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Cutting-Edge Grinding Solutions

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ICR looks at the inner workings of grinding mills in the cement industry to understand the technological advancements that are reshaping the landscape against the foreground of sustainability. Innovations to enhance the grinding processes are aimed at minimising their environmental footprint while increasing efficiency and performance.

In cement manufacturing, the grinding process is of utmost significance, as it entails the comminution of clinker, a raw material composed of calcium carbonate, silica, alumina and iron oxide. This pivotal process converts the raw material into a finely ground powder known as cement, a fundamental constituent in concrete production.
The process is initiated by quarrying and extracting limestone and other essential materials from mines or quarries, followed by crushing them into smaller fragments using crushers or hammer mills. Subsequently, the moisture content in the crushed raw materials is reduced to an appropriate level through drying in large rotary dryers. Once dried, the raw materials undergo grinding, with the primary material being clinker, produced by high-temperature heating of limestone and other components in a kiln. The clinker is then mixed with gypsum and various additives, such as slag, fly ash or limestone, to regulate the cement’s setting time and other properties.
Grinding is typically executed using either ball mills or vertical roller mills (VRMs), where the clinker and additives are combined and finely ground into a powder. After grinding, particle size classification is performed using air classifiers or separators, ensuring the desired quality and performance of the final product. The cement is then stored in silos before being packaged in bags or transported in bulk for distribution to construction sites and end-users.
Throughout the grinding process, meticulous attention is paid to preserving the proper chemical composition and physical characteristics of the cement, with modern cement plants employing advanced automation and process control systems to optimise efficiency and ensure consistent quality. Moreover, environmental considerations are carefully taken into account, aiming to minimise energy consumption and emissions during
grinding operations.

GRINDING EQUIPMENT
In a cement plant, the key grinding equipment plays a vital role in transforming raw materials into finely ground cement powder. The most common and widely used grinding equipment in cement plants are ball mills, which consist of rotating cylinders filled with grinding media such as steel balls. As the cylinder rotates, the grinding media cascade and crush the raw materials, resulting in the formation of a fine powder. Ball mills serve various functions, including reducing the particle size of clinker and additives, mixing and homogenising the raw materials and achieving the desired fineness of the cement.
In recent years, vertical roller mills (VRMs) have gained popularity due to their higher energy efficiency and lower maintenance requirements compared to ball mills. VRMs employ a rotating table onto which grinding rollers are pressed by hydraulic cylinders. The raw materials are fed into the mill and ground between the rollers and the table. VRMs offer better control over the grinding process and provide a narrower particle size distribution, leading to improved cement quality. Their functions encompass grinding, drying and classifying the materials.
Roller presses are another essential grinding equipment, often used in combination with ball mills or as a pre-grinding stage to enhance energy efficiency. They consist of two counter-rotating rollers that press the raw materials against a rotating table, effectively crushing and reducing their particle size before further grinding in a ball mill or VRM. Roller presses primarily aim to improve grinding efficiency and reduce energy consumption.
Additionally, the Horomill has emerged as a more recent grinding technology in the cement industry. Combining the principles of roller press and ball mill grinding, the Horomill employs a horizontal shell containing a rotating horizontal ring with multiple grinding rollers. The raw materials are fed through the centre and ground between the rollers and the ring. Horomills contribute to energy savings and a reduction in the environmental impact of cement production.
“Based on the cement manufacturers requirement, we offer customised solutions for various grinding circuits. Every cement plant has specific requirements. Like some focus on low-cost solutions, some focus on energy efficiency whereas some focus on operational excellence. The input material hardness, moisture, abrasively, feed size and product requirement decide what solution is to be offered for achieving a cost effective and energy efficient solution. We have various sizes of roller presses, various types of roller surfaces, types of rollers and arrangement of roller presses in the circuit like roller press in semi-finish mode, roller press in finish mode, size of ball mill in semi-finish mode, location of static separator in process circuit, etc. So, based on all the factors, we decide what is to be offered,” says Ashok Kumar Dembla, President and Managing Director, KHD Humboldt.
Each of these grinding equipment types serves a crucial role in the cement manufacturing process, providing the means to crush, grind, and refine the raw materials to achieve the desired fineness and chemical composition of the final cement product. The selection of the appropriate grinding equipment depends on factors such as the desired production capacity, specific energy consumption goals, and the characteristics of the raw materials used in the process. Cement plants carefully consider these factors to optimise their grinding operations and ensure the production of high-quality cement efficiently
and sustainably.

