Concrete

Refractories: Enabling Sustainability

Published

3 years ago

October 19, 2023

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Refractories are the cornerstone of sustainability at a cement plant. It is important to understand their role in improving the cost efficiency of cement manufacturing and minimising its environmental impact. ICR looks into the changes in production and maintenance of refractories that have led to customised solutions, in the light of the use of alternative fuel and raw materials.

Cement manufacture is an example of human ingenuity and engineering prowess in the field of heavy industry. This essential building element, which is used everywhere nowadays, goes through a transformation process to become the finished product, and refractory is a crucial element that lies at the heart of this endeavour.
Cement plants are bustling ecosystems of industrial activity, where raw materials such as limestone, clay and shale are subjected to extreme temperatures, chemical reactions, and rigorous mechanical forces. To withstand the unforgiving environment inside cement kilns and related equipment, refractories emerge as the linchpin. These specialised materials are engineered to endure searing temperatures that could make even the hardiest of materials crumble. But refractories do more than just resist heat; they play a multifaceted role in safeguarding the integrity of the entire production process.
According to a report published in Times of India, May 2022, the Indian refractory market was sized at an estimated Rs 9,000 crore, closing in on Rs 10,000 crore in 2019. India’s steel capacity is targeted at 300 MT by 2030, as per India’s Steel Policy. Production is expected to grow to 230 MT by that time from 118 MT in FY 22. The cement industry is expected to grow by 12 per cent against a CAGR of 6 per cent historically. This means that an unprecedented need gap is waiting to be addressed by the refractory industry.
Government’s initiative of Atmanirbhar Bharat, and better understanding of the criticality of refractory to steel and cement making, has caused a change in the consumer industries’ mindset.
Companies around the world, who have built their supply chain around China, now want to de-risk China. There is now a higher demand for ‘Made in India’ products. This trend has significantly accelerated post Covid. As a result, most countries now actively seek alternative suppliers to reduce their heavy dependence on China for both raw material and finished goods.
This has created a significant opportunity for India to step in. The Indian refractory industry now must cater, not only to the increased internal demand, but also around the world.

ROLE OF AUTOMATION
Automation and technology are integral components in the effective utilisation of refractories within cement plants, especially in the context of cement manufacturing. These advanced tools play a multifaceted role in ensuring the optimal performance and longevity of refractory materials.
According to Tushar Khandhadia, General Manager – Production, Udaipur Cement Works Limited, “Technology and automation play a vital role in enhancing efficiency, accuracy, and safety in the use of refractories for cement kilns. AI and machine learning algorithms can analyse vast amounts of data to identify patterns and trends related to refractory behaviour and performance. This enables data-driven decision-making for optimising refractory selection, installation, and maintenance processes.”
One of the key functions of automation is temperature monitoring and control. Automation systems rely on advanced sensors and monitoring devices to continually measure and regulate the temperatures inside cement kilns and other high-temperature zones where refractories are employed. This precision control prevents refractory linings from experiencing overheating or cooling below the necessary levels, ultimately extending their lifespan and efficacy.
Rajesh Pathak, Managing Director, Schenck Process Solutions India, says, “Since our core value is to meet customer expectations, we meet and understand customer requirements and make alterations in the system for it to fit suitably in their process. There are two different types of MULTICOR® systems for Pyro; (a) For coal-Schenck offers combination of MULTICELL® (pre-feeder) + MULTICOR® K (Measuring Unit) and (b) For Raw Meal- Schenck offers combination of Dosing Valve (pre-feeder) + MULTICOR® S (Measuring Unit).”
Moreover, automation goes beyond mere temperature control. It incorporates predictive maintenance capabilities, coupling data analytics and predictive algorithms to foresee potential wear, damage, or deterioration in refractories. By identifying issues early on, cement plant operators can proactively schedule maintenance activities, minimising downtime and preventing production disruptions.
“By leveraging the power of automation and AI-driven analytics, the cement industry can reduce maintenance costs, enhance equipment reliability, and achieve higher energy efficiency, ultimately leading to improved productivity and profitability. We are also focusing on automation and technology up gradation to optimise the use of energy in cement plants. To achieve this, various steps have been taken towards energy conservation and technology absorption,” says Pankaj Kejriwal, Managing Director, Star Cement.
Furthermore, modern cement plants integrate remote monitoring and control systems. These centralised control rooms enable operators to oversee operations from a distance, facilitating rapid responses to issues that may affect refractory performance. This remote control aspect enhances both operational efficiency and safety.
Keyur Shah, Business Manager, SB Engineers, states, “Data from our systems gives better control to the plant and process monitoring. It allows for optimising processes. It helps with any adjustment of the fuel being pumped or to the burning zone, burner air, axil air or any other air, which is being provided to the burner. Available data also helps to make process improvements that helps optimise all critical processes at the cement plants.”
“A major challenge as of now for us occurs because the cement industry is undergoing transformation from technically automation run plants to data driven running plants. This transformation furthering the adaptability of these new changes by the plant operators or by the plant operations team is a major challenge,” he adds.

