Concrete

Decarbonising Cement

Published

4 years ago

April 10, 2023

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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.

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Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

4 hours ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

Concrete

CII Calls for Greater Alternative Fuel Use in Cement Industry

Published

1 day ago

October 29, 2026

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The Confederation of Indian Industry (CII), through its Green Business Centre and Energy Efficiency Council, inaugurated the 16th Conference on Alternative Fuel and Raw Material Usage (AFR) in Goa on 27 October 2026. The two-day conference brought together more than 350 industry leaders, policymakers, waste management experts and technology providers to explore strategies for accelerating alternative fuel adoption in India’s cement industry.

Held under the theme ‘Preparation for Net-Zero: Alternative Fuels & Raw Material in Cement Manufacturing’, the conference focused on reducing dependence on conventional fuels, improving waste utilisation and strengthening circular economy practices across cement manufacturing operations.

E R Raj Narayanan, Chairman, AFR Conference 2026, and Business Head and Chief Manufacturing Officer, UltraTech Cement, highlighted the industry’s progress in alternative fuel adoption. He emphasised the need to scale implementation, strengthen supply chains and extend circularity beyond fuel substitution to alternative raw materials through technological innovation and industry collaboration.

Harish Adconkar, Managing Director, Goa Waste Management Corporation, highlighted Goa’s progress in scientific waste management and refuse-derived fuel (RDF) production. He stated that approximately 765,000 tonnes of RDF had been supplied to cement plants, contributing to an estimated displacement of 320,000–560,000 tonnes of coal. He emphasised the importance of consistent RDF offtake and stronger coordination between urban local bodies, waste management agencies and cement manufacturers.

Dr L P Singh, Director General, National Council for Cement and Building Materials, identified AFR as an important opportunity for decarbonisation and resource efficiency. Drawing parallels with the industry’s successful utilisation of fly ash, he stressed the need to address quality, technological and economic challenges to expand alternative fuel adoption.

Dr Sharad P Kale, Special Advisor to the Chief Minister of Goa and former Head of Technology Transfer and Collaboration at BARC, emphasised treating waste as a resource. He highlighted decentralised biodegradable waste processing, reduced food waste and improved resource recovery as essential measures for minimising landfill dependence.

Kiran Ananth, Executive Director, Energy Efficiency, Renewable Energy and Green Entrepreneurship, CII-Green Business Centre, noted that India’s cement production reached approximately 491 million tonnes in FY2025-26, while the industry’s thermal substitution rate (TSR) stood at 7.5 per cent, with around 7 million tonnes of alternative fuels utilised annually.

He added that the industry had invested over Rs 12 billion in co-processing infrastructure during the past six years. Improving RDF supply reliability and quality assurance would be crucial to maximising the utilisation of existing infrastructure and accelerating industrial decarbonisation.

The conference also featured discussions on advanced AFR co-processing technologies, waste pre-processing solutions and industrial best practices for improving fuel substitution and resource recovery.

A publication titled ‘From Waste to Kiln: Scaling the Use of MSW-Derived RDF in Indian Cement Plants’ was launched during the inaugural session. The report identified inconsistent RDF supply and quality as major barriers to achieving higher thermal substitution rates.

According to the publication, many cement kilns already possess the technical capability to achieve higher alternative fuel substitution. However, variations in RDF availability, moisture content, particle size and calorific value continue to limit utilisation. The report emphasised the need to strengthen waste segregation, pre-processing and aggregation systems to establish reliable RDF supply chains.

The conference’s second-day agenda includes discussions on innovative domestic and industrial waste management solutions, alternative raw materials for low-carbon cement and strategies to increase alternative fuel utilisation across India’s cement manufacturing sector.

Concrete

Sameera Group Enters Industrial and Logistics Real Estate

Rs. 1.5 bn project to support manufacturing and supply-chain firms

Published

2 days ago

October 28, 2026

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Sameera Group has entered the industrial and logistics real estate segment with a 450,000 sq ft development in Sriperumbudur, Chennai. The group will invest Rs. 1.5 bn in the project, expanding beyond residential plotted developments into business-to-business real estate.

The proposed park will serve light manufacturing, e-commerce, third-party logistics and other supply-chain businesses. Building plan approvals have been secured, with construction expected to begin shortly. The development is scheduled to become operational within 12 to 15 months.

Sameera Group Managing Director and Chief Executive Officer Jayakumar Murugesan said the project marked the next stage of the company’s growth after nearly four decades in land acquisition and real estate development. He attributed the choice of Sriperumbudur to its industrial activity and growth prospects.

The Grade A development will include internal movement routes and shared infrastructure for modern manufacturing and logistics operations. The group is pursuing Indian Green Building Council (IGBC) Platinum certification and plans to provide rooftop solar readiness, rainwater harvesting, wastewater recycling, energy and water monitoring, and electric vehicle charging facilities.

The project is being developed amid increased demand for industrial and warehousing space in Chennai. Knight Frank’s India Warehousing Market Report 2026 recorded 8.3 mn sq ft of warehousing transactions in the city during 2025, up 42 per cent from the previous year, with manufacturing accounting for 59 per cent of demand. The Sriperumbudur-Oragadam cluster contributed 77 per cent of transactions.

Sameera Group plans to develop 5 to 6 mn sq ft across a larger industrial and logistics portfolio over the next five years, involving an estimated investment of Rs. 18 bn. Land has been acquired for projects in Chennai, Hosur and Bengaluru. Established in 1982, the group has developed more than 900 acres, sold over 13,700 residential plots, and currently has 35 projects under development and 28 in its pipeline.