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Green Fuel for Thought

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Ganesh W Jirkuntwar, Senior Executive Director and National Manufacturing Head, Dalmia Cement (Bharat) talks about technology and alternative fuels, which are important tools in the cement industry’s march towards reduction of carbon footprint.

Dalmia Cement Bharat has evolved to create a distinct identity for itself that is synonymous with sustainability and growth. The philosophy of ‘Clean and Green is Profitable and Sustainable’ has helped the company deliver on the expectations of its stakeholders. As a champion of blended cement, it is rapidly gaining popularity as a ‘green’ alternative to the traditional Ordinary Portland Cement in the construction sector. Three levers are being used to decarbonise the cement. Uses of supplementary cementitious materials like fly ash and slag have reduced clinker consumption and hence reduced carbon footprint in cement. Alternative fuels (green fuel) like industrial wastes, renewable biomass, municipal wastes etc., have reduced consumption of fossil fuel facilitating in achieving carbon neutrality. Increased dependence on renewable power sources like solar, waste heat recovery systems, wind power etc., is also helping the company achieve its goal of becoming the second green cement manufacturer.
Alternative fuels to the tune of 20 per cent by heat substitution are being used, putting it far ahead of any other Indian cement manufacture in uses of alternative fuel. Dalmia Cement Bharat wants to lead and drive the industry’s shift towards a sustainable use of alternative fuel in cement production by investing in requisite technology and machineries, and setting an ambitious target of achieving 35 per cent TSR by FY25. It uses industrial wastes, municipal wastes, agricultural wastes etc., as alternative fuel, which otherwise goes either into a water source or landfill and creates environmental issues. The use of these industrial wastes is a great example of a circular economy ecosystem.

Reducing the Carbon Footprint
Uses of alternative fuels and raw materials is helping the company fast-track its journey of achieving carbon negative. Dalmia carbon footprint at 467 kg CO2/tonne of cement (specific net CO2) is one of the lowest in the cement sector globally. Since the announcement of the carbon negative ambition in 2018, the specific carbon footprint has reduced by more than 9 per cent in the Scope 1 category and it is currently at 12.55 million tCO2/year. By reducing the scope 1 GHG emissions to 32 per cent per ton of cementitious material by FY ’34, they have also reduced overall scope 2 emissions by 30 per cent and are targeting to reduce scope 2 GHG emissions to 61.9 per cent per tonne of cementitious material by FY’34. Both these are on FY ’19 as base year and within the same timeframe validated by SBTi.

Role of Technology
Technology plays a pivotal role in determining the quantum of alternative raw materials and fuels to be used without compromising properties of cement. Online sampling, online particle size analyser, robotic lab etc., are great enablers for determining composition of alternative raw materials and fuels to be used. Nowadays digital technology is also facilitating in generating lots of insights from process data, which is helping in taking real-time basis decisions on desired composition of alternative raw materials and alternative fuels for achieving targeted quality of clinker and cement.
Cement making process has not undergone major overhaul since inception of dry cement making process, therefore basic chemistry and machinery are pretty much standardised across the industry. Cement composition is decided based on end uses and does not depend on plant machinery per say. Plant machineries are upgraded for switching to newer and efficient designed machines, replacing the old and obsolete machines etc. Plant machinery upgradation is a situational call in Dalmia and is decided based on group guidelines for reliability, technology adoption, ROA etc.

Alternative Fuels and Profitability
Cement producers worldwide are striving to lower their production costs. One effective method of achieving this end is the use of alternative fuels. Use of low-grade alternative fuels such as sewage sludge, biomass fuels such as wood products, agricultural wastes, etc. in precalciners is a viable option because combustion in a precalciner vessel takes place at a lower temperature.
Alternative fuel uses have been quite beneficial for us not only in terms of improving bottom-line but also helping gain tall recognition at the international stage. During peak fossil fuel prices, its uses helped reduce the spend on fuel to great extent and optimise variable cost of cement. Despite having a handicap of regional presence, Dalmia Cement Bharat could beat pan India cement players on cost front as result of substantial uses of alternative fuels.
Usages of alternative fuels lead to marginal increase in overall heat consumption. In case preheater fans and other equipment are being used at its full capacity, usage of alternative fuels may result in marginal reduction of clinker throughput.
Similarly, uses of alternative raw materials may impact cement quality, if not proportioned carefully.
Alternative fuel uses in Indian cement kilns is at the cusp of transformational change. Almost all cement players are adopting traditional technology and installing necessary infra for using alternative fuels in kilns. Uses of alternative fuel in kilns are limited by its chloride and ash contents. These issues are being taken care of by industry wide research and piloting of technologies, which has potential to reduce chloride and ash contents from alternative fuels. Various technologies for preprocessing of alternative fuels like pyrolysis, pyrorotor etc. are being piloted in India.
Government bodies, academia, industry bodies etc. are also doing extensive research on uses
of alternative raw materials for decarbonising cement.

ABOUT THE AUTHOR:
Ganesh W Jirkuntwar, National Manufacturing Head (Sr Executive Director) and EXCOM Member – Dalmia Group,
comes with 27 years of experience in cement plant and manufacturing, operations and management, logistics, planning, quality and team management. He is also well-versed with lean management, TPM, Six Sigma and ISO 9000, 14000 and 18000. standards.

