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Decarbonising Cement

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S K Rathore, Head Manufacturing – Grey Cement, J K Cement, gives a 360-degree overview of making cement manufacturing a sustainable activity and resolving environmental issues arising out of it.

The Indian cement industry is the second largest producer of cement with around 8 per cent of global cement capacity. It is one of the major contributors to the GDP of the country. The Indian cement sector is one of the most energy-efficient sectors in our country. It has adopted various new practices for improving energy efficiency, environmental performance and cost competitiveness but still has a long way to go to achieve the global targets on carbon footprint reduction.
At JK Cement Ltd (JKCL), they are at the forefront of their sustainability journey. Their progress is on the right speed to achieve their alignment with cement sectors Sustainable Development Goals (SDG). To meet global SDG, they are working on various levels, which include improving energy efficiency, green power, circular economy, clinker factor/blended cement, water footprint and biodiversity.
For the circular economy, JKCL has adopted an environmentally friendly way by disposing of the waste and hazardous waste in cement kilns to replace fossil fuel. For conservation of natural resources, JKCL is using various industrial waste such as fly ash and slag as alternative raw materials.
Circular Economy
A circular economy is a suitable and environmentally friendly way to dispose of the waste and hazardous waste in cement kilns, which replaces fossil fuel.
All their cement kilns are equipped with state-of-the-art pre-processing and feeding of a wide range of liquid and solid waste materials in the calciner. They have increased their Thermal Substitution Rate (TSR) from 6 per cent 2017-18 to 12.9 per cent till YTD FY 2023 and aim to reach 35 per cent by FY30. One of their plants in the state of Karnataka is currently using around 18 per cent Alternative Fuel and Raw Materials (AFR). Recently the company has signed a MoU with PRESPL for the supply of biofuel, biomass to achieve the TSR target.
To strengthen the existing AFR feeding system and to overcome the process challenges, the company is investing in advanced pre-processing and feeding facilities, and in chloride bypass systems to utilise all types of waste including hazardous waste. The company has installed a state-of-the-art R&D lab across all the sites to check the compatibility of waste and
process stabilisation.


They are increasing the share of blended cement by the use of industrial waste such as fly ash and slag as alternative raw materials. As of now the company has achieved a clinker factor of 65 per cent by Q2 FY23, and achieved the target set for FY 2030 under SBTi by company.

Advanced processes are the key to manufacturing green cement as a carbon-negative approach is required to achieve this.

Reducing the Carbon Footprint
Cement being an energy-intensive sector and major contributor to CO2 emissions needs to take major steps to reduce its carbon footprint.
The major GHG emissions are released during clinker production. To achieve their targets, the company is closely monitoring and putting efforts to decarbonise their operations according to the United Nations Framework Convention on Climate Change (UNFCC) campaign’s Race to Zero pledged by the company under the egis of GCCA. In their 2030 agenda, they have targeted to reduce gross carbon emissions from 680 kg CO2/t cement to 532 kg CO2/t cement and net carbon emissions (Scope 1) from base year FY20 level of 580 to 465 kg CO2/t cement.
In the last three years, JKCL has reduced gross GHG emission by 16.62 per cent to 567 kgCO2/t cementitious material and net Scope-1 emission by 10 per cent to 522 kgCO2/t cementitious material till FY2023 Q3.

Role of Automation
JK Cement’s primary focus is on improving energy efficiency and lowering fuel consumption and emissions. By optimising the performance of process control loops, significant energy efficiency can be achieved at a minimal cost, to start with. A process loop optimiser with an AI-based module also helps to optimise fuel use by minimising operational disturbances resulting in decreased carbon emissions. The future bucket list of decarbonisation phases includes AFR gasification, CO2 capturing and upcycling.


Business sustainability is directly linked to automating the cement process and so is the same for JK Cement, too. They have recently developed an AI-based WHRS efficiency enhancement model, and the AI module predicts and makes suggestions to optimise cooler operation for effective and economic solutions for WHRs.

Spreading Awareness
Structured programmes and awareness campaigns for increasing awareness on sustainability are offered to the employees in order to help build world-class competencies and skills. Corporate Sustainability Council is formed, with representation from plant and functional heads, which is working for implementation of sustainability initiatives across the organisation. It plays a major role in developing sustainability awareness and is responsible for communication, reporting and alignment with the global best practices. The Council also facilitates sustainability audits, participating in environmental and social events, while providing relevant information and disclosures to the stakeholders as well as sustainability rating bodies.
The corporate sustainability team monitors climate-related interventions across the organisation, collects and monitors sustainability data and reports to the Corporate Sustainability Council.
Cement is a key ingredient for the development of our cities and societies: construction material is responsible for putting roofs over the heads of billions. As the backbone of the housing and infrastructure sector, it also fuels widespread economic growth but at same time produces a lot of CO2 and it is a hard-to-abate sector from an environmental point of view as the main process itself generates CO2 apart from use of energy in other forms.

India’s infrastructure and urban growth will bring the necessary impetus for innovation in green cement and related technologies


About 40 percent of the emissions come from fossil-fuel combustion and the rest from chemical reactions inherent to the cement making process. It’s a challenge to 100 per cent replacement of fossil fuel by AFR as the quality of AFR available in India is inconsistent.
Scarcity of good quality Secondary Cementitious Material (SCM) due to global switching to renewable energy from fossil fuel based power plants is going to be a major challenge to reduce clinker factor. It is resulting in the need to explore alternative SCMs like good quality clay sources to produce the under development LC3 cement in future and acceptance in the market.

The Future of ‘Green Cement’
India is a growing country with a plethora of construction prospects, which drives cement consumption. Green cement has a promising future in India, if the supply-demand cycle is balanced while maintaining environmental standards.


It is estimated that the cement industry contributes 8 per cent of the total CO2 emissions. To cut down on future emissions, green cement is one such innovation in the cement industry. The green cement is manufactured with a net carbon-negative, technologically advanced process. It is environmentally friendly since it recycles industrial waste and decreases carbon dioxide emissions in total. At the moment, blended cements account for 73 per cent of total cement production, while ordinary Portland cement accounts for 27 per cent. There are several BIS standards under development related to green cement, e.g., Portland limestone cement (PLC), Limestone Calcined Clay Cement (LC3), and Portland Composite Cement (limestone-based), which will be great alternatives to eliminate production of Ordinary Portland Cement.
By using green cement and concrete, CO2 emissions can be reduced further. Also, it reduces the use of freshwater in ready-mix concrete. Eco-friendly products are the need of the hour and will help the cement industry resolve environmental issues.

ABOUT THE AUTHOR:
S K Rathore, BE(Mech), PGDM,
has been associated with JKCement for almost 40 years. Throughout his stint with the organisation, he has worked in all technical and operational areas of manufacturing plants. He has contributed immensely to plant operations for stabilisation and improvements with consistent efficient performance.

Economy & Market

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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Economy & Market

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?

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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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