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Taking a Carbon-Negative Approach

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Pankaj Kejriwal, Whole Time Director and COO, Star Cement talks about the future of eco-friendly green cement, its advantages, efforts taken by cement producers, new technological innovation and operational efficiency improvements.

The hon’ble Finance Minister in her budget speech for FY 2023-24 has highlighted seven priorities to act as Saptarishi, guiding us through the Amrit Kaal. One of them is Green Growth. This Green Growth will be achieved by using green fuel, green energy, green buildings etc. and eventually providing green jobs.
Green cement is a step in this direction. Green cement is an eco-friendly cement that uses a carbon-negative process of manufacturing. The major raw materials used to produce green cement include mostly the discarded waste from the industry. The slag from the blast furnace and fly ash are the chief materials used in the manufacturing of green cement.
Concrete with green cement is a form of eco-friendly concrete that is manufactured using waste or residual materials from different industries, and requires less energy for production. Compared to traditional concrete, it produces less carbon dioxide, and is considered environmentally friendly and more durable. Green concrete has a lower shrinkage rate and also becomes stronger far more quickly than concrete made with traditional cement.

Types of Newly Invented Green Cement

  1. Ekkomaxx Cement
    It is a type of green cement produced in the United States that is composed of 95 per cent fly ash and 5 per cent renewable liquid additives. Based on standards such as the International Code Council and United States Green Building Council, this cement, which is manufactured by Ceratech Company, has nearly zero carbon footprint.
    Not only did the process of cement production decline the use of virgin material by 95 per cent but it also decreased the water requirement by half.
    The main characteristics of Ekkomax cement are high early strength, resilience, crack resistance, low chloride permeability, sulphate attack resistance, durability and corrosion resistance, which is more than three times of conventional cement, and the resistance to freezing and thawing is greater than that of normal cement.
  2. Magnesium Oxychloride Cement
    Magnesium Oxychloride Cement (MOC) is an environmentally friendly and carbon-neutral cement, which is produced from two main materials namely: magnesium oxide (MgO) powder and a concentrated solution of magnesium chloride (MgCl2). These are by products from magnesium mining.
    The MOC has great compressive strength and sets quickly and MgO absorbs CO2 from the atmosphere, but water can reduce its strength considerably. However, this weakness of MOC can be tackled to a certain extent by introducing 15 per cent of fly ash and the same amount of silica fume.
    These additives fill the pore structure in MOC, which makes the concrete denser. Consequently, both strength and durability of concrete is improved considerably. Furthermore, it is required to add phosphoric acid and soluble phosphates to improve the resistance of this type of green cement against warm water.
    Finally, Magnesium Oxychloride Cement leads to the corrosion of steel, hence this type of cement cannot be used for construction reinforced concrete structure unless this problem is tackled.
  3. Geopolymer cement
    Geopolymer, which is also known as alkali-activated cement, is produced from alumino-silicates instead of the more environmentally damaging calcium oxide.
    The aluminosilicates are obtained from industrial by-products like fly ash. The geopolymer cement is competitive with ordinary Portland cement in performance and cost, and it emits 95 per cent less CO2 than the ordinary Portland cement.
  4. Ferrocrete
    Ferrocrete cement is manufactured by mixing silica and iron, which are waste by products from the steel and glass industry. This material mixture is then cured with CO2, and consequently, it potentially becomes carbon-negative material. The scientists at the University of Arizona invented Ferrocrete.
  5. Calcium Sulfoaluminate Cement
    The calcium sulfoaluminate cement is produced in a kiln that requires a temperature of 1232oC (2250F) rather than 1426.6oC (2500oF) of conventional cement. As a result, less CO2 would be released into the atmosphere. The calcium sulfoaluminate cement sets rapidly and gains 28-day strength of conventional concrete in 24 hours.
    That is why it is used in projects where rapid setting of concrete is crucial such as bridge decks and airport runways. The calcium sulfoaluminate cement can be used as shrinkage compensating cement when a higher quantity of gypsum is added.
    This type of cement can achieve energy savings as high as 25 per cent and provide environmental benefits by reducing CO2 emissions by around 20 per cent when compared with Portland cement.
  6. Sequestrated Carbon Cement
    The Calera Corp. cement in California produced cement from seawater or brine mixed with CO2 that may be used as a Portland cement substitute. In this cement production process, CO2 rich gases are filtered through seawater.
    The calcium and magnesium are stripped from the seawater and react with CO2 to produce high-quality cement, which is white, air-permeable and stronger than regular OPC.
  7. Cement Produced Using Superheated Steam
    The process of superheated steam can be used to change the cement particles in order to make them more reactive. In this process, the emitted CO2 can be captured after it has been separated.
  8. Low Carbon Cement (Ecocem Technology)
    This type of cement contains clinker content up to 20 per cent with 80 per cent SCM’s and limestone filler. The drastic reduction in clinker factor will provide significant savings in energy consumption.
  9. Cement Produced with Reactive Hydrothermal Liquid-phase Densification
    This type of cement is produced using the same raw materials as ordinary Portland cement, but at lower temperature and through a different chemical reaction that produces less CO2 compared with traditional Portland cement production process.
    This cement is blended with water and CO2 and reacts with CO2 to produce calcium carbonate and silica, which eventually hardens to make concrete. This type of green cement is produced by Solidia Technology Company based in the United States, and has partnership with Lafarge to commercialise the cement production technology.

