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Clinker factor determines the CO2 footprint of cement

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Manoj Kumar Rustagi, Chief Sustainability and Innovation Office (CSIO), JSW Cement, gives insights into the process of producing blended cement with supplementary cementitious materials for more strength and durability.

What are the core raw materials used in the production of cement?
Cement manufacturing is an energy and resource intensive process. Primary raw material is limestone which is mined, crushed, ground and mixed with bauxite, iron ore and other additives/correctives to make raw meal which is then heated to a temperature as high as ~1400°C in a horizontal kiln. Coal is the primary fuel which provides energy for the combustion process. The hot material is then cooled down to form clinker, an intermediate product for making cement. Clinker is further ground and blended with gypsum (mineral or chemical) to make the final product called ordinary Portland cement (OPC).
When clinker is blended with other supplementary cementitious materials like fly ash or slag or both, the product is known as blended cement.

What are the alternative raw materials that can be used in the production of cement? How does that impact the process of production?
Cement sector accounts for ~7 per cent of global CO2 emissions, and therefore it needs to be aggressive on its decarbonisation strategy wherein one of the primary lever is using alternative raw materials for the production of clinker and supplementary cementitious materials (SCMs) as cement/clinker replacements. Different fine-grained silica, silicate and alumina-silicate materials either natural or synthetic can be used in the final cement product to obtain a new eco-friendly cementitious binder with similar or better properties. The most commonly used SCMs are fly ash, granulated blast furnace slag, natural volcanic pozzolana etc.
When clinker is blended with other supplementary cementitious materials like fly ash, slag or both, products are called Portland Pozzolona Cement (PPC), Portland Slag Cement (PSC) and composite cement (CC) respectively. Blended cement products have a much lower carbon footprint than OPC. Since clinker manufacturing is the phase where most thermal energy is consumed and CO2 is emitted, reducing clinker factor in cement not only results in lowering the process CO2 but also the thermal energy and electrical energy requirements.
There are other alternative raw materials like Spent Pot Liner (SPL), red mud, lime sludge and steel slag, which are used in the clinker manufacturing to reduce consumption of limestone and consequently reducing the process CO2 that comes from limestone calcination.

Can cement maintain its quality standard with inclusion of supplementary raw materials as against limestone?
Yes, blended cement products not only maintain the most quality standards as OPC but also have superior properties in various parameters when compared to conventional OPC. Blended cements are preferred for its late strength, chemical resistance, alkali resistance and for coastal applications and dams and irrigation projects where they are technically most suitable.
The use of SCMs/mineral admixture/blended cements in concrete significantly helps in mitigating the expansion due to alkali silica reaction (ASR), due to the reduction in the availability of alkalis in the pore solution and the refinement of the pore structure. Not only does this reduce maintenance costs of infrastructure such as dams and bridges, but also allows the consumption of local aggregates that may contain deleterious materials. The reduced expansion in SCM-blended structures reduces the risk of expansion and cracking. This pozzolanic reaction also has a beneficial impact on resistance to sulphate attack.
Recently GCCA, India has published a detailed report on Benefits of Blended Cement Products, which has been prepared by NCCBM and reviewed by IIT, Madras, and that captures all the environment and technical benefits.

Explain the impact on carbon emission of the production unit when alternative raw materials are used in various proportions.
In cement manufacturing, CO2 is primarily emitted as a result of the chemical conversion process used in the production of clinker in which limestone (CaCO3) is first converted to lime (CaO) and then to hydraulic compounds. CO2 is also emitted during cement production by fossil fuel (primarily coal) combustion. Thus ~80-85 per cent of the CO2 emissions could be attributed to the production of clinker. This is partly reduced by using alternative raw materials and mineralisers in the raw mix design of clinker.
The amount of clinker in cement, known as clinker factor, determines the CO2 footprint of cement. In OPC, clinker factor is ~90 per cent thus, it has a carbon footprint of around 800 – 850 kg/MT of cement. When clinker is replaced with SCMs, the CO2 emissions are reduced as SCMs don’t have embodied carbon emissions. That is why blended cement have much lower carbon footprint than OPC. Currently in Portland Slag Cement (PSC) production almost 60 to 65 per cent of clinker is replaced with slag which results in ~60 per cent of CO2 footprint and the final carbon footprint is around 300 – 350 kg/MT. Similarly, in PPC where ~35 per cent of clinker is replaced, carbon footprint will be in the range of 500 – 550 kg/MT.

-Kanika Mathur

Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

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FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

 

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Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

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Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

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Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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