Efforts to reduce energy consumption in cement grinding are essential for sustainability and cost-effectiveness.

ENERGY CONSUMPTION IN CEMENT GRINDING
Energy consumption in cement grinding is a significant aspect of cement production and constitutes a substantial portion of the overall energy consumption in cement manufacturing. The grinding process is energy-intensive, mainly due to the comminution of raw materials and clinker. Several factors contribute to energy consumption during cement grinding:
Grinding Equipment: The type and efficiency of the grinding equipment used in cement plants have a considerable impact on energy consumption. Traditional ball mills are known to be energy-intensive, while modern vertical roller mills (VRMs) and roller presses offer improved energy efficiency and lower specific power consumption. Therefore, the selection of appropriate grinding equipment can have a substantial effect on overall energy consumption.
Particle Size Distribution: The fineness of the cement significantly influences energy consumption during the grinding process. Finer grinding requires more energy, and achieving the desired particle size distribution involves additional energy expenditure. Cement producers often aim to optimise the particle size distribution to strike a balance between strength development and energy consumption.
Clinker Composition: The composition of clinker, the primary component of cement, affects the grindability of the material. Clinker with higher levels of tricalcium silicate (C3S) and dicalcium silicate (C2S) typically require less energy for grinding. Therefore, cement plants may adjust the clinker composition to optimise energy consumption during grinding.
Grinding Aids: Cement producers may use grinding aids to improve the efficiency of the grinding process and reduce energy consumption. Grinding aids are chemicals that aid in reducing the surface energy of particles, leading to more efficient comminution. They can also improve cement flowability and reduce agglomeration, further enhancing grinding efficiency.
Process Optimisation: Modern cement plants employ advanced process control systems to optimise grinding operations. These systems monitor various parameters, such as mill load, material flow and separator efficiency, and make real-time adjustments to optimise energy consumption while maintaining the desired cement quality.
Alternative Fuels and Raw Materials: The use of alternative fuels and raw materials in cement production can also impact energy consumption in the grinding process. These alternatives may have different grindability characteristics, which can affect the overall energy requirements for grinding.
According to an article published in Journal of Materials Research and Technology, Volume 9, Issue 4, 2020, “Grinding is a central process in mineral processing to achieve particle size reduction and mineral liberation, and is highly energy-intensive. It accounts for 50 per cent of power consumption in a concentrator. In general, grinding has poor energy efficiency and accounts for about 2 per cent to 3 per cent of the world’s generated electricity. Due to the depleting resources, the processing of refractory ores is becoming common. Such processes require fine grinding or ultrafine grinding to liberate the valuable minerals from gangue material; thus, energy-efficient technologies and strategies are required.”
Efforts to reduce energy consumption in cement grinding are essential for sustainability and cost-effectiveness. Cement manufacturers continually invest in research and technology to develop more energy-efficient grinding methods and equipment. The adoption of best practices, the use of alternative fuels, and the application of innovative technologies are key strategies for reducing energy consumption in cement grinding and promoting sustainable
cement production.

Grinding efficiency is mainly evaluated based on energy consumed per given mass of material as a function of time.

