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Automation leads to significant gains through optimal raw mix

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D L Kantham, Director – Technical, Penna Cement, discusses the use of alternative raw materials and fuels in making green cement, along with the use of technology and automation, to ensure that the industry moves towards Net Zero goals.

Tell us about the importance of going green for the Indian cement industry.
Globally cement production capacity stands at 4.2 billion tonnes per annum. Cement production, a source of anthropogenic CO2, accounts for 8 per cent of global emissions. Indian production capacity currently stands at about 550 million tonnes per annum with annual production of around 370 million tons per annum. Annual cement production is expected to reach about 480 million tons annually by 2028-29. Hence, the cement industry in India must ‘Go Green’ to be aligned with the Net Zero Target by 2050. This target is aligned with the Paris Agreement to limit global warming to 1.50C.

What are the key alternative raw materials used to manufacture green cement?
We use fly ash, slag and other pozzolanic materials as key alternative raw materials to manufacture greener cement.

What is the role of fuel in making cement green? How does the use of alternative fuels impact the productivity and efficiency of the manufacturing process?
Using alternative fuels like pharma wastes and municipal solid wastes, leads to reduced fossil fuel (coal) usage, thereby reducing carbon emission. Alternative fuel utilisation in the cement industry reduces production costs and reduces CO2 emissions in the atmosphere.

Tell us about the cement blends or products from your organisation that are lower in their carbon content.
Penna Power (Portland Pozzolana Cement) conforming to IS 1489:2015 (32-35 per cent fly ash blended), Penna Suraksha (Portland Slag Cement) conforming to IS 455:2015 (38-48 per cent GGBS Blended) and Concrete Guard, a premium blended product conforming to IS: 1489:2015 aimed to motivate and supply 100 per cent blended cement in retail markets satisfying the customer requirements in IHB market segments.

Tell us about your Net Zero goals. How much have you achieved so far?
Our Net Zero goal is to increase our blended cement production ratio to 75 per cent from the 40 per cent level in 2015. Currently, blended cement production constitutes about 55 per cent.

How do you incorporate sustainability in your cement manufacturing process

  • Increasing Clinker to Cement Ratio (Higher use of PFA/GGBS in the mix).
  • Alternative fuels like pet coke, pharma waste and municipal waste.
  • Energy efficiency technologies, such as Waste Heat Recovery to reduce fossil fuel requirements and adaptation of better cement grinding systems (Roller Press), grinding aids, etc.

What is the role of automation and technology in making cement an eco-friendly product?
Automation leads to significant gains through optimal raw mix, better product output in quantity and quality through minimal human involvement and saves time in decision making on end product quality by quicker analysis of raw materials.

What are the major challenges in reducing the carbon content of cement manufacturing, and how can they be resolved?
Two key areas for reducing the carbon content from cement include:
Reduction in clinker to cement ratio through greater uptake of blended cement in all the key consumption segments – housing, government projects, precast cement products and ready-mix concrete. This involves developing new blended cement to suit the requirements in segments where OPC is still preferred for specific reasons, and to adapt to a higher percentage of alternative fuels in the process.
Following actions may be taken to improve greater uptake of blended cements, which leads to a reduction in the clinker cement ratio:

  • We need to enhance market awareness and acceptability because users are reluctant to select blended cement over portland cement in some regions, though substantial progress has happened in India over the past two decades.
  • Need to involve all the key stakeholders – cement manufacturers, government policymakers – national standards, consultants, key end users, and related allied products, e.g., chemical admixtures used in concrete production for exchange of experience on reducing clinker to cement ratio, promote training events with national standardisation bodies and accreditation institutes etc.
  • Independent organisations to develop cement and concrete standards and codes that allow the widespread use of blended cements while ensuring product reliability and durability at final applications to promote the use of blended cement. For example, additional types of blended cement with a higher blending ratio for specific end applications.
  • Government to promote blended cement in sourcing and public procurement policies and the private big project consultants.
  • Industries and universities conduct R&D into processing techniques for potential cement blending materials that cannot be used due to quality constraints, for example, rice husk ash.
  • Introducing a freight subsidy for transporting supplementary cementitious materials from surplus areas to cement clusters is desirable where SCM availability is limited.
  • Deploying innovative technologies (including carbon capture, usage and storage (CCUS)). Government can stimulate investment and innovation in these areas through funding for R&D.

Broadly, CCUS prevents CO2 from being released into the atmosphere by capturing it and either using it or injecting it in geological formations for permanent storage. CCUS will be crucial to reduce cement sector CO2 emissions, particularly the process emissions released during limestone calcination. While the commercial deployment of CCUS is currently limited, several innovative efforts have been underway in recent years.