KILN ENVIRONMENT AND MAINTENANCE
Cement refractory kilns are unforgiving environments characterised by extreme conditions that can take a toll on the refractory materials used in these facilities. With temperatures exceeding 1400°C during clinker production, thermal stress and wear become significant concerns. Frequent exposure to such high temperatures necessitates regular maintenance to repair or replace damaged refractory linings, ensuring their integrity remains intact. Additionally, the chemically aggressive environment, with alkalis, sulphates and other compounds in the raw materials, can lead to erosion and corrosion. To combat this, inspections are vital to monitor conditions and the use of high-quality refractory materials resistant to chemical attack is essential.
“Our process is ISO certified. We are a premium refractory manufacturer, so we are very keen on choosing our raw material and we are doing a lot of testing of our finished goods before they are dispatched. So, you can say that there is rigorous testing of our raw material and finished goods as far as refractories are concerned,” says Mayank Kamdar, Marketing Director, Lilanand Magnesites.
Dust and particulate emissions in the cement manufacturing process can settle on refractory surfaces, potentially affecting their performance. Thus, frequent cleaning and dust removal are crucial to ensuring optimal refractory conditions and preventing blockages or reduced airflow. Thermal cycling, caused by heating and cooling cycles in the kilns, can result in thermal shock, leading to cracks and fractures in refractories. To mitigate these effects, the use of thermal cycling-resistant refractory materials and adherence to proper operating procedures are essential.
“We perform tests on refractories once in two or three years through reputed laboratories or testing agencies. However, regular inspections through shell temperature profile help us identify defects early, allowing for timely repairs or replacements to maintain the integrity and performance of the refractory lining in kilns. These intervals mentioned are indicative and may vary based on kiln operating conditions, refractory type, and specific industry guidelines,” says Khandhadia.
Abrasion is another challenge in cement kilns, caused by the constant movement of materials and interaction with gases and dust. This issue demands ongoing monitoring and maintenance, with quality refractories designed to withstand abrasion playing a pivotal role. Mechanical stress resulting from various factors, including thermal cycling and the weight of materials, poses another threat. Regular inspections and maintenance are essential to address such mechanical wear and maintain the structural integrity of refractory linings.
Lastly, the quality of refractory materials plays a pivotal role in their performance within cement kilns. Low-quality materials can lead to premature failure and increased maintenance costs. Therefore, it is imperative to use high-quality refractory materials specifically designed for cement kiln applications, and rigorous quality control in material selection and installation is necessary to maximise refractory lifespan and performance. In conclusion, maintaining refractory integrity in cement kilns involves addressing the demanding conditions they face through regular maintenance and the use of superior-quality refractory materials, ensuring the efficient and safe operation of these critical industrial facilities.
Refractories in industrial settings experience shutdowns primarily due to factors such as thermal stress, chemical attack, abrasion, mechanical impact, dust accumulation, thermal cycling, insufficient maintenance, subpar quality of refractory materials, improper installation and overheating. These shutdowns can disrupt industrial processes, leading to downtime and increased operational costs. To mitigate such issues, industries focus on regular maintenance, inspections, and repairs, employ high-quality refractory materials suited to the specific conditions, ensure proper installation techniques, and adhere to operational limits and safety protocols. These proactive measures aim to extend the lifespan of refractories,
minimise unplanned shutdowns, and maintain the reliable and efficient functioning of industrial equipment.
“Production efficiency comes from low shutdowns. If the cement plants must take a shutdown for 15-20 days every 2 to 3 months versus taking only one shutdown, the number of days of operations increases by 20 to 30 days. This means they gain one month of additional production and this is how our refractories help them achieve higher production, higher profits and achieve efficient outputs,” elaborates Vivek Singh, Sales Director – Thermal & Exports, South West Asia, Calderys Refractories India.
“Our focus is to help cement plants increase their outputs with the available infrastructure by reducing the need for shutdowns and possibilities of stopping production,” he adds.