ADDITIVES FOR THE GRINDING PROCESS
Additives are integral to the cement grinding process as they serve multiple important functions in enhancing the properties and performance of the final cement product. By regulating the setting time, additives ensure the proper curing and strength development of the cement. Additionally, certain additives like fly ash, blast furnace slag (BFS),
silica fume and pozzolans react with calcium hydroxide during cement hydration, resulting in improved strength, durability, and resistance to aggressive environments.
According to a report by IMARC, the global cement grinding aid and performance enhancers market is expected to exhibit a CAGR of 3.68 per cent during 2022-2027.
Over the last few decades, in order to address the high energy consumption and scarcity of potable water for mineral processing, chemical additives or grinding aids have become a promising alternative in the cement manufacturing process. Also, studying the effect of grinding aids on size reduction units is crucial for the beneficiation value chain of minerals and the impact on downstream processes.
Grinding aids range from organic to inorganic chemicals. For example, organic chemicals include, polyols, alcohols, esters and amines, while inorganic chemicals include calcium oxide, sodium silicate, sodium carbonate, sodium chloride, etc. The process of grinding cement is required to be efficient and productive. Grinding aids are added to support the same. Grinding efficiency is mainly evaluated based on energy consumed per given mass of material as a function of time. A study on these materials shows reduction in the energy consumption increases by increasing grinding aid dosage to a maximum, after which further addition gives no effect.
Workability and flowability of the cement paste are enhanced through additives like superplasticisers, facilitating easier handling during construction. Furthermore, some additives allow for partial replacement of cement clinker, thereby reducing CO2 emissions and promoting sustainable cement production. Improved particle size distribution and enhanced grindability are also achieved with specific additives, leading to greater cement quality and energy efficiency during grinding. By mitigating alkali-silica reaction (ASR) and optimising cement characteristics, additives play a vital role in producing high-quality cement tailored to meet diverse construction requirements. Cement manufacturers meticulously assess and utilise additives to ensure consistent performance and meet the demands of various construction applications.
Anant Pokharna, CEO, Unisol Inc, says, “Most legacy grinding aids (commercially available chemical additives typically supplied to cement producers) contain > 50 per cent water. Such high content of a low-value, high-volume ingredient, as water, leads to significantly higher costs associated with freight, duties and handling of pre-blended liquid solutions.
“In addition, such pre-blended, ready-to-use chemical additives offer considerably diminished possibility of modifying concentration and formulation for different cement grades or for different objectives or for different process conditions” he adds.
The main uses of additives in the cement grinding process are as follows:
Set Time Control: One of the primary functions of additives is to regulate the setting time of cement. By controlling the rate of cement hydration, additives ensure that the cement achieves the desired strength development and curing characteristics. Gypsum is a common additive used for this purpose, as it retards the setting time, preventing the cement from hardening
too rapidly.
Strength Enhancement: Additives can improve the strength and performance of the final cement product. Various additives like fly ash, blast furnace slag (BFS), silica fume and pozzolans react with calcium hydroxide produced during cement hydration, forming additional cementitious compounds. This results in enhanced strength, durability and resistance to aggressive environments.
Workability and Flowability: Additives can modify the rheology of cement paste, making it more workable and easier to handle during construction. Chemical additives, such as superplasticisers, reduce the water content in cement without sacrificing workability, allowing for the production of high-strength, low-water cement mixtures.
Reduction of CO2 Emissions: Certain additives, like fly ash and BFS, allow for partial replacement of cement clinker, which is a major source of CO2 emissions in cement production. By reducing the clinker content, these additives contribute to lower carbon emissions and more sustainable cement production.
Improved Particle Size Distribution: Additives can influence the particle size distribution of the cement during grinding. A more controlled and optimised particle size distribution results in
better cement quality and improved performance in concrete.
Reduced Energy Consumption: Some additives can enhance the grindability of clinker, reducing the specific energy consumption during cement grinding. This leads to more energy-efficient grinding processes and cost savings for
cement producers.
Control of Alkali-Silica Reaction: Certain additives, such as pozzolans, can mitigate the alkali-silica reaction (ASR) in concrete, which can cause expansion and cracking in concrete structures over time.
Additives in the cement grinding process offer a range of benefits, from setting time control and strength enhancement to improved workability, reduced environmental impact, and increased energy efficiency. Proper selection and dosing of additives are critical to achieving the desired cement properties and meeting the specific requirements of different construction applications. Cement manufacturers carefully study the effects of additives to optimise their use and ensure the production of high-quality cement with consistent performance characteristics.

