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Automation can provide real-time monitoring of emissions

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Anil Gupta, Technical Head, JK Cement Works, Nimbahera, discusses the adverse effects of dust emissions on human health and the environment and how use of advanced filtration systems, automation and other technology solutions can help reduce it.

What are the key areas where dust emission is prominent in cement manufacturing?
Cement manufacturing unit consists of various sections such as mining, crusher, raw mill, kiln, coal mill, cement mill, packing plant, etc. However, the key areas where dust emission is highly prominent are dump hoppers of limestone and additive crusher, raw material storage yards, feeding circuits of clinker and cement raw material, packing and loading area, raw mill bag house, cooler ESP, coal transport and grinding circuit, cement mills bag house and CPP stack.

What are the measures taken to control the dust emissions at a cement plant?
We have two types of dust emissions:

  • Stack or vent duct: From process operation and have fixed point of release.
  • Fugitive dust: Dust that is generated or emitted from open air operations or at material transport point (emissions that do not pass through as stack or vent).

To control both the types of dust emissions in a cement plant, following measures are taken:

  • Installation of de-dusting bag filter.
  • Installation of bag house and electro static precipitator.
  • Installation of water spray system in yard area.
  • Enclosure should be provided for all unloading operations, except wet materials like gypsum.
  • The pathways in the coal yard for vehicle movement should be paved.
  • Accumulated dust shall be removed / swept regularly and water the area after sweeping.
  • Air borne fines extracted from the clinker cooler shall be separated and sent to the last possible destination directly, if possible.


Tell us about governmental regulations and compliance for dust emissions.
For achieving effective prevention and control of potential fugitive emission sources in cement manufacturing plants, specific requirements along with guidelines have been evolved by the central government. For the Indian cement industry, the Ministry of Environment Forest and Climate Change has notified the norms for reduction of dust emission from cement plants, which includes particulate matter, SOx and NOx. The notification clearly defines the limits for above mentioned emissions, particulate matter should be < 30 milligram, SOx should be
< 100 milligram, NOx should be < 1000, 800, 600 milligrams. It depends on the age of the plant or we can say that on the commissioning date of the plant.
Some relaxation is there in the SOx limit. It should be 700 and 1000 milligram with more pyretic sulphur presence in limestone deposit. In cases where SPM concentrations exceed the prescribed limit, necessary corrective measures in terms of improving the controls shall be taken and action taken records of improvements carried out be maintained.

Tell us about the role of dust collectors in cement production.
A dust collector is a system used to enhance the quality of air released from industrial processes by collecting dust and other impurities from air or gas. It is designed to handle high-volume dust loads. A dust collector system consists of a blower, dust filter, a filter-cleaning system, and a dust receptacle. It is distinguished from air purifiers, which use disposable filters to remove dust. It may be of single unit construction, or a collection of devices used to separate particulate matter from the process air. It is also used as an air pollution control device to maintain or improve air quality.
A dust collector also helps to increase productivity as when dirt, dust and debris collect on equipment, it can make its way inside, interfering with the mechanics of the equipment. This can lead to slower machines and broken equipment. Compromised machinery constantly needs attention and repairs. Dust collectors remove this risk, allowing your machinery to work at optimal performance.

Where is the collected dust discarded?
The environmental concerns related to cement production, emission and disposal of dust is becoming progressively significant. Cement kiln dust (CKD) is fine-grained, particulate material chiefly composed of oxidised, anhydrous, micron-sized particles collected from electrostatic precipitators during the high temperature production of clinker. CKD so generated is partly reused in cement plant. No dust is discarded in the environment except stack dust. However, Stack emitted dust is discarded in an environment which is under the limit of governmental norms.

What is the impact of dust emission on the environment in and around?
In the past, cement dust spread out over large areas due to wind and rain and accumulated over the soil and plants. It has the potential to affect animal and human health adversely. Dust from cement factories adversely affects the forest ecosystem, soil enzymes, fungi and bacteria population within the vicinity of cement factories. Furthermore, it was shown that plant height, phytomass, net primary productivity, chlorophyll content, metabolites and yield were reduced in response to cement dust in the polluted areas.
After the 1990s, the cement industry did a lot of investment for dust control. Several modifications have also been carried out in the existing system to make the system more efficient. This can be achieved through the use of advanced filtration systems, alternative fuels, automation and other technology solutions. It is also important to monitor and report emissions to regulatory agencies to ensure compliance with environmental regulations. No significant impact has been observed in and around the cement plant.

