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Green Fuel for Thought

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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.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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