Concrete

India Sets Up First Carbon Capture Testbeds for Cement Industry

Five CCU testbeds launched to decarbonise cement production

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The Department of Science and Technology (DST) recently unveiled a pioneering national initiative: five Carbon Capture and Utilisation (CCU) testbeds in the cement sector, forming a first-of-its-kind research and innovation cluster to combat industrial carbon emissions.
This is a significant step towards India’s Climate Action for fostering National Determined Contributions (NDCs) targets and to achieve net zero decarbonisation pathways for Industry Transition., towards the Government’s goal to achieve a carbon-neutral economy by 2070.
Carbon Capture Utilisation (CCU) holds significant importance in hard-to-abate sectors like Cement, Steel, Power, Oil &Natural Gas, Chemicals & Fertilizers in reducing emissions by capturing carbon dioxide from industrial processes and converting it to value add products such as synthetic fuels, Urea, Soda, Ash, chemicals, food grade CO2 or concrete aggregates. CCU provides a feasible pathway for these tough to decarbonise industries to lower their carbon footprint and move towards achieving Net Zero Goals while continuing their operations efficiently. DST has taken major strides in fostering R&D in the CCUS domain.
Concrete is vital for India’s economy and the Cement industry being one of the main hard-to-abate sectors, is committed to align with the national decarbonisation commitments. New technologies to decarbonise emission intensity of the cement sector would play a key role in achieving of national net zero targets.
Recognizing the critical need for decarbonising the Cement sector, the Energy and Sustainable Technology (CEST) Division of Department launched a unique call for mobilising Academia-Industry Consortia proposals for deployment of Carbon Capture Utilisation (CCU) in Cement Sector. This Special call envisaged to develop and deploy innovative CCU Test bed in Cement Sector with thrust on Developing CO2 capture + CO2 Utilisation integrated unit in an Industrial set up through an innovative Public Private Partnership (PPP) funding model.
As a unique initiative and one of its first kind in India, DST has approved setting up of five CCU testbeds for translational R&D, to be set up in Academia-Industry collaboration under this significant initiative of DST in PPP mode, engaging with premier research laboratories as knowledge partners and top Cement companies as the industry partner.
On the occasion of National Technology Day celebrations, on May 11, 2025 the 5 CCU Cement Test beds were announced and grants had been handed over to the Test bed teams by the Chief Guest, Union Minister of State (Independent Charge) for Science and Technology; Earth Sciences and Minister of State for PMO, Department of Atomic Energy, Department of Space, Personnel, Public Grievances and Pensions, Dr Jitendra Singh in the presence of Secretary DST Prof. Abhay Karandikar.
The five testbeds are not just academic experiments — they are collaborative industrial pilot projects bringing together India’s top research institutions and leading cement manufacturers under a unique Public-Private Partnership (PPP) model. Each testbed addresses a different facet of CCU, from cutting-edge catalysis to vacuum-based gas separation.
The outcomes of this innovative initiative will not only showcase the pathways of decarbonisation towards Net zero goals through CCU route in cement sector, but should also be a critical confidence building measure for potential stakeholders to uptake the deployed CCU technology for further scale up and commercialisation.
It is envisioned that through continuous research and innovation under these test beds in developing innovative catalysts, materials, electrolyser technology, reactors, and electronics, the cost of Green Cement via the deployed CCU technology in Cement Sector may considerably be made more sustainable.
Secretary DBT Dr Rajesh Gokhale, Dr Ajai Choudhary, Co-Founder HCL, Dr. Rajesh Pathak, Secretary, TDB, Dr Anita Gupta Head CEST, DST and Dr Neelima Alam, Associate Head, DST were also present at the programme organized at Dr Ambedkar International Centre, New Delhi.

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Concrete

JK Lakshmi Adopts EVs to Cut Emissions in Logistics

Electric vehicles deployed between JK Puram and Kalol units

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JK Lakshmi Cement, a key player in the Indian cement industry, has announced the deployment of electric vehicles (EVs) in its logistics operations. This move, made in partnership with SwitchLabs Automobiles, will see EVs transporting goods between the JK Puram Plant in Sirohi, Rajasthan, and the Kalol Grinding Unit in Gujarat.
The announcement follows a successful pilot project that showcased measurable reductions in carbon emissions while maintaining efficiency. Building on this, the company is scaling up EV integration to enhance sustainability across its supply chain.
“Sustainability is integral to our vision at JK Lakshmi Cement. Our collaboration with SwitchLabs Automobiles reflects our continued focus on driving innovation in our logistics operations while taking responsibility for our environmental footprint. This initiative positions us as a leader in transforming the cement sector’s logistics landscape,” said Arun Shukla, President & Director, JK Lakshmi Cement.
This deployment marks a significant step in aligning with India’s push for greener transport infrastructure. By embracing clean mobility, JK Lakshmi Cement is setting an example for the industry, demonstrating that environmental responsibility can go hand in hand with operational efficiency.
The company continues to embed sustainability into its operations as part of a broader goal to reduce its carbon footprint. This initiative adds to its vision of building a more sustainable and eco-friendly future.
JK Lakshmi Cement, part of the 135-year-old JK Organisation, began operations in 1982 and has grown to become a recognised name in Indian cement. With a presence across Northern, Western, and Eastern India, the company has a cement capacity of 16.5 MTPA, with a target to reach 30 MT by 2030. Its product range includes ready-mix concrete, gypsum plaster, wall putty, and autoclaved aerated fly ash blocks.

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Concrete

Holcim UK drives sustainable construction

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Holcim UK has released a report titled ‘Making Sustainable Construction a Reality,’ outlining its five-fold commitment to a greener future. The company aims to focus on decarbonisation, circular economy principles, smarter building methods, community engagement, and integrating nature. Based on a survey of 2,000 people, only 41 per cent felt urban spaces in the UK are sustainably built. A significant majority (82 per cent) advocated for more green spaces, 69 per cent called for government leadership in sustainability, and 54 per cent saw businesses as key players. Additionally, 80 per cent of respondents stressed the need for greater transparency from companies regarding their environmental practices.

Image source:holcim

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