REFRACTORIES FOR CEMENT PLANTS
In cement plants, various types of refractories are strategically employed to cater to the
distinct demands of different stages in the cement manufacturing process.
Alumina-based refractories, resistant to moderate temperatures and abrasion, are used in preheater and cyclone stages. Basic refractories, primarily magnesia-based, excel in the burning zone of rotary kilns due to their ability to withstand high temperatures and resist chemical attacks from alkalis.
Silica-based refractories find their place in cooler areas, offering good abrasion resistance and thermal insulation.
Chrome-based refractories, renowned for their resistance to extreme heat and chemical attack, are crucial in the kiln’s burning zone.
Zirconia-based refractories shine where thermal shock is a concern, such as the cooler and transition zones.
Finally, lightweight insulating refractories are deployed to reduce heat loss and improve energy efficiency, often found in areas requiring thermal insulation.
The choice of refractory type is tailored to the specific conditions of each process stage, ensuring efficiency, longevity and optimal performance in cement plants.
According to a report titled Refractories Selection for Cement Industry, August 2020 published by IN Chakraborty, Ace Calderys Limited, Nagpur, refractory selection is the most important step for the maximisation of its performance. The major deciding factors for refractory selection are the working environment where the refractory would be used. The working environment, in general, is defined by the following parameters:
• Operating temperature
• Chemical condition
• Chemical nature of solid or liquid, i.e., acidic, or basic, in contact with the refractory
• Characteristic of the gaseous environment
• Thermal shock
• Mechanical stress
• Abrasion
Refractory selection is the most important step for the maximisation of its performance. The major deciding factor for refractory selection is the working or operating environment where the refractory would be used.
Identification of critical parameters for a given working environment is vital for refractory life maximisation at optimal cost. Once the critical operating parameters are identified, the refractory should be so selected that it can withstand the operating condition for the stipulated lifespan. In the context of the refractory life in the cement rotary kiln, the lining design as well as the quality of refractory installation play a very critical role.
As a function of the cement manufacturing process, a raw meal i.e., a mix of limestone, quartz, clay and some lateritic material is fed in the kiln. This operating condition in this kiln is not severe except for in the burning zone where temperature can go up to 1450oC and the liquid content of the feed material falls in the range of 25 per cent to 27 per cent.

CONCLUSION
In the complex and high-temperature world of cement production, refractories stand as the unsung heroes, meticulously selected, and tailored to withstand the unique challenges of each stage in the manufacturing process. The choice of refractory type is a testament to the careful consideration of the specific conditions and requirements at every stage, ensuring the reliable and efficient production of this vital building material. Cement plants may be a symbol of industry, but behind the scenes, it is the adaptability and resilience of refractories that keep the fires burning and the cement flowing.

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Cement Makers’ Margins To Fall Rs 50-75 Per Tonne Amid West Asia Conflict

Crisil Sees Margins Easing Despite Steady Demand

Published

3 weeks ago

July 29, 2026

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Crisil said operating margins of Indian cement manufacturers are expected to decline by Rs 50-75 per tonne (t) this fiscal to Rs 925-950 per t due to higher input costs triggered by the West Asia conflict. The analysis covered 18 cement companies accounting for nearly 90 per cent of India’s domestic cement capacity and noted margins had improved sharply to around Rs 1,000 per t in fiscal 2026.

Crisil noted that the reduction would be driven mainly by higher power and fuel costs, which account for about 30 per cent of total costs, as petcoke and imported coal prices have surged amid geopolitical uncertainties. Freight costs, which account for about a quarter of total costs, are also expected to remain elevated because of higher diesel prices. The impact on profitability is likely to be more pronounced in the first half of the fiscal year before easing commodity prices moderate cost pressures later.