Advantages

  1. Lowers carbon dioxide emission as it does not require as much heat during its production, releasing up to 80 per cent less carbon dioxide.
  2. Makes use of industrial waste such as fly ash, silica fume and blast furnace slag that may require several hectares of land for disposal. As a result, it protects land from becoming a dumping ground and ultimately being destroyed.
  3. Requires less energy. Since industrial by-products present in green cement, the energy needed in production is greatly reduced. Additionally, it withstands temperature fluctuations and
    hence decreases costs related to both heating and cooling.

Efforts Towards Going Green
Decarbonising the cement industry is likely to require significant advances on three fronts: operational efficiency, technological innovation, and business model reorientation. More collaboration across the cement ecosystem will be pivotal. Despite the increasing complexity and challenges each ecosystem player faces, first movers may gain the upper hand by taking immediate action across the value chain to help the industry reach its decarbonisation targets. These green-cement disruptors are likely to capture headwinds as sustainability becomes increasingly urgent.

Operational Efficiency
Even after decades of effort to make cement production more efficient, the industry still has considerable room for efficiency improvements. McKinsey analysis suggests that continued application of proven emissions-abatement methods could reduce emissions by about one-fifth by 2050.
These methods include using clinker substitutes more widely, increasing plant utilisation (which can lower energy intensity), and boosting the effectiveness of equipment. Other opportunities include applying advanced analytics and replacing fossil fuels with alternatives such as biomass-based fuels.

Technological Innovation
Promising changes in the formulation of cement have begun to emerge. For example, lowering the proportion of limestone in cement can result in fewer process and fuel emissions. Adding CO2 to concrete as it cures can strengthen the solid material, reduce the amount of cement needed, and sequester captured CO2. And improving carbon-capture technology would make it more economical to keep process emissions from entering the atmosphere. Coolbrook technology for calciner and kiln electrification using rotodynamic reactors can be a game changer in future.

Business Model Reorientation
Cement-based concrete will probably remain the construction industry’s preferred material. But if engineers, technologists, construction companies and building-materials businesses (which account for about 30 per cent of construction emissions) work together more closely, they could optimise the design of buildings and infrastructure to use less cement overall.
This might involve rethinking structures and shapes, altering the material mix and replacing cement with alternative materials such as cross-laminated timber and employing novel methods such as prefabrication and 3-D printing.
Star Cement has started using green fuel i.e. bamboo for its power plant and clinkerisation unit thus enhancing the green fuel efficiency in the plant, and aiding in the green growth initiative of the country.
Star Cement is adding waste heat recovery systems (WHRS) with existing clinker production lines. It promises to bring the latest technologies for reducing carbon emissions to all the upcoming/existing plants and to bring green cement to the market.

ABOUT THE AUTHOR:
Pankaj Kejriwal, Whole Time Director and COO, Star Cement, has been responsible for conceptualising, engineering, implementation and commissioning of all cement projects.

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.

India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.

Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:

  • September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
  • December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
  • August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
  • April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
  • Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
  • Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
  • Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
  • Orient Cement: It would serve as a principal manufacturing facility following the merger.

Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:

  • By FY 2026: Reach 118 MTPA
  • By FY 2028: Target 140 MTPA

These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).

Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.

Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.

Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.

Challenges potentially include:

  • Integration challenges across systems, corporate cultures, and plant operations
  • Regulatory sanctions for pending mergers and new capacity additions
  • Environmental clearances in environmentally sensitive areas and debt management with input price volatility

When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.

Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.

About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.

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Concrete

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

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PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.

Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

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Concrete

Driving Measurable Gains

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Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.

Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.

Beyond energy efficiency, the retrofit significantly improved operational parameters:

  • Lower thermal stress on equipment
  • Extended lubricant drain intervals
  • Reduction in CO2 emissions and operational costs

These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.

Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:

  • Enhanced component protection
  • Extended oil life under high loads
  • Stable performance across fluctuating temperatures

By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.

Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.

A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

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