Concrete

A New Revolution in Cement

Published

2 years ago

January 12, 2024

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Dr Hitesh Sukhwal, Deputy General Manager (Environment), Udaipur Cement Works, discusses the early adoption of breakthrough technologies that will help the Indian cement industry take faster strides towards its Net Zero target.

Technology is a vital enabler of sustainability. Delivering on the sustainability agenda will be impossible without technology adoption. To make better usage of available resources, technology plays a pivotal role for the best and efficient utilisation of resources. The concept of sustainability has many dimensions. It is a long way journey where initial effort converts into result, later. Many companies (service, manufacturing, etc) are now convinced that the environment-friendly process, product and services will provide them with a less competitive atmosphere from their peers. It has become a priority for every business. Sustainable business demands new technology, process and innovative solutions to manage the available resources.
The cement industry is confronting many challenges due to availability and quality of raw material, geographical location and natural resources, climate linked environmental concerns. Cement is the second most consumed product globally after potable water and it is utilised in almost every built-up structure viz. houses, roads, railways, airport infrastructure, dams, etc. The global economic growth and rapid urbanisation increases demand for cement. The cement industry is an energy intensive and significant contributor to climate change. Cement production contributes greenhouse gases directly / indirectly into the atmosphere through calcination and usage of fossil fuel in an energy form.
Worldwide, the cement industry is the best example for adoption of advanced best technology for energy and operational efficiency among the industry sectors. However, cement industries contribute significantly to carbon dioxide emissions. Decarbonising cement manufacturing will play a vital role for sustaining the cement business. There will be several challenges to decarbonise cement completely in all aspects of production, supply chain and usage.

Sustainability and technological innovation
Cement manufacturing requires a large number of resources – from raw material to finished goods. The cement manufacturing process can be divided into four major processes viz. mining, raw material processing, clinkerisation and finish grinding processing. Cement concrete is the second most consumed product in the world after potable water. With this distinctive manufacturing process and its key ingredients, cement is highly carbon intensive and a source of CO2 emissions. Thus, the cement industry is responsible for around 8 per cent of total global emissions1.
To meet the Government’s plans on development of highways, smart cities, affordable housing and other infrastructure, the projected demand for cement in 2019–2020 is 415 million tonnes, implying installed capacity of at least 460 million tonnes at 90?per cent utilisation. The Indian cement industry is expected to continue its fast-paced growth and attain installed capacity of 850 million ton per annum by 2030 and 1350 million tonnes per annum by 20502.
With the vision 2030, the above industrial growth cannot be realised without considering environmental sustainability. The Indian cement industry has given time, invested in R&D and adopted technological advancement for upgradation of process and pollution control equipment throughout the manufacturing process. At present, almost all cement manufacturing units are having a dry process and in mature stage with existing cement standards for operational parameters, environmental and energy.
The Indian cement industry is among the most energy and carbon-efficient of cement industries globally and has the lowest carbon footprint3. In November 2021, at the Glasgow Climate summit, India announced Net Zero carbon emissions by 2070.
The cement industry has implemented various technological innovations in their mining mineral, process optimisation, energy production and conservation, water management and fuel consumption. However, sustainable cement manufacturing is still the need of the hour as cement production is one of the highest emitting industries.
Decarbonising the cement industry cannot be achieved by a signal solution, instead, every stage in the value chain must reduce its carbon footprint to reach the decarbonisation target. To achieve the necessary carbon reduction target, more innovative solutions viz. new technologies and alternative building materials will be required. Potential strategies for lowering carbon emissions in the cement sector include increasing the energy efficiency of the cement production process, switching to lower carbon fuels, improving material efficiency by reducing the clinker-to-cement ratio and implementing carbon capture and utilisation or sequestration technologies4.
Currently, there are few efforts available and economically viable for the cement industry to develop low emission with a clear technology road map. Efforts are focused primarily on reducing the fossil fuels consumption by using alternative fuels, lowering the clinker to cement ratio, blended cement, renewable energy and clean energy technology such as waste heat recovery and Supplementary Cementitious Materials (SCMs such as fly ash and slag). Each of the above efforts has some benefits as well as limitations to utilise efficiently. In India, fly ash and slag (fossil based) are used widely as SCMs however, these cannot be a long-term solution since supply of both SCMs will decline as blast furnaces and coal-based power plants phase out. Therefore, all potential carbon reduction levers need to be exploited fully across all stages of the cement production process.

