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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

ICRA Sees Steady Cement Demand Growth Ahead

Volumes seen rising 6–7 per cent in FY27 on infra push

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India’s cement industry is expected to record steady growth over the coming years, with cement volumes projected to expand by 6–7 per cent in FY27, supported by sustained demand from the housing and infrastructure sectors, according to a report by rating agency ICRA.

The agency said the sector is likely to maintain healthy momentum after registering growth of 6.5–7.5 per cent in FY26, despite a higher base in the second half of FY25. Cement demand remained strong in the current financial year, with volumes increasing by 8.5 per cent during the first eight months of FY26, driven by robust construction activity across regions.

ICRA expects demand to strengthen further in the second half of FY26 as construction activity accelerates after the monsoon. Continued government focus on infrastructure spending and the possibility of a reduction in goods and services tax on cement are also expected to support demand through FY26 and FY27.

Against this favourable demand backdrop, cement manufacturers are continuing to expand capacity through both organic and inorganic routes to strengthen their market positions. The industry is estimated to add 85–90 million tonnes per annum of capacity during FY26–FY27, including around 43–45 million tonnes per annum in FY26 and a further 42–44 million tonnes per annum in FY27.

Commenting on the outlook, Anupama Reddy, Vice President and Co-Group Head, Corporate Ratings at ICRA, said sector profitability is expected to improve significantly in FY26, supported by better pricing and higher volumes. Operating profit before interest, depreciation, tax and amortisation per tonne is projected to rise to around Rs 900–950 per tonne in FY26, compared with Rs 810 per tonne in FY25.

However, ICRA expects some moderation in earnings in FY27 due to rising input costs. Operating profit per tonne is estimated at Rs 880–930 in FY27, as costs related to pet coke and freight are likely to increase and remain influenced by global crude oil prices and geopolitical developments.

On a regional basis, North and Central India are expected to report capacity utilisation levels above the national average, while the southern region may continue to see relatively moderate utilisation due to existing capacity overhang. ICRA noted that recent merger and acquisition activity in the southern market has helped large players strengthen their regional and pan-India presence.

Overall capacity utilisation for the cement industry is projected to remain stable at around 70–71 per cent in FY27, broadly in line with FY26 levels, albeit on an expanded capacity base.

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Concrete

GCCA India–NCB Carbon Uptake Report Released at NCB Foundation Day

New report highlights CO? absorption by concrete in Indian conditions

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The Global Cement and Concrete Association (GCCA) India–NCB Carbon Uptake Report was recently released during the 63rd Foundation Day celebrations of the National Council for Cement and Building Materials (NCB). On the occasion, a Gypsum Board Testing Laboratory and a Micro-Characterisation Laboratory were also inaugurated, strengthening India’s research and quality infrastructure for construction materials.

The laboratories were inaugurated by Urmila, Economic Advisor, Department for Promotion of Industry and Internal Trade (DPIIT), and Mohd. Kamal Ahmad, Special Director General, Central Public Works Department (CPWD), in the presence of L. P. Singh, Director General, NCB.

The newly established Gypsum Board Testing Laboratory will support quality assurance and standardisation requirements of the gypsum board industry, particularly in the context of the Gypsum-Based Building Materials (Quality Control) Order, 2024. The Micro-Characterisation Laboratory is equipped with advanced analytical tools for detailed investigation of cementitious and construction materials.

Addressing the gathering, Ms Urmila highlighted NCB’s sustained contributions to research, technology development, quality assurance and capacity building for the cement sector. Shri Mohd. Kamal Ahmad also commended NCB’s role in promoting sustainable construction practices through focused research and development.

The GCCA India–NCB report titled Carbon Uptake by Concrete assesses CO? uptake through carbonation in concrete under Indian conditions. Prepared in collaboration with the Global Cement and Concrete Association (GCCA) India, the study is based on the Tier-I methodology of IVL Swedish Environment Research Institute. It notes that while the cement industry contributes around seven per cent of global anthropogenic emissions, carbon uptake by concrete can partially offset process-related emissions.

The report outlines future actions to improve data robustness, refine estimation methodologies and support integration of carbon uptake into national sustainability and climate reporting frameworks. It will be submitted to the Ministry of Environment, Forest and Climate Change for consideration of inclusion as a carbon sink in India’s National Communications to the UNFCCC.

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Concrete

Shree Cement To Invest Rs 20 Billion In Maharashtra Plant

New 2 mtpa unit to strengthen capacity expansion plans

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Shree Cement Ltd has announced an investment of Rs 20 billion to set up a new cement plant in Maharashtra, the country’s third-largest cement maker said on Friday at the World Hindu Economic Forum (WHEF) 2025. The letter of intent for the proposed investment was signed in the presence of Maharashtra Chief Minister Devendra Fadnavis in Mumbai. Shree Cement chairman Hari Mohan Bangur said the company will establish a 2 million tonnes per annum plant in Chandrapur district, where land has already been acquired. He added that the project is awaiting environmental clearance and, once approved, is expected to be completed within two years. The expansion will be funded through internal cash reserves, with the company reporting a cash balance of Rs 65.41 billion at the end of FY25.

Shree Cement currently has an installed capacity of 62.8 million tonnes per annum. During the second quarter of FY26, the company commissioned a 3.65 mtpa clinker unit at Jaitaran in Rajasthan, while a 3 mtpa cement mill at the same location is expected to start operations shortly. A 3 mtpa integrated plant at Kodla in Karnataka is in the final stages of development and is scheduled to be commissioned within the third quarter of FY26. Following these ongoing expansions, the company’s total capacity is expected to rise to 68.8 mtpa, according to an ICICI Direct Research note dated 29 October.

Analysts estimate that Shree Cement’s capacity could reach between 72 and 75 mtpa by FY27E, with further potential to scale up to 80 mtpa by FY28E or FY29E, depending on demand trends. However, market observers have flagged medium-term risks, noting that industry-wide capacity additions may outpace demand growth through FY28-29, particularly in northern and western India where significant new capacity is expected. At the same time, cement prices declined sharply in the third quarter, especially in eastern and southern regions, though analysts expect some recovery from January, led by the South and East.

The announcement comes amid aggressive expansion plans by larger peers. UltraTech Cement recently raised its capacity target from 167 mtpa to 240 mtpa by FY28, while the Adani Group increased its cement capacity target by nearly 10 per cent to 155 mtpa by the same period. Shree Cement reported a 15 per cent year-on-year rise in revenue to Rs 43.03 billion in the September quarter, driven by higher volumes, premiumisation efforts and a value-over-volume strategy. The company’s chief financial officer Ashok Bhandari has guided for capital expenditure of around Rs 30 billion in FY26-27, with a similar level expected in FY27-28. Shares of Shree Cement ended 0.18 per cent lower on Friday, while the benchmark Sensex closed 0.53 per cent higher.

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