps and measures to reduce our overall carbon footprint.

Deployed latest technology and energy-efficient processes with roller press grinding system for manufacturing cement and cementitious products.
Utilisation of industrial waste i.e., blast furnace slag / fly ash in manufacturing cement and cementitious products.
Co-processing of alternative fuel in the clinker plant at our Nandyal and Fujairah unit to reduce consumption of fossil fuels.
Utilisation of waste hot gases from clinker plant for slag drying, thus saving coal/diesel.
Utilising solar power at the Nandyal unit – 5.5 MW and the Salboni unit – 3.5 MW.
Installing 12.2 MW capacity waste heat recovery systems (WHRS) at our Nandyal unit (Project in Progress).
Established rainwater harvesting facilities inside the plant premises across our plant locations.
Development of greenbelt in and around our plant premises.

Salboni and Vijayanagar Plant: Improving energy efficiency with PAT targets

During FY 2020-21, the Salboni and Vijayanagar plants were considered as designated consumer (DC) in the Perform, Achieve, Trade Cycle (PAT) 2020-21 to 2022-23 as per the Bureau of Energy Efficiency (BEE). The targets specified by BEE were as follows:

1. Salboni Plant

Baseline Specific Energy Consumption, SEC – 0.0227 toe/tonne of equivalent product
Target Specific Energy Consumption (2022-23), SEC – 0.0210 toe/tonne of equivalent product

2. Vijayanagar Plant

Baseline Specific Energy Consumption, SEC – 0.0438 toe/tonne of equivalent product
Target Specific Energy Consumption (2022-23), SEC – 0.0372 toe/tonne of equivalent product

Both the plants are improving energy efficiency by implementing various measures related to product mix, optimisation of process energy, shift to the latest energy efficient equipment wherever feasible and energy efficiency improvement projects among others.

Sustainability initiatives

In aligning with the triple bottom line, we have undertaken definitive steps to produce quality cement and cementitious products in an efficient and environment-friendly manner.

1. Reduction in clinker ratio

As a continuous effort of the company, our R&D team is developing processes that will help us in conserving limestone and energy, which will in turn help us reduce the manufacturing cost of cement. During FY 2020-21, our R&D team developed an in-house additive used in cement grinding, which helps in the reduction of clinker consumed per tonne of cement produced. Through this initiative, we have avoided 24140 Tonnes of CO2 emissions at our Salboni and Jajpur plants.

2. Manufacturing of Composite Cement

Our company has put in efforts in R&D, to manufacture a new range of blended cement products called composite cement, which uses both, fly ash and blast furnace slag as supplementary cementitious materials. Our Jajpur grinding unit mainly produces composite cement and that forms ~68% of the overall product mix from the plant. This product helps us in reducing our manufacturing costs while utilising multiple industrial waste as supplementary cementitious materials to produce quality low carbon cement products as per BIS.

3. Use of alternate fuel / reduced solid fuels like coal / pet coke

During FY 2020-21, ~23,200 tonnes of waste was co-processed at our Nandyal plant, in our cement kiln in an environmentally friendly manner. We have successfully reduced 18,121 tonnes of CO2 emissions by utilising different types of wastes in place of traditional fuels.

4. Use of solar energy

5. During FY 2020-21, we have consumed ~ 1,15,04,567 units of solar power at our Nandyal and Salboni plant, thus avoiding ~ 10,469 tonnes of CO2 emissions

6. Circular economy

A major part of our product portfolio consists of blended cement products and cementitious materials, which are manufactured using industrial wastes or by-products. During FY 2020-21, around 88% of production was blended cements, a 1% increase as compared to the previous year. We have consumed 4.97 million tonnes of slag and 0.16 million tonnes of fly ash for our cement manufacturing process during FY 2020-21, thus reducing the consumption of natural resources such as limestone, water and energy.