EFFICIENCY THROUGH GRINDING
Grinding and the judicious use of grinding aids significantly contribute to efficiency in cement manufacturing through multifaceted mechanisms that optimise the grinding process and elevate the performance of the final cement product.
By reducing the specific energy consumption during grinding, grinding aids lower the surface energy of cement particles, resulting in energy savings and diminished production costs. Furthermore, these aids promote enhanced comminution of cement particles by augmenting the interaction between grinding media and clinker particles, thereby fostering faster and more effective grinding, leading to augmented throughput rates and heightened productivity in cement grinding mills. In addition, the proper grinding and utilisation of grinding aids facilitate control over the particle size distribution of cement, minimising agglomeration and ensuring uniform particle size distribution, consequently maximising packing density, bolstering cement performance in concrete, and optimising the usage of cementitious materials.
“A high-efficiency separator is used in the grinding process to separate the ground particles according to their size. The separator ensures that only the fine particles are collected as the final product, while the coarse particles are returned to the grinding mill for further grinding. By optimising the separator operation and adjusting its parameters, such as the rotor speed and air flow, the desired fineness can be achieved,” says Tushar Khandhadia, General Manager – Production, Udaipur Cement Works.
“At Udaipur Cement, we have Modern grinding systems that often incorporate advanced process automation and control technologies. These systems continuously monitor and optimise the grinding process based on real-time data, including fineness measurements. By using feedback control mechanisms, the system can automatically adjust the grinding parameters to maintain the desired fineness within the specified range,” he adds.
Grinding aids act as safeguards against the formation of coatings and cake build-up on grinding media and mill internals, mitigating coagulation effects, thereby ensuring consistent and efficient cement grinding. The heightened workability and flowability of cement paste and concrete are a direct outcome of proper grinding and the application of grinding aids, as the latter results in reduced water demand and enhanced particle dispersion, engendering a cement product with superior workability, streamlining the handling and placement processes during construction, thereby amplifying overall construction efficiency.

CONCLUSION
Grinding aids have proven to be instrumental in facilitating efficient comminution, preventing clogging, and enhancing cement strength development. The resulting benefits include reduced production costs, lower environmental impact, and the production of high-quality cement tailored to meet the demands of diverse construction applications.
As the cement industry continues to embrace technological advancements and sustainable practices, the integration of efficient grinding methods and carefully selected grinding aids will remain instrumental in ensuring a more resource-efficient and sustainable future for cement production.

Dalmia Cement has ordered one MVR 3750 C-4 each for two cement grinding plants, one in Ariyalur and one in Kadapa from Gebr. Pfeiffer India (a 100% subsidiary of Gebr. Pfeiffer, Germany). The mills will produce Ordinary Portland Cement and also fly ash cement at up to 160 t/h. This type of mill also has the highest power density of all available vertical roller mills, which positively impacts the overall investment.

Concrete

Akhoya Gets New 2.2 Km Road Link Under SASCI

Two cement concrete roads opened at Rs 29.1 million (mn) cost

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Two cement concrete pavement roads covering a total stretch of 2.2 km in Akhoya village were inaugurated on 27th June 2026 by MLA Nuklutoshi Longkumer, who attended as the special guest. The project comprises the one km L Pangersowa Road and the one point two km Longchara Junction to RC Chiten Jamir Memorial Government High School road. A formal programme followed the inauguration at the school auditorium.

A technical report was presented by Er Waloniba of the Urban Engineering Wing-III, Kohima, which stated the project was sanctioned in March 2026 under the Special Assistance to States for Capital Investment scheme for 2025-26 at a sanctioned cost of Rs 29.1 million (mn). The work order was issued to M/s Ensign Construction on thirtieth April 2026 with a stipulated completion period of 12 months. Work commenced on fourth May 2026 and was completed on sixth June 2026, with the contractor and team finishing the tasks in around two months. The project included a single-lane cement concrete pavement with side drains, two slab culverts and breast walls at required locations.