Can dust emission be qualified as a health hazard at a cement plant?
Yes, dust emission can be qualified as a health hazard at a cement plant. Inhalation of cement dust can cause a range of respiratory problems, including bronchitis, asthma and silicosis, a lung disease caused by inhaling crystalline silica dust. Prolonged exposure to high levels of cement dust can also increase the risk of developing lung cancer.
To minimise the health risks associated with dust emissions, cement plants are continuously implementing measures to reduce the amount of dust generated during the manufacturing process. This is achieved through the use of advanced filtration systems, automation, and other technology solutions. It is also important to provide proper personal protective equipment (PPE) to workers and to ensure that they receive adequate training on the health risks associated with working in a cement plant.

How can automation and technology help in reduction of dust emissions?
Automation and technology are contributing in reduction of dust emissions in following ways:

  • Real-time monitoring and control: Automation can provide real-time monitoring of emissions, which can help to identify and address potential issues before they become major problems. This can be achieved through the use of sensors and advanced data analytics.
  • Optimised process control: Advanced process control technologies can optimise the cement manufacturing process and minimise dust emissions. This technology can help operators monitor and control the process in real-time, ensuring that emissions are kept to a minimum.
  • Advanced filtration and scrubbing systems: Technology can improve the efficiency of filtration and scrubbing systems, such as bag filters and electrostatic precipitators. These systems can remove particulate matter and other pollutants from the air, reducing dust emission.
  • Use of drones for inspection: Drones can be used to inspect hard-to-reach areas in the plant, such as the top of the kiln or preheater tower, without risking the safety of personnel. This can help to identify areas where dust emissions are high, and take corrective actions.
  • Overall, automation and technology can help reduce dust emissions in cement plants by providing real-time monitoring and control, optimising process control, improving filtration and scrubbing systems and using drones for inspection.

Tell us about newer innovations that help reduce the dust missions and control it?
The cement industry has been under increasing pressure to reduce its environmental impact, especially concerning the emission of dust and pollutants. Here are some of the newer innovations that the cement industry is adapting to reduce dust emissions and control them:

  • Use of Low-NOx Burners: The use of low-NOx burners in cement kilns reduces the emission of nitrogen oxides (NOx), which are one of the major contributors to air pollution. These burners help in reducing the temperature inside the kiln, which in turn reduces the formation of NOx.
  • Installation of Bag Filters: Bag filters are used to capture particulate matter emitted during the cement manufacturing process. These filters are highly efficient and can capture up to 99 per cent of the particulate matter emitted from the kiln. This reduces the emission of dust and improves the air quality around the cement plant.
  • Use of Alternative Fuels: Cement manufacturers are increasingly using alternative fuels, such as waste materials, biomass, and municipal solid waste, to power their kilns. These fuels emit less carbon dioxide (CO2) and other pollutants than traditional fossil fuels.
  • Automation of Process Control: Advanced process control technologies can optimise the cement manufacturing process and minimise dust emissions. This technology can help operators monitor and control the process in real-time, ensuring that emissions are kept to a minimum.
  • Introduction of Green Cement: Green cement is a new type of cement that is produced using environmentally friendly manufacturing processes. It can reduce carbon emissions by up to 80 per cent compared to traditional cement. Green cement can be produced using waste materials such as fly ash and slag, and can also be made using renewable energy sources.

Overall, the cement industry is making significant strides in reducing its environmental impact, particularly concerning dust emissions. These innovations are helping to improve the sustainability of the industry and protect the health of nearby communities.

Kanika Mathur

Concrete

Akhoya Gets New 2.2 Km Road Link Under SASCI

Two cement concrete roads opened at Rs 29.1 million (mn) cost

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Two cement concrete pavement roads covering a total stretch of 2.2 km in Akhoya village were inaugurated on 27th June 2026 by MLA Nuklutoshi Longkumer, who attended as the special guest. The project comprises the one km L Pangersowa Road and the one point two km Longchara Junction to RC Chiten Jamir Memorial Government High School road. A formal programme followed the inauguration at the school auditorium.