7. Energy efficiency

Some of the energy efficiency initiatives implemented during FY 2020-21:

Medium VoltageVariable Frequency Drive (MV VFD) installation in grinding mill at Jajpur
Optimisation of compressed air utilisation at Jajpur
Discharge chute modification for wagon loading and truck loading at Vijaynagar
VFD installation in HAG coal conveying at Vijaynagar
Reduction in pressure drop across cement mill dust collection circuit at Nandyal
Replacing of conventional lighting to LED lighting in VRM -1 and Packing Plant at Dolvi

Apart from these initiatives, we have made significant efforts by committing to various initiatives related to climate change action.

We are a signatory to the ‘Global Framework Principles on Heavy Industry Initiative,’ which has a vision to ‘Accelerate and scale-up the decarbonisation of heavy industry to align with a 1.5C global warming trajectory with urgency’.
We have also committed to all three of the Climate Group’s campaigns – RE100, EV100 and EP100 in a single go and we are globally the first company in heavy industries to do so.
Carbon Disclosure Project (CDP) is a not-for-profit charity that runs the global disclosure system for investors, companies, cities, states and regions to manage their environmental impacts. The CDP headquarter is based out of London, UK, and is working towards securing a thriving economy that works for the people and the planet by creating a global database on carbon emissions across industries. We have been participating in the CDP response for the last three years to ensure open and transparent communication to our stakeholders and the society at large. Our last year CDP response was a ‘B-’ rating, which is in the Management Band.
We are part of Global Cement & Concrete Association (GCCA), globally as well as of the Indian chapter. GCCA is working on various initiatives on sustainability and innovation along-with its member companies, affiliates and partners. As part of this, there are working groups on various aspects of sustainability. We lead the working group related to communications and policy advocacy. We have also become a member of GCCA Innovandi network, which is a standalone entity that works on R&D programmes in minimising the carbon footprint of cement and is a global research network of technology suppliers, academic institutions and manufacturers of cement and concrete industry.

ABOUT THE AUTHOR:

Manoj Kumar Rustagi, EVP – Business Strategy & Capex Projects, Sustainability and R&D, JSW Cement Limited, is a senior business leader, who has significantly contributed to business strategy and project management, and other strategic initiatives, in the cement, steel and energy sectors in his 29 years of professional career. In his present role as Executive Vice President, he is leading sustainability, R&D, business strategy and capex projects for JSW Cement Limited, India. He is a Director on the boards of various subsidiary companies of JSW Cement Limited. He is also on the board of GCCA Private Limited, India, in his personal capacity. He is a Mechanical Engineering graduate from BITS Pilani, India and an MBA from Indian School of Business (ISB), India.

Sustainability Performance 2020-21

We have a distinctive performance on the carbon intensity and are one of the lowest specific carbon emitters globally within the cement industry.

As per GCCA GNR data the global average of scope 1 net CO2 emissions per tonne of cementitious product is ~ 600 kg and India average is ~ 560 kg.

Compared to this for FY 20-21 our specific carbon emission is ~ 200 kg, which translates into a saving of 2.9 million MT of CO2 saving compared to India average and 3.2 million MT of CO2 saving compared to global average. We understand our responsibility for the nation and have taken definitive measures to lead our industry towards a zero net carbon economy much before the 2070 target.

200kg ~23345 tonnes 81 litres

SCOPE-1 Net CO2 emissions per tonne of cementitious material of alternative fuels consumed 66% of raw material consumption is from waste derived resources Water Consumption per tonne of cementitious material

LTIFR Share of renewable energy in total power consumption

0.44 3.15%

Natural capital Natural capital

Total fuel used: ~241959 tonnes
Total gas consumed: ~ 3.48 Crore nm3
Total water used: 618370 m3
Total electrical energy consumed: ~36.55 crore kWh
Thermal substitution rate: 4.23 % • 37 % of the total water consumption met from harvested water, thus reducing the dependency on groundwater and surface water resources

Emissions

Absolute net CO2 emissions (Scope 1): 1521828 Tonnes
Absolute net CO2 emissions (Scope 2): 322123 Tonnes

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

1 week ago

June 5, 2026

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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.

Concrete

Building a Greener Future Together

Published

1 week ago

June 4, 2026

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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.

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

2 weeks ago

June 1, 2026

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.