Longkumer acknowledged the Chief Minister, the advisor for urban development, contractors and other stakeholders for the allocation and support, and he commended the contractor for early completion. He noted that cooperation from landowners and the community had been important in resolving land related issues that can otherwise delay developmental works. He emphasised that planned developmental activities carried out with collective effort would enable more projects to be implemented successfully.

The headmaster of RC Chiten Jamir Memorial Government High School, I Chubasenba Longkumer, outlined the school background, noting it was established in 1962, was earlier known as Government High School Changtongya and was renamed in 2014. Local representatives said the improved approach roads would ease access for students, staff, patients and the general public and fulfil a long standing aspiration of residents. A dedicatory prayer was offered by the pastor and the programme concluded with a ribbon cutting attended by village council and town council representatives.

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Green Construction Through Cement Innovation

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Indian Cement Review (ICR) and Fuller Technologies brought industry, policy and technology leaders together to discuss how cement innovation can drive green construction at scale, writes Rakesh Rao.

India is building at a pace few countries can match. Highways, airports, housing, logistics parks, industrial corridors and urban infrastructure are reshaping the country’s economic geography. But beneath this growth story lies a difficult question: can India continue to build at scale without locking itself into a high-carbon future?

That question formed the core of an online panel discussion titled “Driving Green Construction Through Cement Innovation”, organised by Indian Cement Review (ICR) in association with Fuller Technologies as the Presenting Partner on June 25, 2026. The webinar brought together experts from cement technology, R&D, global industry platforms, building performance policy and international development cooperation to examine how low-carbon cement and material innovation can accelerate India’s green construction transition.

The discussion came at a crucial time. India has committed to achieving net-zero emissions by 2070 and reducing the carbon intensity of its economy by 45 per cent by 2030. At the same time, the country’s construction sector is expanding rapidly, driven by urbanisation, infrastructure development, housing demand and industrial growth. Cement, as one of the most widely used construction materials, sits at the heart of this transition. It is indispensable to development, but also central to the challenge of reducing embodied carbon in buildings and infrastructure.

Moderated by Nitika Krishan, Senior Urban Infrastructure and Sustainable Policy Consultant, the panel featured:

  • Kiranmai Sanagavarapu, Director, Low Carbon Solutions, Fuller Technologies;
  • Dr Hemantkumar Aiyer, VP and Head R&D, Nuvoco Vistas Corp Ltd;
  • Devika Wattal, Innovation Lead, Global Cement and Concrete Association (GCCA);
  • Dr Sunita Purushottam, MD, GBPN India (Global Buildings Performance Network); and
  • Vaibhav Rathi, Senior Technical Advisor, GIZ (the German Agency for International Cooperation)

Setting the tone for the discussion, Nitika Krishan underlined the scale of the challenge before the sector. “The question before us is no longer whether we build, but how we build sustainably,” she said. She pointed out that construction accounts for nearly 40 per cent of global energy-related carbon emissions when both operational and embodied carbon are considered. Cement production, she added, remains one of the hardest industrial processes to decarbonise.

For India, this is not merely an environmental issue. It is a development issue, a competitiveness issue and increasingly, a market issue. As one of the world’s largest cement producers and among the fastest-growing construction markets, India’s material choices will influence the carbon trajectory of its built environment for decades. As Krishan observed, sustainability solutions in economies such as India must not remain limited to laboratory success. They must be scalable, commercially viable and practical at national level.

The innovation gap: From technology to market

Experts believe that there is a need to bridge the innovation gaps for making decarbonisation in cement and concrete scalable. Devika Wattal of GCCA, explained, “The starting point must be the core cement manufacturing process itself. The first and foremost is the heart of our process, the heart of cement manufacturing. How do we reduce clinker? That is always a topic where industry is working very intrinsically.”

