Concrete

Green Fuel for Thought

Published

4 years ago

April 7, 2023

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Ganesh W Jirkuntwar, Senior Executive Director and National Manufacturing Head, Dalmia Cement (Bharat) talks about technology and alternative fuels, which are important tools in the cement industry’s march towards reduction of carbon footprint.

Dalmia Cement Bharat has evolved to create a distinct identity for itself that is synonymous with sustainability and growth. The philosophy of ‘Clean and Green is Profitable and Sustainable’ has helped the company deliver on the expectations of its stakeholders. As a champion of blended cement, it is rapidly gaining popularity as a ‘green’ alternative to the traditional Ordinary Portland Cement in the construction sector. Three levers are being used to decarbonise the cement. Uses of supplementary cementitious materials like fly ash and slag have reduced clinker consumption and hence reduced carbon footprint in cement. Alternative fuels (green fuel) like industrial wastes, renewable biomass, municipal wastes etc., have reduced consumption of fossil fuel facilitating in achieving carbon neutrality. Increased dependence on renewable power sources like solar, waste heat recovery systems, wind power etc., is also helping the company achieve its goal of becoming the second green cement manufacturer.
Alternative fuels to the tune of 20 per cent by heat substitution are being used, putting it far ahead of any other Indian cement manufacture in uses of alternative fuel. Dalmia Cement Bharat wants to lead and drive the industry’s shift towards a sustainable use of alternative fuel in cement production by investing in requisite technology and machineries, and setting an ambitious target of achieving 35 per cent TSR by FY25. It uses industrial wastes, municipal wastes, agricultural wastes etc., as alternative fuel, which otherwise goes either into a water source or landfill and creates environmental issues. The use of these industrial wastes is a great example of a circular economy ecosystem.

Reducing the Carbon Footprint
Uses of alternative fuels and raw materials is helping the company fast-track its journey of achieving carbon negative. Dalmia carbon footprint at 467 kg CO2/tonne of cement (specific net CO2) is one of the lowest in the cement sector globally. Since the announcement of the carbon negative ambition in 2018, the specific carbon footprint has reduced by more than 9 per cent in the Scope 1 category and it is currently at 12.55 million tCO2/year. By reducing the scope 1 GHG emissions to 32 per cent per ton of cementitious material by FY ’34, they have also reduced overall scope 2 emissions by 30 per cent and are targeting to reduce scope 2 GHG emissions to 61.9 per cent per tonne of cementitious material by FY’34. Both these are on FY ’19 as base year and within the same timeframe validated by SBTi.

Role of Technology
Technology plays a pivotal role in determining the quantum of alternative raw materials and fuels to be used without compromising properties of cement. Online sampling, online particle size analyser, robotic lab etc., are great enablers for determining composition of alternative raw materials and fuels to be used. Nowadays digital technology is also facilitating in generating lots of insights from process data, which is helping in taking real-time basis decisions on desired composition of alternative raw materials and alternative fuels for achieving targeted quality of clinker and cement.
Cement making process has not undergone major overhaul since inception of dry cement making process, therefore basic chemistry and machinery are pretty much standardised across the industry. Cement composition is decided based on end uses and does not depend on plant machinery per say. Plant machineries are upgraded for switching to newer and efficient designed machines, replacing the old and obsolete machines etc. Plant machinery upgradation is a situational call in Dalmia and is decided based on group guidelines for reliability, technology adoption, ROA etc.

Alternative Fuels and Profitability
Cement producers worldwide are striving to lower their production costs. One effective method of achieving this end is the use of alternative fuels. Use of low-grade alternative fuels such as sewage sludge, biomass fuels such as wood products, agricultural wastes, etc. in precalciners is a viable option because combustion in a precalciner vessel takes place at a lower temperature.
Alternative fuel uses have been quite beneficial for us not only in terms of improving bottom-line but also helping gain tall recognition at the international stage. During peak fossil fuel prices, its uses helped reduce the spend on fuel to great extent and optimise variable cost of cement. Despite having a handicap of regional presence, Dalmia Cement Bharat could beat pan India cement players on cost front as result of substantial uses of alternative fuels.
Usages of alternative fuels lead to marginal increase in overall heat consumption. In case preheater fans and other equipment are being used at its full capacity, usage of alternative fuels may result in marginal reduction of clinker throughput.
Similarly, uses of alternative raw materials may impact cement quality, if not proportioned carefully.
Alternative fuel uses in Indian cement kilns is at the cusp of transformational change. Almost all cement players are adopting traditional technology and installing necessary infra for using alternative fuels in kilns. Uses of alternative fuel in kilns are limited by its chloride and ash contents. These issues are being taken care of by industry wide research and piloting of technologies, which has potential to reduce chloride and ash contents from alternative fuels. Various technologies for preprocessing of alternative fuels like pyrolysis, pyrorotor etc. are being piloted in India.
Government bodies, academia, industry bodies etc. are also doing extensive research on uses
of alternative raw materials for decarbonising cement.

ABOUT THE AUTHOR:
Ganesh W Jirkuntwar, National Manufacturing Head (Sr Executive Director) and EXCOM Member – Dalmia Group, comes with 27 years of experience in cement plant and manufacturing, operations and management, logistics, planning, quality and team management. He is also well-versed with lean management, TPM, Six Sigma and ISO 9000, 14000 and 18000. standards.

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Concrete

JK Lakshmi Cement to Expand EV Fleet to 120 Vehicles by March 2027

JK Lakshmi Cement has deployed more than 70 EVs across its logistics network.

Published

17 hours ago

October 30, 2026

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JK Lakshmi Cement has deployed more than 70 electric vehicles (EVs) across its logistics network and plans to increase the fleet to 120 vehicles by March 2027. The expansion is part of its decarbonisation strategy, which aims to reduce transport-related emissions and improve operational efficiency.

The company has achieved nearly 100 per cent EV-based clinker dispatches from its Sirohi plant in Rajasthan to the Kalol Grinding Unit in Gujarat. The transition marks an increased use of electric mobility for long-haul cement transportation and is intended to lower the environmental impact of logistics operations.

The existing fleet operates on routes connecting the Sirohi plant with the Kalol Grinding Unit, Palanpur Unit and Surat Grinding Unit. JK Lakshmi Cement is working with electric vehicle logistics providers SwitchLabs and Billion E to support fleet deployment and manage transportation requirements across these routes.

The company expects the planned expansion to increase the use of electric mobility throughout its logistics network for moving cement and clinker. Chairperson and Managing Director Vinita Singhania said the programme reflected the integration of sustainable practices with the company’s focus on long-term business efficiency, while describing the Sirohi–Kalol transition as an important step in its wider decarbonisation strategy.

The EV programme forms part of JK Lakshmi Cement’s green logistics and sustainability roadmap, alongside initiatives to improve efficiency and reduce emissions across its value chain. The company has set a long-term target of achieving net-zero emissions by 2047. It is part of the JK Organisation and operates integrated cement plants in Rajasthan and Chhattisgarh, along with grinding units in Gujarat, Haryana and Odisha. The company has an annual turnover of more than Rs. 60 bn, combined cement capacity of approximately 18 mn t per annum and a target to raise capacity to 30 mn t by 2030. Its portfolio includes ready-mix concrete, gypsum plaster, wall putty, primer, adhesives and fly ash blocks.

Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

23 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

2 days 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.