The rating agency said steady domestic demand and strong balance sheets should keep credit profiles stable despite the moderation in margins. Green energy currently accounts for 35-40 per cent of the sector’s total electricity consumption and is expected to partly cushion higher energy costs. Operating cash flows are likely to remain resilient, supported by projected 6-7 per cent growth in cement demand this fiscal.

Crisil highlighted that demand growth will be driven primarily by infrastructure spending, which meets about one-third of sector consumption, and by a nearly 18 per cent higher budgetary allocation for core ministries that should support project execution. Weaker rural housing demand amid pressure on agricultural incomes from a possible below-average monsoon may be offset by improved urban housing demand supported by favourable home-loan rates and a strong pipeline of Pradhan Mantri Awas Yojana-Urban projects. Ongoing capacity additions will keep capital expenditure elevated and may lift net debt to EBITDA to between 1.2 and 1.4 times from around 1.0 time last fiscal, though ratios are expected to remain healthy.

Concrete

UltraTech Board Approves Rs 50 bn Fundraise Via NCDs

Company to issue half a million debentures for expansion plan

Published

3 weeks ago

July 28, 2026

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UltraTech Cement’s board of directors has approved raising Rs 5,000 crore (Rs 50 bn) through non?convertible debentures issued in rupees.

The finance committee cleared a proposal to issue up to 500,000 fully paid, unsecured, listed, rated, redeemable, rupee?denominated, non?convertible, non?cumulative debentures of Rs 1 lakh each (Rs 0.1 mn each), aggregating to the Rs 5,000 crore programme.

As of June 2026 the firm reported net debt of Rs 15,875 crore (Rs 158.75 bn) and said its capacity expansion projects under execution are backed by capital expenditure of about Rs 17,000 crore (Rs 170 bn) over the next two to two?and?a?half years.

UltraTech spent Rs 9,500 crore (Rs 95 bn) on capital expenditure in financial year 2026 and in April the group crossed 200.1 mn tonnes per annum of domestic grey cement capacity and 205.5 mn tonnes per annum of global capacity.

The chief financial officer indicated the company would take consolidated capacity beyond 242 mn tonnes per annum, with grey cement capacity reaching 212.7 mn tonnes per annum by the end of financial year 2027. He noted the net debt?to?earnings before interest, taxes, depreciation and amortisation ratio stood at 0.87 times as of June 2026 and the company was confident of ending financial year 2027 with the ratio below one time.

In the first quarter of financial year 2026?27 UltraTech’s net profit attributable to owners rose 16.8 per cent year?on?year to Rs 2,599.3 crore (Rs 25.993 bn) and revenue from operations increased 15.9 per cent to Rs 24,648.20 crore (Rs 246.482 bn). The board approval is expected to complement internal cash flows as the company advances its expansion programme.

Concrete

Reimagining the Future

Published

4 weeks ago

July 21, 2026

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From LC3 and AI-driven kilns to RDF gasification, ICR explores the full breadth of technological innovation reshaping India’s cement industry. Low-carbon materials, digital manufacturing, alternative fuels and breakthrough concrete science are collectively advancing the sector’s transition from high-emission commodity producer toward a net-zero, infrastructure-ready future.

Innovation has become the defining force shaping the future of the cement industry. As the world’s second-largest cement producer, India is witnessing rising demand driven by infrastructure development, urbanisation, affordable housing, and industrial growth. At the same time, the International Energy Agency (IEA) estimates that cement production accounts for nearly 7 per cent to 8 per cent of global CO2 emissions, with clinker manufacturing contributing the largest share, making innovation an operational necessity. The industry is therefore investing heavily in low-carbon cement technologies, artificial intelligence (AI), digital manufacturing, alternative fuels, renewable energy and carbon capture, utilisation and storage (CCUS). Innovations such as limestone calcined
clay cement (LC3), supplementary cementitious materials (SCMs), AI-driven process optimisation and automated quality control are enabling manufacturers to produce more sustainable, efficient, and high-performance cement.
According to the Global Cement and Concrete Association (GCCA), achieving net-zero emissions will require a combination of material innovation, digital transformation, circular economy practices and collaborative research, making innovation central to the industry’s long-term competitiveness and India’s sustainable infrastructure growth.