A technical report was presented by Er Waloniba of the Urban Engineering Wing-III, Kohima, which stated the project was sanctioned in March 2026 under the Special Assistance to States for Capital Investment scheme for 2025-26 at a sanctioned cost of Rs 29.1 million (mn). The work order was issued to M/s Ensign Construction on thirtieth April 2026 with a stipulated completion period of 12 months. Work commenced on fourth May 2026 and was completed on sixth June 2026, with the contractor and team finishing the tasks in around two months. The project included a single-lane cement concrete pavement with side drains, two slab culverts and breast walls at required locations.

Longkumer acknowledged the Chief Minister, the advisor for urban development, contractors and other stakeholders for the allocation and support, and he commended the contractor for early completion. He noted that cooperation from landowners and the community had been important in resolving land related issues that can otherwise delay developmental works. He emphasised that planned developmental activities carried out with collective effort would enable more projects to be implemented successfully.

The headmaster of RC Chiten Jamir Memorial Government High School, I Chubasenba Longkumer, outlined the school background, noting it was established in 1962, was earlier known as Government High School Changtongya and was renamed in 2014. Local representatives said the improved approach roads would ease access for students, staff, patients and the general public and fulfil a long standing aspiration of residents. A dedicatory prayer was offered by the pastor and the programme concluded with a ribbon cutting attended by village council and town council representatives.

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Green Construction Through Cement Innovation

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Indian Cement Review (ICR) and Fuller Technologies brought industry, policy and technology leaders together to discuss how cement innovation can drive green construction at scale, writes Rakesh Rao.

India is building at a pace few countries can match. Highways, airports, housing, logistics parks, industrial corridors and urban infrastructure are reshaping the country’s economic geography. But beneath this growth story lies a difficult question: can India continue to build at scale without locking itself into a high-carbon future?

That question formed the core of an online panel discussion titled “Driving Green Construction Through Cement Innovation”, organised by Indian Cement Review (ICR) in association with Fuller Technologies as the Presenting Partner on June 25, 2026. The webinar brought together experts from cement technology, R&D, global industry platforms, building performance policy and international development cooperation to examine how low-carbon cement and material innovation can accelerate India’s green construction transition.

The discussion came at a crucial time. India has committed to achieving net-zero emissions by 2070 and reducing the carbon intensity of its economy by 45 per cent by 2030. At the same time, the country’s construction sector is expanding rapidly, driven by urbanisation, infrastructure development, housing demand and industrial growth. Cement, as one of the most widely used construction materials, sits at the heart of this transition. It is indispensable to development, but also central to the challenge of reducing embodied carbon in buildings and infrastructure.

Moderated by Nitika Krishan, Senior Urban Infrastructure and Sustainable Policy Consultant, the panel featured:

  • Kiranmai Sanagavarapu, Director, Low Carbon Solutions, Fuller Technologies;
  • Dr Hemantkumar Aiyer, VP and Head R&D, Nuvoco Vistas Corp Ltd;
  • Devika Wattal, Innovation Lead, Global Cement and Concrete Association (GCCA);
  • Dr Sunita Purushottam, MD, GBPN India (Global Buildings Performance Network); and
  • Vaibhav Rathi, Senior Technical Advisor, GIZ (the German Agency for International Cooperation)

Setting the tone for the discussion, Nitika Krishan underlined the scale of the challenge before the sector. “The question before us is no longer whether we build, but how we build sustainably,” she said. She pointed out that construction accounts for nearly 40 per cent of global energy-related carbon emissions when both operational and embodied carbon are considered. Cement production, she added, remains one of the hardest industrial processes to decarbonise.

For India, this is not merely an environmental issue. It is a development issue, a competitiveness issue and increasingly, a market issue. As one of the world’s largest cement producers and among the fastest-growing construction markets, India’s material choices will influence the carbon trajectory of its built environment for decades. As Krishan observed, sustainability solutions in economies such as India must not remain limited to laboratory success. They must be scalable, commercially viable and practical at national level.