Clinker reduction remains one of the most important pathways for lowering emissions in cement. Since clinker production is energy-intensive and chemically emits carbon dioxide, reducing the clinker factor through supplementary cementitious materials (SCMs), blended cements and new chemistries can have a significant impact. Wattal also noted that carbon capture, utilisation and storage (CCUS) will have a role, though it may not be the first lever for all markets.

However, she stressed that innovation cannot stop at technology development. A solution that works in the lab must also be adaptable to industry, scalable in production and acceptable in construction practice. “It is important for that innovation to be adaptable, to be scalable, and so that it can be executed in real time,” she said.

Wattal also called for stronger enabling systems around innovation. These include performance-based standards, product-level embodied carbon databases and clearer frameworks for evaluating green materials. Without these, low-carbon cement products may struggle to compete with conventional materials in procurement and design.

R&D must balance carbon, cost and performance

Bringing in the R&D perspective into the discussion, Dr Hemantkumar Aiyer of Nuvoco Vistas emphasised that low-carbon cement development cannot be treated as a single-variable exercise. Cement must perform in real construction conditions. It must deliver strength, durability, consistency and cost competitiveness, while also reducing carbon.

“The root of understanding and balancing all these aspects lies in materials, and knowing the materials,” he said.

According to Dr Aiyer, R&D teams must understand the variability of raw materials such as fly ash, slag and clinker. Different sources produce different material behaviours. This makes mix optimisation, material characterisation and processing-property relationships critical. When performance is affected, cement manufacturers must understand how strength enhancers, admixtures and other performance chemicals interact with the material system.

He also linked material science with process efficiency. Clinkerisation takes place at extremely high temperatures, around 1,400 to 1,450 degrees Celsius. Any improvement in raw mix design, process control or energy optimisation can, therefore, help reduce emissions and cost. Dr Aiyer pointed to artificial intelligence-based optimisation, Cement 4.0 tools and advanced software as important enablers for real-time process and material control.

“The more you understand the materials, the more you can control it,” he said.

LC3: The promise is proven, the sequencing is not

Limestone calcined clay cement, commonly referred to as LC3, has attracted global attention because it can reduce clinker content significantly by using calcined clay and limestone while maintaining performance in many applications. Kiranmai Sanagavarapu of Fuller Technologies said the technology itself has already moved beyond proof of concept. Fuller Technologies has worked with calcined clay technology for nearly two decades and has seen plants running in France and Ghana. These plants, she said, are meeting local and national specifications, while the economics are beginning to make sense.

“The calciner is performing, the economics is stacking up, it is making business sense to produce,” she said.

But if the technology is viable, why has adoption not scaled faster? For Sanagavarapu, the answer lies in project sequencing. Too often, clay characterisation happens after equipment is specified. This, she warned, is a backward approach because calciner design depends on clay mineralogy, kaolinite content, iron levels, reactivity, moisture and other variables.

“If you don’t know what your deposit looks like before you commit for the equipment, you are, in a way, going blind into designing,” she said.

She also identified permitting and plant integration as major bottlenecks. Environmental clearances, mining permissions and local regulatory approvals must begin early. Similarly, calcined clay must be integrated into existing grinding, blending and logistics systems from the design stage, not treated as an afterthought during commissioning.

India already has IS 18189:2023 standard for LC3, but Sanagavarapu pointed out that the standard is not yet visible enough in procurement documents. “The gap between what is technically being permitted and what the procurement is asking is the single biggest bottleneck,” she said.

In her view, successful scale-up depends on getting the sequence right: clay characterisation first, permitting in parallel, standards aligned with construction, and integration built into plant design.

India’s LC3 journey: Progress, but demand remains thin

Providing details of India’s LC3 commercialisation experience, Vaibhav Rathi of GIZ noted that JK Cement carried out the first commercial production of LC3 at its Rajasthan plant, followed by JK Lakshmi Cement three months later. These initiatives were supported by the International Climate Initiative of the Government of Germany, with IIT Delhi contributing deep institutional knowledge on LC3 research and BIS certification.