How do you measure the impact of your green cement on the environment and society, and what steps do you take to continuously improve its sustainability?
Resource and environmental protection agencies use specific indicators to track and enforce
changes. Today, one of the critical measurement techniques is footprint evaluation. The three common footprint indicators are carbon, ecological, water and soil footprint.
Green concrete produced from green cement has been proven to have enhanced the structure’s durability. This ensures a reduction in demand for natural resources (limestone in particular), thereby improving the sustainability, associated energy consumption, and a corresponding decrease in GHG (GreenHouse Gas) emissions.
Additional cement product profiles, for example, Composite Cement and LC3 Cement (Limestone Calcined Clay Cement), are being researched and developed to suit the market requirement, which will help us further improve on sustainability.

-Kanika Mathur

Concrete

Nuvoco Vistas Reports Record Q2 EBITDA, Expands Capacity to 35 MTPA

Cement Major Nuvoco Posts Rs 3.71 bn EBITDA in Q2 FY26

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Nuvoco Vistas Corp. Ltd., one of India’s leading building materials companies, has reported its highest-ever second-quarter consolidated EBITDA of Rs 3.71 billion for Q2 FY26, reflecting an 8% year-on-year revenue growth to Rs 24.58 billion. Cement sales volume stood at 4.3 MMT during the quarter, driven by robust demand and a rising share of premium products, which reached an all-time high of 44%.

The company continued its deleveraging journey, reducing like-to-like net debt by Rs 10.09 billion year-on-year to Rs 34.92 billion. Commenting on the performance, Jayakumar Krishnaswamy, Managing Director, said, “Despite macro headwinds, disciplined execution and focus on premiumisation helped us achieve record performance. We remain confident in our structural growth trajectory.”

Nuvoco’s capacity expansion plans remain on track, with refurbishment of the Vadraj Cement facility progressing towards operationalisation by Q3 FY27. In addition, the company’s 4 MTPA phased expansion in eastern India, expected between December 2025 and March 2027, will raise its total cement capacity to 35 MTPA by FY27.

Reinforcing its sustainability credentials, Nuvoco continues to lead the sector with one of the lowest carbon emission intensities at 453.8 kg CO? per tonne of cementitious material.

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Concrete

Jindal Stainless to Invest $150 Mn in Odisha Metal Recovery Plant

New Jajpur facility to double metal recovery capacity and cut emissions

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Jindal Stainless Limited has announced an investment of $150 million to build and operate a new wet milling plant in Jajpur, Odisha, aimed at doubling its capacity to recover metal from industrial waste. The project is being developed in partnership with Harsco Environmental under a 15-year agreement.

The facility will enable the recovery of valuable metals from slag and other waste materials, significantly improving resource efficiency and reducing environmental impact. The initiative aligns with Jindal Stainless’s sustainability roadmap, which focuses on circular economy practices and low-carbon operations.

In financial year 2025, the company reduced its carbon footprint by about 14 per cent through key decarbonisation initiatives, including commissioning India’s first green hydrogen plant for stainless steel production and setting up the country’s largest captive solar energy plant within a single industrial campus in Odisha.

Shares of Jindal Stainless rose 1.8 per cent to Rs 789.4 per share following the announcement, extending a 5 per cent gain over the past month.

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Concrete

Vedanta gets CCI Approval for Rs 17,000 MnJaiprakash buyout

Acquisition marks Vedanta’s expansion into cement, real estate, and infra

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Vedanta Limited has received approval from the Competition Commission of India (CCI) to acquire Jaiprakash Associates Limited (JAL) for approximately Rs 17,000 million under the Insolvency and Bankruptcy Code (IBC) process. The move marks Vedanta’s strategic expansion beyond its core mining and metals portfolio into cement, real estate, and infrastructure sectors.

Once the flagship of the Jaypee Group, JAL has faced severe financial distress with creditors’ claims exceeding Rs 59,000 million. Vedanta emerged as the preferred bidder in a competitive auction, outbidding the Adani Group with an overall offer of Rs 17,000 million, equivalent to Rs 12,505 million in net present value terms. The payment structure involves an upfront settlement of around Rs 3,800 million, followed by annual instalments of Rs 2,500–3,000 million over five years.

The National Asset Reconstruction Company Limited (NARCL), which acquired the group’s stressed loans from a State Bank of India-led consortium, now leads the creditor committee. Lenders are expected to take a haircut of around 71 per cent based on Vedanta’s offer. Despite approvals for other bidders, Vedanta’s proposal stood out as the most viable resolution plan, paving the way for the company’s diversification into new business verticals.

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