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Dust can adversely affect living organisms

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Pankaj Kejriwal, Whole Time Director and COO, Star Cement, shares how dust pollution is a severe problem and the efforts that are required to keep dust emissions in check.

What are the key areas where dust emission is prominent in cement manufacturing?
In the cement industry, dust is emitted from mining, transportation and many processes such as crushing of limestone, clinker production and storage, cement grinding and packing and power utilities (the coal mill and the power generators).

What are the measures taken to control the dust emissions at the cement plant?
Cement industry is one of the few industries where the dust generated is a value-added raw material and hence all cement manufacturers try to arrest the dust as it has its own pay back.
Generation of dust is being reduced by modification of transfer points, installation of efficient separators, modern cyclones, etc. Dust generation during mining and transportation is being reduced by effective water / mist / fog spraying. Modern mining equipment is deployed with dedicated dust separation systems. Electric/hydraulic equipped mining machinery is also being used to minimise the dust.
The cement industry has been modernised by introducing specific dedusting equipment used in the production, transport and storage processes. The installation is equipped with specific filters (bag filters or electrostatic filters). This has reduced the flue gas emission and amount of dust released into the atmosphere. The main dedusting machine is the state-of-the-art bag filter, which is available and guarantees a maximum emission of 10 mg/Nm3.
Truck mounted road/area sweeping machines are also operated to clean the dusty area. High pressure water spray systems are used to clean the tyres of vehicles moving inside the plant to minimise the fugitive dust emission.

Tell us about the regulations and compliance issued by the government for emission of dust particles in a cement plant.
In India, regulatory bodies like the Ministry of Environment, Forest and Climate Change, the Central Pollution Control Board (CPCB) and the respective State Pollution Control Boards (SPCB) deal with environmental issues. SPCB regularly inspects the cement plants/limestone quarries to verify compliance with emission norms. CPCB also inspects the cement plants to check compliance with emission standards under environmental surveillance squad activities. Cement plants also have to comply with the charter on Corporate Responsibility for Environment Protection (CREP).
The Indian cement industry must comply with the various environmental acts and regulations notified by the Ministry of Environment and Forests (MoEF), etc., which covers different spheres of the environment, encompassing emissions of air pollutants, consumption of water, generation and discharge of trade effluents, utilisation and storage of hazardous waste, noise generation, utilisation of forest land and wildlife areas. For dust emissions, the following are applicable:

  • Air (Prevention & Control of Pollution) Act, 1981
  • Environment (Protection) Act, 1986 (EPA)
  • The Factories Act, 1948
  • The Mines Act, 1952. Mines Rule 1955 and the Metallic Ferrous Mines Regulation 1961

These Acts/Regulations, together with some of the stringent conditions that are relevant for environment protection from industrial pollution are imposed by the pollution control boards. The government has made norms stricter for the cement industry, capping the stack emissions of PM to not more than 30 milligrams per cubic metre from 200 milligrams per cubic metre earlier. The 24-hour safe limits for ambient PM 2.5 and PM 10 are 60 ug/m3 and 100 ug/m3 respectively.

Tell us about the role of dust collectors in cement production?
Dust collector systems (Bag Filters, Electrostatic Precipitator, etc.) control the dust and gases from various sources during process at various stages, which helps to provide the factory with cleaner air that can provide numerous benefits. A dust collection system works by sucking air in from a given application and processing it through a filtering system so that particulate matter can be deposited into a collection area. Then the cleaned air is either returned to the facility or exhausted to the environment.

Where is the collected dust discarded?
After dust-filled air has been captured by a dry dust collection system, dust must be separated, collected, and disposed of. The dust collector separates dust particles from the airstream and discharges cleaned air either into the atmosphere or back into the workplace. The collected dust goes back into the process system as it is a value added product to cement. Nearly 100 per cent collected dust is recycled.

What is the impact of dust emission on the environment in and around the cement plant?
Dust pollution is the introduction of chemicals, particulate matter or biological materials that cause harm or discomfort to humans or other living organisms or cause damage to the natural environment.
Dust can adversely affect living organisms. Increased concentration of cement dust pollutants causes invisible injuries like progressive decline in the physiological process such as photosynthetic ability and respiration rate.

Can dust emission be qualified as a health hazard at a cement plant?
The point source emissions from the cement industry include particulate matter and gaseous emissions. Since the cement industry deals with various size reduction operations from limestone crushing to clinker grinding, dust emissions are a major pollutant. Gaseous emissions such as sulphur dioxide (SO2), oxides of nitrogen (NOx), carbon monoxide (CO), carbon dioxide (CO2), etc., are generated during pyro processing. All of these are major health hazards at a cement plant, if not controlled and minimised.