The innovation gap: From technology to market

Experts believe that there is a need to bridge the innovation gaps for making decarbonisation in cement and concrete scalable. Devika Wattal of GCCA, explained, “The starting point must be the core cement manufacturing process itself. The first and foremost is the heart of our process, the heart of cement manufacturing. How do we reduce clinker? That is always a topic where industry is working very intrinsically.”

Clinker reduction remains one of the most important pathways for lowering emissions in cement. Since clinker production is energy-intensive and chemically emits carbon dioxide, reducing the clinker factor through supplementary cementitious materials (SCMs), blended cements and new chemistries can have a significant impact. Wattal also noted that carbon capture, utilisation and storage (CCUS) will have a role, though it may not be the first lever for all markets.

However, she stressed that innovation cannot stop at technology development. A solution that works in the lab must also be adaptable to industry, scalable in production and acceptable in construction practice. “It is important for that innovation to be adaptable, to be scalable, and so that it can be executed in real time,” she said.

Wattal also called for stronger enabling systems around innovation. These include performance-based standards, product-level embodied carbon databases and clearer frameworks for evaluating green materials. Without these, low-carbon cement products may struggle to compete with conventional materials in procurement and design.

R&D must balance carbon, cost and performance

Bringing in the R&D perspective into the discussion, Dr Hemantkumar Aiyer of Nuvoco Vistas emphasised that low-carbon cement development cannot be treated as a single-variable exercise. Cement must perform in real construction conditions. It must deliver strength, durability, consistency and cost competitiveness, while also reducing carbon.

“The root of understanding and balancing all these aspects lies in materials, and knowing the materials,” he said.

According to Dr Aiyer, R&D teams must understand the variability of raw materials such as fly ash, slag and clinker. Different sources produce different material behaviours. This makes mix optimisation, material characterisation and processing-property relationships critical. When performance is affected, cement manufacturers must understand how strength enhancers, admixtures and other performance chemicals interact with the material system.

He also linked material science with process efficiency. Clinkerisation takes place at extremely high temperatures, around 1,400 to 1,450 degrees Celsius. Any improvement in raw mix design, process control or energy optimisation can, therefore, help reduce emissions and cost. Dr Aiyer pointed to artificial intelligence-based optimisation, Cement 4.0 tools and advanced software as important enablers for real-time process and material control.

“The more you understand the materials, the more you can control it,” he said.

LC3: The promise is proven, the sequencing is not

Limestone calcined clay cement, commonly referred to as LC3, has attracted global attention because it can reduce clinker content significantly by using calcined clay and limestone while maintaining performance in many applications. Kiranmai Sanagavarapu of Fuller Technologies said the technology itself has already moved beyond proof of concept. Fuller Technologies has worked with calcined clay technology for nearly two decades and has seen plants running in France and Ghana. These plants, she said, are meeting local and national specifications, while the economics are beginning to make sense.

“The calciner is performing, the economics is stacking up, it is making business sense to produce,” she said.

But if the technology is viable, why has adoption not scaled faster? For Sanagavarapu, the answer lies in project sequencing. Too often, clay characterisation happens after equipment is specified. This, she warned, is a backward approach because calciner design depends on clay mineralogy, kaolinite content, iron levels, reactivity, moisture and other variables.

“If you don’t know what your deposit looks like before you commit for the equipment, you are, in a way, going blind into designing,” she said.

She also identified permitting and plant integration as major bottlenecks. Environmental clearances, mining permissions and local regulatory approvals must begin early. Similarly, calcined clay must be integrated into existing grinding, blending and logistics systems from the design stage, not treated as an afterthought during commissioning.

India already has IS 18189:2023 standard for LC3, but Sanagavarapu pointed out that the standard is not yet visible enough in procurement documents. “The gap between what is technically being permitted and what the procurement is asking is the single biggest bottleneck,” she said.

In her view, successful scale-up depends on getting the sequence right: clay characterisation first, permitting in parallel, standards aligned with construction, and integration built into plant design.