Next-generation cement
The future of cement lies in reducing its dependence on clinker-the most carbon-intensive component of cement-through the adoption of low-carbon materials and advanced blended cement technologies. Products such as Portland Pozzolana Cement (PPC), Portland Slag Cement (PSC), Portland Composite Cement (PCC), and LC3 are driving this shift by replacing clinker with SCMs like fly ash, GGBS, calcined clay and limestone.
According to GCCA, SCMs can replace 30 to 50 per cent of clinker, with some applications exceeding 70 per cent, significantly reducing carbon emissions without compromising strength or durability. These blended cements also improve concrete performance by enhancing durability, reducing permeability, and increasing resistance to chloride and sulphate attacks. As the availability of traditional SCMs declines with the decarbonisation of the power and steel sectors, the industry is increasingly exploring alternative materials and next-generation cement formulations to support long-term sustainability.
Shrivats Singhania, Deputy Managing Director, JK Lakshmi Cement, says, “Innovation is enabling the cement industry to address one of its most important challenges – producing more with fewer resources and lower emissions. Across the value chain, manufacturers are deploying technologies that simultaneously improve operational efficiency and advance sustainability goals. For example, greater adoption of alternative fuels, waste heat recovery systems, renewable energy, and digital process controls is helping reduce energy consumption and optimise resource utilisation. Data-driven manufacturing allows plants to monitor operations in real time, improve equipment reliability, minimise downtime, and reduce wastage, resulting in both environmental and economic benefits.”
“Meaningful progress is also being achieved through material innovation. The growing use of blended cements and next-generation products such as LC3 reduces dependence on clinker, the most carbon-intensive component of cement production, thereby lowering embodied carbon without compromising performance,” he adds.
Among emerging technologies, LC3 has gained global recognition as one of the most promising low-carbon cement innovations. In a standard formulation, LC3 comprises approximately 50 per cent clinker, 30 per cent calcined clay, 15 per cent limestone, and 5 per cent gypsum. LC3 can reduce CO2 emissions by up to 40 per cent compared with Ordinary Portland Cement (OPC) while delivering comparable strength and enhanced durability. Its reliance on abundant, locally available raw materials, rather than industrial by-products, makes it highly scalable and well suited to countries like India.
According to the LC3 Project, nearly 75 per cent of cement plants worldwide could adopt LC3 using existing manufacturing infrastructure, potentially reducing global CO2 emissions by over 400 million tonnes annually, if adopted at scale globally. India’s introduction of BIS standard IS 18189:2023 for LC3, coupled with its adoption in projects such as the Noida International Airport, marks a step toward commercial implementation. As demand for sustainable construction grows, LC3 is poised to become a cornerstone of low-carbon infrastructure development.

Making of a smart cement plant
The modern cement plant is rapidly evolving into a digitally connected, AI-enabled manufacturing ecosystem where data drives every aspect of production – from raw material proportioning and kiln operations to quality control, maintenance and energy management.
According to IEA, digital technologies can improve energy efficiency in heavy industries by 10 per cent to 20 per cent. Advanced process control systems in cement plants have demonstrated the potential to reduce thermal energy consumption by 3 to 5 per cent, lower electricity consumption by 2 to 10 per cent, and improve kiln throughput and clinker quality. AI-powered predictive maintenance further helps reduce unplanned equipment downtime by 30 to 50 per cent and extend equipment life by continuously analysing sensor data to detect failures before
they occur.
Jignesh Kundaria, Director and CEO, Fornnax Technology, says, “AFR is no longer viewed solely as a sustainability initiative. It has become a strategic business priority for cement manufacturers. Rising fuel costs, stricter environmental regulations, and growing pressure to reduce dependence on conventional fuels are accelerating AFR adoption across the industry. However, the success of an AFR project depends heavily on how effectively waste is processed before it reaches the kiln. Poor preprocessing can negatively impact kiln performance, fuel efficiency, and emission control systems. Inconsistent fuel
quality often forces operators to make frequent adjustments, reducing throughput and increasing energy consumption.”
Dr Kapil Kukreja, General Manager, NCCBM, says, “Variations in composition, particle size, and calorific value can lead to inconsistent combustion behaviour resulting in fluctuating heat release patterns. These fluctuations can affect process stability, temperature control and clinker quality. Additionally, incomplete combustion of RDF particles can result in increased emissions, higher unburnt carbon content, and operational difficulties within the calciner system. Higher ash and inert content of RDF can dilute the clinker quality and reduce calciner efficiency.”
Meanwhile, digital twins are allowing manufacturers to simulate entire production processes, optimise kiln performance, evaluate process changes virtually, and reduce operational risks before implementation. Automated Laboratory Information Management Systems (LIMS), coupled with online and offline XRF and XRD analysers, are delivering real-time monitoring of clinker chemistry and mineralogy, ensuring tighter quality control, lower clinker variability and more consistent cement performance.
Dr Prateek Sharma, Group Project Manager, NCCBM, explains, “Chlorides and alkalis present in RDF can lead to excess buildup and blockages in the kiln and calciner increasing the downtime of cement plants. Hence, issues with direct utilisation of RDF establishes the need for fuel conditioning and alternative utilisation approaches that can maximise the energy potential of RDF while minimising adverse impacts on plant operation. RDF gasification emerges as an efficient tool for converting solid RDF into syngas which can be used as a fuel with improved characteristics.”
Digitalisation and intelligent manufacturing will be among the most critical enablers of achieving the cement industry’s net-zero ambitions by improving operational efficiency while simultaneously reducing energy consumption and greenhouse gas emissions, confirms a GCCA report.