How can automation and technology contribute towards reduction of dust emission?
It is necessarily required to put in place the latest technology, management systems and continuous online monitoring system that helps to routinely implement the activities that facilitate adherence to the emission norms prescribed under the pollution control legislation The real time data of online stack monitoring and Ambient Air Quality Management Systems (AAQMS) is published on the web for better monitoring and controlling.

Tell us about newer innovations that the cement industry is adapting to reduce the emission of dust and control the same.
Some of the sustainable new innovations for air pollution control methods followed by the Indian cement industry are:

  1. In bag filters, use of low air to cloth ratio and use of latest filter media/fabric in pleated/cartridge shaped filter bags. For bag filters, the use of membrane filter bags is a useful innovation.
  2. Installation of hybrid bag filter and electrostatic preceptors for more effective control of
    dust emission.
  3. Substituting clinker with fly ash/blast furnace slag/limestone, which is readily available and reduces dust emissions and fuel consumed for producing clinkers.
  4. Using alternative fuel resources.
  5. Co-processing, i.e., using waste materials as fuel by burning them in the high temperature of the kilns. This also effectively disposes of solid waste.
  6. Installation of Waste Heat Recovery System (WHRS), in clinker production units.

-Kanika Mathur

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India’s Steel Imports Drop 34 Per Cent, Exports Rise 25 Per Cent In April–October

Consumption grows despite weak prices and subdued demand

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India’s finished steel imports fell 34.1 per cent year-on-year to 2.5 million tonnes in the first seven months of the financial year, according to government data. Despite the decline, the world’s second-largest crude steel producer remained a net importer of finished steel during the April–October period. The fall in imports came alongside a 7.4 per cent rise in domestic consumption, which reached 92.2 million tonnes.

South Korea emerged as India’s largest source of finished steel imports, supplying 1.4 million tonnes. It was followed by China, Japan and Russia. Although total imports declined sharply, the figures show a continued inflow of foreign steel into the Indian market.

Domestic production remained strong. Finished steel output stood at 91.6 million tonnes for April–October, while crude steel production reached 95.7 million tonnes, underscoring the scale and resilience of India’s steel industry despite external competition.

In contrast to the fall in imports, India’s finished steel exports jumped 25.3 per cent year-on-year to 3.5 million tonnes. Europe was a major destination, with Italy and Belgium leading as top importers of Indian steel, followed by Spain. This highlights the growing global competitiveness of Indian steel in select markets.

The government noted that domestic steel prices have come under pressure due to weak demand and high supply. Trading activity also remained subdued during the festival season. This challenging environment has been particularly difficult for smaller steel producers, as previously reported.

Overall, the combination of declining imports, rising exports and increasing domestic consumption reflects the complex landscape of the Indian steel sector as it navigates muted internal demand and evolving international trade dynamics.

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JK Lakshmi Cement Plans Rs 18.16 Billion Expansion

Firm to boost clinker and grinding capacity in Chhattisgarh

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JK Lakshmi Cement announced on Tuesday that it will invest Rs 18.16 billion to expand its manufacturing operations in Chhattisgarh. The company intends to raise its clinker production capacity by 2.31 million tonnes per annum (MTPA) and its cement grinding capacity by 1.2 MTPA, supported by this proposed investment.

The Memorandum of Understanding for the expansion was signed during the Chhattisgarh Investor Connect event in New Delhi, in the presence of Chief Minister Vishnu Deo Sai. The added capacity will enhance the company’s ability to serve the rapidly growing markets of Eastern and Central India, where demand for building materials remains robust.

The move supports JK Lakshmi Cement’s broader goal of increasing its total capacity to around 30 MTPA in the coming years. Deputy Managing Director Shrivats Singhania said the expansion marks a significant step in the company’s next phase of growth, adding that Chhattisgarh has long been central to its manufacturing strategy.

Over the past decade, JK Lakshmi Cement has contributed to strengthening Chhattisgarh’s industrial landscape since establishing its integrated plant in Durg in 2015. The company has implemented multiple initiatives, including a manufacturing facility with 1.8 MTPA of clinker capacity and 2.7 MTPA of cement capacity, operational upgrades with energy-efficient technology and automation, and logistics improvements through enhanced rail connectivity.

Chhattisgarh continues to show strong economic momentum, making it one of the most promising markets for cement demand, said Arun Shukla, President and Director at JK Lakshmi Cement. The company’s shares closed 0.28 per cent higher at Rs 782.10 on the BSE.

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Balancing Rapid Economic Growth and Climate Action

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Dr Yogendra Kanitkar, VP R&D, and Dr Shirish Kumar Sharma, Assistant Manager R&D, Pi Green Innovations, look at India’s cement industry as it stands at the crossroads of infrastructure expansion and urgent decarbonisation.