India’s LC3 journey: Progress, but demand remains thin

Providing details of India’s LC3 commercialisation experience, Vaibhav Rathi of GIZ noted that JK Cement carried out the first commercial production of LC3 at its Rajasthan plant, followed by JK Lakshmi Cement three months later. These initiatives were supported by the International Climate Initiative of the Government of Germany, with IIT Delhi contributing deep institutional knowledge on LC3 research and BIS certification.

Rathi said India’s early experience has produced clear lessons. One of the biggest was the need to build capacity among regulators. While BIS certification existed, State Pollution Control Boards were unfamiliar with the technology and unsure about the approval pathway.

“The capacity building is not just needed amongst the producer and the users of the cement, but also the regulators who are working with this technology for the first time,” he said.

He also highlighted the need for better information on China clay deposits. Since China clay is currently classified as a minor mineral, centralised data on availability, quality and location is limited. If cement manufacturers are to adopt LC3 at scale, stronger mineral intelligence will be important.

The third issue is demand. LC3 has already been used in projects such as Palava City in Mumbai and Noida International Airport, but these remain limited examples. “It is in a chicken and egg situation,” Rathi said. “Cement companies are saying we need more demand, and users are saying there is not enough cement available.”

Public procurement, he suggested, could help break this cycle. If agencies such as CPWD and other public bodies begin testing, accepting and specifying LC3, it could create the market confidence needed for cement companies to invest in production and storage.

Building codes must catch up with innovation

Dr Sunita Purushottam of GBPN India argued that material choices will determine built environment emissions over the long term, but India’s current policy signals remain fragmented. Although LC3 has received BIS recognition, she pointed out that building codes, municipal bylaws, schedules of rates and sustainability codes do not yet provide uniform guidance on low-carbon cement.

“The current cement regulations are largely prescriptive and favouring traditional materials,” she said. This limits the ability of alternative materials to compete on performance, durability and emissions.

Dr Purushottam also raised the issue of taxation. Cement, including LC3, currently falls under the same GST bracket as conventional cement. A differentiated tax structure, she argued, could help accelerate market adoption. “In order for the market to demand LC3, that differentiation in the GST could go a long way,” she said.

She noted that green building certifications such as IGBC and GRIHA are already creating demand for low-carbon materials by assigning points for embodied carbon and sustainable material use. However, she said large-scale adoption will require regulatory mandates, particularly through building codes and state-level notifications.

She also cautioned that low-carbon cement alone does not solve the entire building performance problem. A material may reduce embodied carbon, but the operational carbon of a building depends on thermal performance, design, insulation and energy use. “The energy part has two elements,” she said. “One is the embodied carbon of the material itself, and the other is the operational carbon.”

Collaboration is the bridge between invention and impact

Wattal said GCCA sees innovation as a strategic priority and works through platforms that connect industry with academia and start-ups. “There is no way we will decarbonise our sector without innovation,” she said.

However, she stressed that research must be connected to actual industry challenges. Innovations developed in isolation may fail when they encounter real-world barriers such as raw material variability, plant integration, cost, standards and finance. Start-ups, too, need industry mentorship and scale-up pathways.

Wattal also flagged the importance of finance. Even strong technologies may struggle to attract investment if there is no common understanding of bankability. “We have always put projects into, is this a bankable project? But the definition of a bankable project has never been defined,” she said.

For India, she saw strong potential in its academic and start-up ecosystem, but said the challenge lies in alignment and prioritisation. The country has the research base, industrial capacity and market size. What it now needs is a coordinated route from innovation to deployment.

There is a practical concern for cement manufacturers: how can existing plants be adapted for lower emissions without compromising reliability or commercial viability?

Kiranmai Sanagavarapu addressed, “The reliability risk in calcined clay retrofit is definitely real, but it is almost always self-inflicted. The risk arises when a new process is added to an existing circuit without properly redesigning grinding and blending configurations.”

Existing cement plants, she explained, can take two broad routes. The first is external sourcing of calcined clay combined with mill optimisation. This requires lower capital investment and can potentially move in 12 to 18 months if other conditions are in place. It may reduce emissions by around 20 to 30 per cent. The second route is integrated calcination on site, which requires higher capital expenditure and longer lead times, but provides greater control over quality, supply and emissions reduction potential.