Advanced developments
The Indian cement industry has always adopted the best available technology and process setups to become most efficient and sustainable. Indian cement industries are strengthening processes to reduce energy as well as process related carbon emissions through technology advancement, clinker substitution, usage of alternative fuel and raw materials, renewable energy sources such as ground mounted, roof top and floating solar power system, process optimisation, optimise waste heat recovery power generation, etc.
At present, Indian cement industries are focusing on operational efficiency and utilising supplementary cementitious materials. Majority of carbon emission comes from cement production and through the supply chain. Both input of raw material from nearby sources and supply of finished goods contributes emissions in a large amount.
Moreover, the cement industry employed advanced process control systems and automation to optimise production parameters, reducing energy wastage and enhancing overall efficiency. Now, industry has real time monitoring and data analytics for operational parameters, energy consumption patterns to make better decision making to improve efficiency. In the present scenario, Indian cement producers are actively exploring lower-emission technologies like pre-calcining technology and multi-staged pre-calcining processes to effectively reduce CO2 emissions.

Opportunities ahead
Cement concrete can be recycled under certain conditions and the original chemical process cannot be reversed. The industry, with the help of local bodies and competent authorities, can recover useful ingredients from end-of-life cement to reduce the amount of new clinker and hence encourage sustainability through natural resource conservation.
The future challenge is linked with carbon emission from the whole process of cement manufacturing and its branding. At every process of Scope 1, 2 and 3 of greenhouse gas emissions, the cement industry needs to closely watch for checking, verification and monitoring aspects to prepare mitigation plans.
Industrial Internet of Things (IIoT), Artificial Intelligence (AI) and Machine Learning (ML) are some state-of-the-art technologies behind the new revolution in the cement industry. By introducing these powerful techniques, the industry can have a Smart Cement Plant, which can reduce consumption and increase productivity while complying with stringent emission standards. Artificial intelligence (AI) and machine learning (ML) are changing routine practice and process of business. AI is encouraging cement processes in a better way based on data science and analytics. The accuracy of raw mix design, optimise temperature in pyro-process, weighing scale and conveying and feeding of the material, chemical analysis and product design are few of the examples, achievable through adopting AI. Cement industry can use AI tools to optimise the usage of machines like mill, pre-heater, kiln and cooler to automate monitoring and control.
As cement industries are going towards a more sustainable future, implementation of AI and automation can play a critical role in transforming cement manufacturing processes with significant reduction of carbon emissions through real time monitoring. AI systems and ML can reduce risk of accidents, sudden breakdown of machines, and improve quality products with less carbon emission. AI provides benefits in terms of equipment reliability, availability, efficiency and monitoring.
Breakthrough technology like Carbon Capture Utilisation or Storage (CCUS) may become the best technology to minimise carbon emissions at source only. This can help industries to reduce their carbon footprint. The technology exists to clean up the carbon intensive sector, but it remains expensive. This is an urgent requirement to develop a financial tool, R&D and policy to make it economically viable.
In coming years, CCUS and SCMs (clinker substitution) may impact the decarbonisation roadmap but both key technologies require R&D to implement and make it commercially viable. Besides, use of electrical vehicles, green fuels like CNG, LNG etc. in supply chain, nature-based solutions like afforestation and soil carbon sequestration/sink will also be helpful for the sustainability of cement business. The low carbon journey in India will generate opportunities for new jobs and green growth of industry.

References:

https://www.sustainablefitch.com/corporate-finance/challenges-ahead-for-cement-industry-transition-plans-11-04-2023

https://www.zkg.de/en/artikel/zkg_The_Indian_cement_sector_technological_status_and_prospects-2467959.html

RBI recommends technology for India’s cement industry to reduce carbon emissions

https://www.cisl.cam.ac.uk/files/sectoral_case_study_cement.pdf

https://www3.weforum.org/docs/WEF_Surfacing_Supply_of_Near_Zero_Emissions_Fuels_and_Materials_in_India_2023.pdf

ABOUT THE AUTHOR:
Dr Hitesh Sukhwal is the Deputy General Manager – Environment at Udaipur Cement Works. He is a passionate professional about sustainability in the cement industry.

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Cement Makers Reaffirm Commitment to Sustainable Growth

Published

5 days ago

June 5, 2026

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World Environment Day spotlight on innovation and circularity

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

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

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

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

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

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

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

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

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

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

Concrete

Building a Greener Future Together

Published

6 days ago

June 4, 2026

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

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

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

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

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

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

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

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

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

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

1 week ago

June 1, 2026

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

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

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

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