From research to reality
While the cement industry has made remarkable progress in developing breakthrough technologies, the transition from laboratory research to large-scale commercial deployment remains one of its greatest challenges. The successful adoption of innovations such as LC3), CCUS, advanced alternative fuels, green hydrogen and novel SCMs depend not only on technical feasibility but also on economic viability, regulatory support, raw material availability, and market acceptance.
Veerendra Jamdade, CEO and Founder, Vritti Solutions, states, “The cement industry has a market that is constantly in flux, due to factors such as infrastructure investment, seasonality of demand, fuel costs, building activity by region and general economic cycles; therefore, having accurate forecasts is very important in this type of market. Traditional ERP systems are primarily data repositories with limited analytic functionality; thus, they capture transactional and operational information but generally lack advanced analytical capabilities for converting captured data into actionable information. This
affects everything from demand forecasting and inventory planning through procurement and production scheduling.”
According to IEA, technologies that are still at the demonstration or early commercial stage-including CCUS and next-generation low-carbon binders-are expected to contribute nearly 40 per cent of the emissions reductions required for the global cement sector to achieve net-zero emissions by 2050, underscoring the importance of accelerating their scale-up. This requires robust R&D ecosystems, stronger collaboration between cement manufacturers, research institutions, technology providers,
equipment suppliers, and policymakers, as well as supportive standards and financial incentives to reduce investment risks.
Ashutosh Pandita, Director – Head, Cement Business, TKIL Industries, elaborates, “The cement industry’s most transformative innovation today is the increased use of alternative fuels and raw materials (AFR), supported by advanced feeding systems and process technologies that are driving both operational efficiency and decarbonisation. Looking ahead, oxyfuel combustion and carbon capture technologies remain underappreciated but hold immense potential for enabling deep reductions in carbon emissions and accelerating the industry’s journey towards net-zero production. By 2030, cement manufacturing is expected to become significantly more sustainable, energy-efficient, and technology-driven, with widespread adoption of AFR, low-clinker cement technologies, greater digitalisation and automation, and the early commercial deployment of carbon capture solutions, all supported by stronger industry collaboration and a shared commitment to achieving long-term sustainability goals.”
In India, organisations such as the National Council for Cement and Building Materials (NCCBM), leading academic institutions, and major cement companies are working together to develop and validate emerging technologies, while the introduction of standards such as IS 18189:2023 for Limestone Calcined Clay Cement (LC3) marks a significant step towards commercial adoption. However, challenges such as high capital investment, long validation cycles, limited infrastructure for technologies like CCUS, fluctuating availability of alternative raw materials, and customer acceptance continue to slow implementation. Bridging the gap between research and commercial reality will therefore require sustained investment in innovation, knowledge-sharing, pilot projects, policy support, and industry-wide collaboration to ensure that promising technologies evolve into scalable, economically viable solutions capable of transforming the future of cement manufacturing.

