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Technology plays a vital role in utilising alternative materials

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Rajpal Singh Shekhawat, Senior General Manager (Production and QC),JK Lakshmi Cement, stresses on the importance of the quality of alternative raw materials in order to maintain the quality of the output.

What are the core raw materials used in the production of cement?
The first step to manufacturing cement is manufacturing the clinker. The principle raw material required to make clinker is cement grade limestone. Other raw material requirements depend upon the quality of limestone and these could be iron ores like red ochre, blue dust, laterite, alumina ores like bauxite, China clay and siliceous materials like Marl and silica sand. As far as cement is concerned for Ordinary Portland Cement (OPC), clinker and
gypsum are used, for Pozzolana Portland Cement (PPC) clinker, gypsum and fly ash are used and for Portland Slag Cement (PSC) clinker, gypsum and slag are used.

What are the alternative raw materials that can be used in the production of cement? How does that impact the process of production?
Waste from the aluminium industry like red mud, waste from the marble industry like marble slurry and marble khanda, waste from the chemical industry like chemical sludge and ETP sludge, waste from the paper industry like paper sludge can be used in clinker manufacturing. For the cement manufacturing process, waste from chemical industry like chemical gypsum, waste from ceramic industry like mould gypsum, waste from zinc industry like jarosite and waste from the salt industry like marine gypsum can be used.
However, the quantity of alternative material or waste to be utilised depends a lot upon the quality of limestone and quality of other raw materials used in cement grinding. It varies from plant to plant and the quality of these alternative materials varies from source to source.

Can cement maintain its quality standard with inclusion of supplementary raw materials as against limestone?
Certainly, the quality of cement can be maintained by including these supplementary raw materials, however, the raw material proportion must be tweaked according to the quality of alternative raw material and the cost benefit analysis.

Explain the impact on carbon emission of the production unit when alternative raw materials are used in various proportions.
Carbon emission in cement manufacturing is mainly because of limestone, fuel burning, and electrical energy consumption. Majority of the CO2 emission in cement industry is from the decomposition of calcium carbonate and if we replace limestone by alternative raw material which contains calcium in any form other than carbonate, carbon emission can be reduced. For example, if we replace 1 per cent of CaO by other raw materials then around 5 kg CO2/ MT of clinker will be reduced.

How can the cost of production be reduced by using alternative or supplementary raw materials in cement production?
Cost of production depends on the plant location, limestone and raw material quality. The source of alternative raw materials for some plants are significant and in some instances because of high logistic cost economics do not work out. For example, if a cement plant is located near the industry where chemical gypsum is generated, there will be a significant gain to that particular cement plant.

What are the major challenges in using other cementitious materials?
Using alternative materials comes with their own set of challenges. Some of the challenges associated with them are high moisture content, material flowability, consistency in the material quality, chloride and sulphur content.

What role does technology play in deciding which materials can be used and incorporating them in the production process?
Certainly, technology plays a vital role in utilising alternative material, for example if drying technology is available at the plant like drier than even high moisture material can be used and handled otherwise only selected material with less moisture content are allowed.
Likewise in case of alternative fuel, if pre-processing facilities like separation of organic and combustion solid fraction, screening and pre-shredding is available then MSW can be directly used. However, when the pre-processing and shredding facility is not available at the plant then the plant requires shredded RDF <80 mm in case of in-line calciner and <40-50 mm in case of separate line calciner. Regarding utilisation of high chloride and high sulphur material if akali/chloride by-pass is installed then even high chloride/sulphur can be accepted based on the cost benefit analysis otherwise chloride input is to be restricted to 200-300gm/tonne of clinker.

Does your organisation manufacture a variant of cement made from alternative raw materials? Tell us more about its performance and use.
Yes, we are utilising various alternative raw materials like chemical gypsum, mould gypsum, ETP and phosphate sludges. Talking about chemical gypsum, its purity is more than natural gypsum. The performance of concrete made by the cement by utilising partial replacement of chemical gypsum is more cohesive than the cement made from natural gypsum. Moreover, the cement made by utilising chemical gypsum improves the workability of cement. Likewise, we utilise various alternative fuels at our premises and their consumption is being optimised looking into process and quality.
By utilising various alternative raw materials and fuels we are saving around 25 kg CO2/Mt of clinker and working on alternative materials and fuels that can reduce carbon footprints further.

How do you foresee future of production?
The per capita capital cement consumption in India is still much lower than the world average. Therefore, there is a huge potential for the industry to grow. There has been a continuous rise in the cost of fuel post covid and post the Russia-Ukraine engagement and still rising.
Owing to this, there is pressure on the industry to maintain the margins. Although, Indian cement industry is co-processing various alternative fuels and alternative raw materials to reduce its carbon footprint, it will in the future also put its focus on utilising alternative materials and fuels to bring down the cost of production.

-Kanika Mathur

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

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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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.

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