The cement industry plays an indispensable role in India’s infrastructure development and economic growth. As the world’s second-largest cement producer after China, India accounts for more than 8 per cent of global cement production, with an output of around 418 million tonnes in 2023–24. It contributes roughly 11 per cent to the input costs of the construction sector, sustains over one million direct jobs, and generates an estimated 20,000 additional downstream jobs for every million tonnes produced. This scale makes cement a critical backbone of the nation’s development. Yet, this vitality comes with a steep environmental price, as cement production contributes nearly 7 per cent of India’s total carbon dioxide (CO2) emissions.
On a global scale, the sector accounts for 8 per cent of anthropogenic CO2 emissions, a figure that underscores the urgency of balancing rapid growth with climate responsibility. A unique challenge lies in the dual nature of cement-related emissions: about 60 per cent stem from calcination of limestone in kilns, while the remaining 40 per cent arise from the combustion of fossil fuels to generate the extreme heat of 1,450°C required for clinker production (TERI 2023; GCCA).
This dilemma is compounded by India’s relatively low per capita consumption of cement at about 300kg per year, compared to the global average of 540kg. The data reveals substantial growth potential as India continues to urbanise and industrialise, yet this projected rise in consumption will inevitably add to greenhouse gas emissions unless urgent measures are taken. The sector is also uniquely constrained by being a high-volume, low-margin business with high capital intensity, leaving limited room to absorb additional costs for decarbonisation technologies.
India has nonetheless made notable progress in improving the carbon efficiency of its cement industry. Between 1996 and 2010, the sector reduced its emissions intensity from 1.12 tonnes of CO2 per ton of cement to 0.719 tonnes—making it one of the most energy-efficient globally. Today, Indian cement plants reach thermal efficiency levels of around 725 kcal/kg of clinker and electrical consumption near 75 kWh per tonne of cement, broadly in line with best global practice (World Cement 2025). However, absolute emissions continue to rise with increasing demand, with the sector emitting around 177 MtCO2 in 2023, about 6 per cent of India’s total fossil fuel and industrial emissions. Without decisive interventions, projections suggest that cement manufacturing emissions in India could rise by 250–500 per cent by mid-century, depending on demand growth (Statista; CEEW).
Recognising this threat, the Government of India has brought the sector under compliance obligations of the Carbon Credit Trading Scheme (CCTS). Cement is one of the designated obligated entities, tasked with meeting aggressive reduction targets over the next two financial years, effectively binding companies to measurable progress toward decarbonisation and creating compliance-driven demand for carbon reduction and trading credits (NITI 2025).
The industry has responded by deploying incremental decarbonisation measures focused on energy efficiency, alternative fuels, and material substitutions. Process optimisation using AI-driven controls and waste heat recovery systems has made many plants among the most efficient worldwide, typically reducing fuel use by 3–8 per cent and cutting emissions by up to 9 per cent. Trials are exploring kiln firing with greener fuels such as hydrogen and natural gas. Limited blends of hydrogen up to 20 per cent are technically feasible, though economics remain unfavourable at present.
Efforts to electrify kilns are gaining international attention. For instance, proprietary technologies have demonstrated the potential of electrified kilns that can reach 1,700°C using renewable electricity, a transformative technology still at the pilot stage. Meanwhile, given that cement manufacturing is also a highly power-intensive industry, several firms are shifting electric grinding operations to renewable energy.
Material substitution represents another key decarbonisation pathway. Blended cements using industrial by-products like fly ash and ground granulated blast furnace slag (GGBS) can significantly reduce the clinker factor, which currently constitutes about 65 per cent in India. GGBS can replace up to 85 per cent of clinker in specific cement grades, though its future availability may fall as steel plants decarbonise and reduce slag generation. Fly ash from coal-fired power stations remains widely used as a low-carbon substitute, but its supply too will shrink as India expands renewable power. Alternative fuels—ranging from biomass to solid waste—further allow reductions in fossil energy dependency, abating up to 24 per cent of emissions according to pilot projects (TERI; CEEW).
Beyond these, Carbon Capture, Utilisation, and Storage (CCUS) technologies are emerging as a critical lever for achieving deep emission cuts, particularly since process emissions are chemically unavoidable. Post-combustion amine scrubbing using solvents like monoethanolamine (MEA) remains the most mature option, with capture efficiencies between 90–99 per cent demonstrated at pilot scale. However, drawbacks include energy penalties that require 15–30 per cent of plant output for solvent regeneration, as well as costs for retrofitting and long-term corrosion management (Heidelberg Materials 2025). Oxyfuel combustion has been tested internationally, producing concentrated CO2-laden flue gas, though the high cost of pure oxygen production impedes deployment in India.
Calcium looping offers another promising pathway, where calcium oxide sorbents absorb CO2 and can be regenerated, but challenges of sorbent degradation and high calcination energy requirements remain barriers (DNV 2024). Experimental approaches like membrane separation and mineral carbonation are advancing in India, with startups piloting systems to mineralise flue gas streams at captive power plants. Besides point-source capture, innovations such as CO2 curing of concrete blocks already show promise, enhancing strength and reducing lifecycle emissions.
Despite progress, several systemic obstacles hinder the mass deployment of CCUS in India’s cement industry. Technology readiness remains a fundamental issue: apart from MEA-based capture, most technologies are not commercially mature in high-volume cement plants. Furthermore, CCUS is costly. Studies by CEEW estimate that achieving net-zero cement in India would require around US$ 334 billion in capital investments and US$ 3 billion annually in operating costs by 2050, potentially raising cement prices between 19–107 per cent. This is particularly problematic for an industry where companies frequently operate at capacity utilisations of only 65–70 per cent and remain locked in fierce price competition (SOIC; CEEW).
Building out transport and storage infrastructure compounds the difficulty, since many cement plants lie far from suitable geological CO2 storage sites. Moreover, retrofitting capture plants onto operational cement production lines adds technical integration struggles, as capture systems must function reliably under the high-particulate and high-temperature environment of cement kilns.
Overcoming these hurdles requires a multi-pronged approach rooted in policy, finance, and global cooperation. Policy support is vital to bridge the cost gap through instruments like production-linked incentives, preferential green cement procurement, tax credits, and carbon pricing mechanisms. Strategic planning to develop shared CO2 transport and storage infrastructure, ideally in industrial clusters, would significantly lower costs and risks. International coordination can also accelerate adoption.
The Global Cement and Concrete Association’s net-zero roadmap provides a collaborative template, while North–South technology transfer offers developing countries access to proven technologies. Financing mechanisms such as blended finance, green bonds tailored for cement decarbonisation and multilateral risk guarantees will reduce capital barriers.
An integrated value-chain approach will be critical. Coordinated development of industrial clusters allows multiple emitters—cement, steel, and chemicals—to share common CO2 infrastructure, enabling economies of scale and lowering unit capture costs. Public–private partnerships can further pool resources to build this ecosystem. Ultimately, decarbonisation is neither optional nor niche for Indian cement. It is an imperative driven by India’s growth trajectory, environmental sustainability commitments, and changing global markets where carbon intensity will define trade competitiveness.
With compliance obligations already mandated under CCTS, the cement industry must accelerate decarbonisation rapidly over the next two years to meet binding reduction targets. The challenge is to balance industrial development with ambitious climate goals, securing both economic resilience and ecological sustainability. The pathway forward depends on decisive governmental support, cross-sectoral innovation, global solidarity, and forward-looking corporate action. The industry’s future lies in reframing decarbonisation not as a burden but as an investment in competitiveness, climate alignment and social responsibility.