Creating a green future
Clinker production will increasingly rely on low-carbon technologies such as LC3, high-volume SCMs, AFR, renewable energy, waste heat recovery, and eventually CCUS, enabling manufacturers to significantly reduce their environmental footprint.
Achieving net-zero concrete by 2050 will require a combination of clinker substitution (around 37 per cent of cumulative CO2 reductions), carbon capture technologies (approximately 36 per cent), and improvements in thermal efficiency, renewable energy, and circular economy practices.
Industry Expert SA Khadilkar comments, “Customer requirements are a key driver of innovation in the cement industry, influencing product development, process improvements, sustainability initiatives, and digital solutions. Innovation is most effective when it addresses real market needs, particularly in areas such as performance, durability, and application-specific requirements. Around a decade ago, ACC and Ambuja Cements (now Adani Cement) recognised this shift and introduced performance-oriented blended cement brands with enhanced durability, reduced water penetration, and OPC-like properties. Their success encouraged other major cement manufacturers to develop specialised cement brands with unique performance characteristics, demonstrating how product innovation has evolved to meet changing customer expectations.”
“Ultimately, customer expectations have transformed innovation from a technology-driven exercise into a market-driven strategy, ensuring that new developments create measurable value across the construction value chain,” he adds.
India is expected to add nearly 500 million square metres of urban built-up area by 2030, driving sustained demand for greener, more durable, and higher-performing construction materials, according to NITI Aayog. Meeting this demand will require cement manufacturers to evolve from commodity producers into integrated providers of sustainable building solutions, supported by data-driven manufacturing, collaborative R&D, customer-centric product innovation, and circular resource management. The cement plant of tomorrow will therefore be defined not only by its production capacity but also by its ability to manufacture smarter, cleaner, and more sustainable construction materials that support India’s ambitious infrastructure and climate goals.

Conclusion
The path ahead is clear in its direction, if not yet in its pace. India’s position as the world’s second-largest cement producer, combined with its infrastructure ambitions and its 2070 net-zero commitment, makes this transition both urgent
and consequential.
What this article has made evident is that no single technology will carry the industry to net zero. LC3 addresses clinker dependency. Digital manufacturing addresses efficiency and waste. Alternative fuels address fossil fuel dependence. CCUS addresses the residual process emissions that no other lever can reach. Each is necessary. None is sufficient alone. The industry’s task is to advance all of them simultaneously, at a pace that matches the scale of the challenge.
The plants that will build tomorrow’s highways, airports and homes will need to do so with a fraction of today’s carbon footprint.

Innovations in cement and concrete

Carbon mineralisation in concrete: A 2026 peer-reviewed study in the Journal of the American Ceramic Society by MIT’s Masic Lab and CarbonCure Technologies used in-situ Raman microspectroscopy to show that CO2 injected during cement mixing triggers a three-stage hydration sequence, producing a more uniform microstructure with approximately 13 per cent higher early strength while permanently sequestering carbon within the concrete matrix.

Source: www.carboncure.com

Zero-clinker geopolymer blocks: Theseus Development manufactures geopolymer blocks using upcycled aluminosilicate waste from quarries and mines through an inorganic polymerisation process, achieving up to 80 per cent lower embodied carbon compared to conventional cement blocks. An interlocking block design reduces mortar requirements, lowering construction costs while eliminating clinker entirely from the production process.

Source: www.rmi.org

3D-printed basalt fibre grids: Austrian startup Fiber Elements, founded in 2023, uses robotically wound continuous basalt fibres arranged into three-dimensional reinforcement grids that replace steel in concrete structures. The resulting composites are three times stronger than steel, weigh two-thirds less, resist corrosion entirely and reduce CO2 emissions by up to 70 per cent compared to conventional steel-reinforced concrete.

Source: www.eitmanufacturing.eu

Self-healing concrete: Dutch company Basilisk leads commercial deployment of bacteria-based self-healing concrete, with licensed production now active in Japan and a highway viaduct pilot planned for 2026. Dormant Bacillus bacteria embedded in the mix activate upon crack formation, metabolising nutrients to precipitate calcium carbonate that autonomously seals fractures. The global self-healing concrete market is projected to grow significantly through 2031, driven by green building mandates and infrastructure agencies targeting lower maintenance costs and extended structural life.

Sources: www.thelegaljournalontechnology.com and www.mordorintelligence.com