For Sanagavarapu, the principle is simple: low-carbon retrofits must be designed with intent. “Design it with an intent properly from the start. Start in the market conditions where the economics are already working,” she said.

Circularity: The overlooked advantage

According to Vaibhav Rathi, fly ash and slag are already well established in cement and construction (C&D), but construction and demolition waste remains underutilised. “C&D waste is a growing business opportunity which not many have taken up,” he said. India’s continuous construction and demolition activity creates huge volumes of waste, much of which contributes to air pollution, land degradation and material inefficiency. With the right processing and standards, this waste can be converted into useful construction products.

Rathi also pointed out that LC3 has a circular economy dimension that is often overlooked. It can use low-grade kaolin-rich clay left behind after high-grade clay is extracted for other applications. “LC3 is not only a low-carbon solution, but also a circular economy solution,” he said.

At the same time, he cautioned that LC3 in India is not yet cheap because it has not reached scale. Site-specific techno-commercial feasibility studies, supported jointly by development agencies and industry, could help companies assess whether LC3 production makes technical and financial sense at a given location.

Dr Purushottam added that India must address both low-carbon cement and construction waste together. “Both low-carbon cement and C&D waste go hand in hand. India does not have an option but to work on both,” she said.

Dr Aiyer called for policy shifts from both government and industry, including preferential purchasing of sustainable materials, minimum supplementary cementitious material requirements in public and public-private projects, and faster regulatory implementation. “If we can fast-track the regulatory standards and their implementation on the ground, that is the way to go,” he said.

From green ambition to green construction

Cement innovation is no longer only about chemistry. It is about systems. Low-carbon cement will scale only when technology, standards, procurement, finance, regulation, education and construction practice move together.

LC3 and other low-carbon technologies have shown promise. India has early commercial examples, strong research capability and growing market interest. But mainstream adoption will depend on whether demand can be created, regulators can be capacitated, standards can be embedded in procurement, and manufacturers can see a clear business case.

For a country building at India’s scale, the opportunity is enormous. Cement will continue to be central to infrastructure and urban development. The challenge now is to ensure that the cement used in India’s growth story carries a lower carbon burden.

  • Rakesh Rao

Participate in Cement Expo 2026 and discover how next-gen infrastructure can be built with innovations in cement.

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JK Cement Declared Preferred Bidder For Gilund Limestone Block

Shares Edge Higher As Company Wins Rajasthan Block

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JK Cement gained after being declared preferred bidder for the Gilund Limestone Block in Chittorgarh, Rajasthan, a lease area of 370.96 hectares. The firm saw its shares trade at Rs. 5550.05, up by 28.45 points or 0.52 per cent from the previous close of Rs. 5521.60 on the BSE. The scrip opened at Rs. 5569.15 and touched a high of Rs. 5625.00 and a low of Rs. 5531.00.

The stock recorded turnover of 1742 shares on the counter and the BSE group A stock with face value Rs. 10 has a 52 week high of Rs. 7565.00 on 20-Aug-2025 and a 52 week low of Rs. 4670.05 on 12-Jun-2026. Last one week high and low stood at Rs. 5625.00 and Rs. 5329.00 respectively. The promoters holding in the company stood at 45.66 per cent, while institutions and non-institutions held 40.61 per cent and 13.73 per cent respectively.

The e-auction conducted by the Government of Rajasthan resulted in the company being declared preferred bidder for the mining lease, and the allocation will enable the company to plan phased development of the deposit, subject to regulatory approvals. The Gilund block spans 370.96 hectares and its allocation is intended to support raw material security for the company’s cement operations in the region. The designation follows the government auction process and will allow the company to plan development and integration of the deposit into its supply chain.

The current market capitalisation stands at Rs. 430.38 billion (bn), reflecting market response to the mining news and prevailing valuation levels for the sector. Investors and analysts will watch for formal allotment and related disclosures that can clarify timelines, capital expenditure and expected production profiles. The report is intended for informational purposes and does not constitute investment advice, and market participants are advised to consult advisers before making decisions.

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