Rathi said India’s early experience has produced clear lessons. One of the biggest was the need to build capacity among regulators. While BIS certification existed, State Pollution Control Boards were unfamiliar with the technology and unsure about the approval pathway.

“The capacity building is not just needed amongst the producer and the users of the cement, but also the regulators who are working with this technology for the first time,” he said.

He also highlighted the need for better information on China clay deposits. Since China clay is currently classified as a minor mineral, centralised data on availability, quality and location is limited. If cement manufacturers are to adopt LC3 at scale, stronger mineral intelligence will be important.

The third issue is demand. LC3 has already been used in projects such as Palava City in Mumbai and Noida International Airport, but these remain limited examples. “It is in a chicken and egg situation,” Rathi said. “Cement companies are saying we need more demand, and users are saying there is not enough cement available.”

Public procurement, he suggested, could help break this cycle. If agencies such as CPWD and other public bodies begin testing, accepting and specifying LC3, it could create the market confidence needed for cement companies to invest in production and storage.

Building codes must catch up with innovation

Dr Sunita Purushottam of GBPN India argued that material choices will determine built environment emissions over the long term, but India’s current policy signals remain fragmented. Although LC3 has received BIS recognition, she pointed out that building codes, municipal bylaws, schedules of rates and sustainability codes do not yet provide uniform guidance on low-carbon cement.

“The current cement regulations are largely prescriptive and favouring traditional materials,” she said. This limits the ability of alternative materials to compete on performance, durability and emissions.

Dr Purushottam also raised the issue of taxation. Cement, including LC3, currently falls under the same GST bracket as conventional cement. A differentiated tax structure, she argued, could help accelerate market adoption. “In order for the market to demand LC3, that differentiation in the GST could go a long way,” she said.

She noted that green building certifications such as IGBC and GRIHA are already creating demand for low-carbon materials by assigning points for embodied carbon and sustainable material use. However, she said large-scale adoption will require regulatory mandates, particularly through building codes and state-level notifications.

She also cautioned that low-carbon cement alone does not solve the entire building performance problem. A material may reduce embodied carbon, but the operational carbon of a building depends on thermal performance, design, insulation and energy use. “The energy part has two elements,” she said. “One is the embodied carbon of the material itself, and the other is the operational carbon.”

Collaboration is the bridge between invention and impact

Wattal said GCCA sees innovation as a strategic priority and works through platforms that connect industry with academia and start-ups. “There is no way we will decarbonise our sector without innovation,” she said.

However, she stressed that research must be connected to actual industry challenges. Innovations developed in isolation may fail when they encounter real-world barriers such as raw material variability, plant integration, cost, standards and finance. Start-ups, too, need industry mentorship and scale-up pathways.

Wattal also flagged the importance of finance. Even strong technologies may struggle to attract investment if there is no common understanding of bankability. “We have always put projects into, is this a bankable project? But the definition of a bankable project has never been defined,” she said.

For India, she saw strong potential in its academic and start-up ecosystem, but said the challenge lies in alignment and prioritisation. The country has the research base, industrial capacity and market size. What it now needs is a coordinated route from innovation to deployment.

There is a practical concern for cement manufacturers: how can existing plants be adapted for lower emissions without compromising reliability or commercial viability?

Kiranmai Sanagavarapu addressed, “The reliability risk in calcined clay retrofit is definitely real, but it is almost always self-inflicted. The risk arises when a new process is added to an existing circuit without properly redesigning grinding and blending configurations.”

Existing cement plants, she explained, can take two broad routes. The first is external sourcing of calcined clay combined with mill optimisation. This requires lower capital investment and can potentially move in 12 to 18 months if other conditions are in place. It may reduce emissions by around 20 to 30 per cent. The second route is integrated calcination on site, which requires higher capital expenditure and longer lead times, but provides greater control over quality, supply and emissions reduction potential.