References

  • Infomerics, “Indian Cement Industry Outlook 2024,” Nov 2024.
  • TERI & GCCA India, “Decarbonisation Roadmap for the Indian Cement Industry,” 2023.
  • UN Press Release, GA/EF/3516, “Global Resource Efficiency and Cement.”
  • World Cement, “India in Focus: Energy Efficiency Gains,” 2025.
  • Statista, “CO2 Emissions from Cement Manufacturing 2023.”
  • Heidelberg Materials, Press Release, June 18, 2025.
  • CaptureMap, “Cement Carbon Capture Technologies,” 2024.
  • DNV, “Emerging Carbon Capture Techniques in Cement Plants,” 2024.
  • LEILAC Project, News Releases, 2024–25.
  • PMC (NCBI), “Membrane-Based CO2 Capture in Cement Plants,” 2024.
  • Nature, “Carbon Capture Utilization in Cement and Concrete,” 2024.
  • ACS Industrial Engineering & Chemistry Research, “CCUS Integration in Cement Plants,” 2024.
  • CEEW, “How Can India Decarbonise for a Net-Zero Cement Industry?” (2025).
  • SOIC, “India’s Cement Industry Growth Story,” 2025.
  • MDPI, “Processes: Challenges for CCUS Deployment in Cement,” 2024.
  • NITI Aayog, “CCUS in Indian Cement Sector: Policy Gaps & Way Forward,” 2025.

ABOUT THE AUTHOR:
Dr Yogendra Kanitkar, Vice President R&D, Pi Green Innovations, drives sustainable change through advanced CCUS technologies and its pioneering NetZero Machine, delivering real decarbonisation solutions for hard-to-abate sectors.

Dr Shirish Kumar Sharma, Assitant Manager R&D, Pi Green Innovations, specialises in carbon capture, clean energy, and sustainable technologies to advance impactful CO2 reduction solutions.

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