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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

ICRA Sees Steady Cement Demand Growth Ahead

Volumes seen rising 6–7 per cent in FY27 on infra push

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India’s cement industry is expected to record steady growth over the coming years, with cement volumes projected to expand by 6–7 per cent in FY27, supported by sustained demand from the housing and infrastructure sectors, according to a report by rating agency ICRA.

The agency said the sector is likely to maintain healthy momentum after registering growth of 6.5–7.5 per cent in FY26, despite a higher base in the second half of FY25. Cement demand remained strong in the current financial year, with volumes increasing by 8.5 per cent during the first eight months of FY26, driven by robust construction activity across regions.

ICRA expects demand to strengthen further in the second half of FY26 as construction activity accelerates after the monsoon. Continued government focus on infrastructure spending and the possibility of a reduction in goods and services tax on cement are also expected to support demand through FY26 and FY27.

Against this favourable demand backdrop, cement manufacturers are continuing to expand capacity through both organic and inorganic routes to strengthen their market positions. The industry is estimated to add 85–90 million tonnes per annum of capacity during FY26–FY27, including around 43–45 million tonnes per annum in FY26 and a further 42–44 million tonnes per annum in FY27.

Commenting on the outlook, Anupama Reddy, Vice President and Co-Group Head, Corporate Ratings at ICRA, said sector profitability is expected to improve significantly in FY26, supported by better pricing and higher volumes. Operating profit before interest, depreciation, tax and amortisation per tonne is projected to rise to around Rs 900–950 per tonne in FY26, compared with Rs 810 per tonne in FY25.

However, ICRA expects some moderation in earnings in FY27 due to rising input costs. Operating profit per tonne is estimated at Rs 880–930 in FY27, as costs related to pet coke and freight are likely to increase and remain influenced by global crude oil prices and geopolitical developments.

On a regional basis, North and Central India are expected to report capacity utilisation levels above the national average, while the southern region may continue to see relatively moderate utilisation due to existing capacity overhang. ICRA noted that recent merger and acquisition activity in the southern market has helped large players strengthen their regional and pan-India presence.

Overall capacity utilisation for the cement industry is projected to remain stable at around 70–71 per cent in FY27, broadly in line with FY26 levels, albeit on an expanded capacity base.

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GCCA India–NCB Carbon Uptake Report Released at NCB Foundation Day

New report highlights CO? absorption by concrete in Indian conditions

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The Global Cement and Concrete Association (GCCA) India–NCB Carbon Uptake Report was recently released during the 63rd Foundation Day celebrations of the National Council for Cement and Building Materials (NCB). On the occasion, a Gypsum Board Testing Laboratory and a Micro-Characterisation Laboratory were also inaugurated, strengthening India’s research and quality infrastructure for construction materials.

The laboratories were inaugurated by Urmila, Economic Advisor, Department for Promotion of Industry and Internal Trade (DPIIT), and Mohd. Kamal Ahmad, Special Director General, Central Public Works Department (CPWD), in the presence of L. P. Singh, Director General, NCB.

The newly established Gypsum Board Testing Laboratory will support quality assurance and standardisation requirements of the gypsum board industry, particularly in the context of the Gypsum-Based Building Materials (Quality Control) Order, 2024. The Micro-Characterisation Laboratory is equipped with advanced analytical tools for detailed investigation of cementitious and construction materials.

Addressing the gathering, Ms Urmila highlighted NCB’s sustained contributions to research, technology development, quality assurance and capacity building for the cement sector. Shri Mohd. Kamal Ahmad also commended NCB’s role in promoting sustainable construction practices through focused research and development.

The GCCA India–NCB report titled Carbon Uptake by Concrete assesses CO? uptake through carbonation in concrete under Indian conditions. Prepared in collaboration with the Global Cement and Concrete Association (GCCA) India, the study is based on the Tier-I methodology of IVL Swedish Environment Research Institute. It notes that while the cement industry contributes around seven per cent of global anthropogenic emissions, carbon uptake by concrete can partially offset process-related emissions.

The report outlines future actions to improve data robustness, refine estimation methodologies and support integration of carbon uptake into national sustainability and climate reporting frameworks. It will be submitted to the Ministry of Environment, Forest and Climate Change for consideration of inclusion as a carbon sink in India’s National Communications to the UNFCCC.

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Concrete

Shree Cement To Invest Rs 20 Billion In Maharashtra Plant

New 2 mtpa unit to strengthen capacity expansion plans

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Shree Cement Ltd has announced an investment of Rs 20 billion to set up a new cement plant in Maharashtra, the country’s third-largest cement maker said on Friday at the World Hindu Economic Forum (WHEF) 2025. The letter of intent for the proposed investment was signed in the presence of Maharashtra Chief Minister Devendra Fadnavis in Mumbai. Shree Cement chairman Hari Mohan Bangur said the company will establish a 2 million tonnes per annum plant in Chandrapur district, where land has already been acquired. He added that the project is awaiting environmental clearance and, once approved, is expected to be completed within two years. The expansion will be funded through internal cash reserves, with the company reporting a cash balance of Rs 65.41 billion at the end of FY25.

Shree Cement currently has an installed capacity of 62.8 million tonnes per annum. During the second quarter of FY26, the company commissioned a 3.65 mtpa clinker unit at Jaitaran in Rajasthan, while a 3 mtpa cement mill at the same location is expected to start operations shortly. A 3 mtpa integrated plant at Kodla in Karnataka is in the final stages of development and is scheduled to be commissioned within the third quarter of FY26. Following these ongoing expansions, the company’s total capacity is expected to rise to 68.8 mtpa, according to an ICICI Direct Research note dated 29 October.

Analysts estimate that Shree Cement’s capacity could reach between 72 and 75 mtpa by FY27E, with further potential to scale up to 80 mtpa by FY28E or FY29E, depending on demand trends. However, market observers have flagged medium-term risks, noting that industry-wide capacity additions may outpace demand growth through FY28-29, particularly in northern and western India where significant new capacity is expected. At the same time, cement prices declined sharply in the third quarter, especially in eastern and southern regions, though analysts expect some recovery from January, led by the South and East.

The announcement comes amid aggressive expansion plans by larger peers. UltraTech Cement recently raised its capacity target from 167 mtpa to 240 mtpa by FY28, while the Adani Group increased its cement capacity target by nearly 10 per cent to 155 mtpa by the same period. Shree Cement reported a 15 per cent year-on-year rise in revenue to Rs 43.03 billion in the September quarter, driven by higher volumes, premiumisation efforts and a value-over-volume strategy. The company’s chief financial officer Ashok Bhandari has guided for capital expenditure of around Rs 30 billion in FY26-27, with a similar level expected in FY27-28. Shares of Shree Cement ended 0.18 per cent lower on Friday, while the benchmark Sensex closed 0.53 per cent higher.

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