For Sanagavarapu, the principle is simple: low-carbon retrofits must be designed with intent. “Design it with an intent properly from the start. Start in the market conditions where the economics are already working,” she said.

Circularity: The overlooked advantage

According to Vaibhav Rathi, fly ash and slag are already well established in cement and construction (C&D), but construction and demolition waste remains underutilised. “C&D waste is a growing business opportunity which not many have taken up,” he said. India’s continuous construction and demolition activity creates huge volumes of waste, much of which contributes to air pollution, land degradation and material inefficiency. With the right processing and standards, this waste can be converted into useful construction products.

Rathi also pointed out that LC3 has a circular economy dimension that is often overlooked. It can use low-grade kaolin-rich clay left behind after high-grade clay is extracted for other applications. “LC3 is not only a low-carbon solution, but also a circular economy solution,” he said.

At the same time, he cautioned that LC3 in India is not yet cheap because it has not reached scale. Site-specific techno-commercial feasibility studies, supported jointly by development agencies and industry, could help companies assess whether LC3 production makes technical and financial sense at a given location.

Dr Purushottam added that India must address both low-carbon cement and construction waste together. “Both low-carbon cement and C&D waste go hand in hand. India does not have an option but to work on both,” she said.

Dr Aiyer called for policy shifts from both government and industry, including preferential purchasing of sustainable materials, minimum supplementary cementitious material requirements in public and public-private projects, and faster regulatory implementation. “If we can fast-track the regulatory standards and their implementation on the ground, that is the way to go,” he said.

From green ambition to green construction

Cement innovation is no longer only about chemistry. It is about systems. Low-carbon cement will scale only when technology, standards, procurement, finance, regulation, education and construction practice move together.

LC3 and other low-carbon technologies have shown promise. India has early commercial examples, strong research capability and growing market interest. But mainstream adoption will depend on whether demand can be created, regulators can be capacitated, standards can be embedded in procurement, and manufacturers can see a clear business case.

For a country building at India’s scale, the opportunity is enormous. Cement will continue to be central to infrastructure and urban development. The challenge now is to ensure that the cement used in India’s growth story carries a lower carbon burden.

  • Rakesh Rao

Participate in Cement Expo 2026 and discover how next-gen infrastructure can be built with innovations in cement.

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Concrete

JK Cement Declared Preferred Bidder For Gilund Limestone Block

Shares Edge Higher As Company Wins Rajasthan Block

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JK Cement gained after being declared preferred bidder for the Gilund Limestone Block in Chittorgarh, Rajasthan, a lease area of 370.96 hectares. The firm saw its shares trade at Rs. 5550.05, up by 28.45 points or 0.52 per cent from the previous close of Rs. 5521.60 on the BSE. The scrip opened at Rs. 5569.15 and touched a high of Rs. 5625.00 and a low of Rs. 5531.00.

The stock recorded turnover of 1742 shares on the counter and the BSE group A stock with face value Rs. 10 has a 52 week high of Rs. 7565.00 on 20-Aug-2025 and a 52 week low of Rs. 4670.05 on 12-Jun-2026. Last one week high and low stood at Rs. 5625.00 and Rs. 5329.00 respectively. The promoters holding in the company stood at 45.66 per cent, while institutions and non-institutions held 40.61 per cent and 13.73 per cent respectively.

The e-auction conducted by the Government of Rajasthan resulted in the company being declared preferred bidder for the mining lease, and the allocation will enable the company to plan phased development of the deposit, subject to regulatory approvals. The Gilund block spans 370.96 hectares and its allocation is intended to support raw material security for the company’s cement operations in the region. The designation follows the government auction process and will allow the company to plan development and integration of the deposit into its supply chain.

The current market capitalisation stands at Rs. 430.38 billion (bn), reflecting market response to the mining news and prevailing valuation levels for the sector. Investors and analysts will watch for formal allotment and related disclosures that can clarify timelines, capital expenditure and expected production profiles. The report is intended for informational purposes and does not constitute investment advice, and market participants are advised to consult advisers before making decisions.

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