Vimal Kumar Jain, Director – Technical, HeidelbergCement India, discusses how his company has utilised technology to decarbonise the cement manufacturing process with the use of new-age methodologies.
HeidelbergCement India (HC India) produces world-class products under the brands Mycem and Zuari. HC India is a part of Heidelberg Materials, Germany, which is one of the world’s largest producers of building materials. Heidelberg Materials stands for competence and quality, in over 50 countries. HC India has four integrated cement plants, four grinding units and a terminal with an installed capacity of about 14 MTPA. At the centre of our actions lies our responsibility for the environment. We are the front runner on the road to carbon neutrality and circular economy in the building materials industry. We are working on intelligent and sustainable building materials as well as solutions for the future. We have taken green initiatives like water positivity, green power generation by installing a waste heat recovery system and solar power plant, NOx emission reduction system (SNCR), alternative fuel utilisation in place of fossil fuels, etc.
Municipal Solid Waste (MSW) The production of cement requires a high degree of thermal energy. The traditional fuels used in the kilns are coal, oil, petroleum coke etc. The substitution of fossil fuels by alternative fuels in the production of cement clinker is having great importance for society and climate control because it conserves fossil fuel reserves and reduces greenhouse gas (GHG) emissions. We are aiming to maximise the usage of alternative fuels such as industrial wastes, plastics, used tires, biomass wastes and municipal wastes, thus replacing conventional fuels. Disposal of MSW is a challenge for environment and climate control. Earlier, municipal waste was openly burned or land-filled, which generated greenhouse gas emissions and leachate from the landfilling sites induced secondary pollution. HC India has taken the challenge to co-process the municipal solid waste in kilns to reduce GHG emissions and conserve natural resources. Co-processing of municipal waste needs special expertise and state-of-the-art technology for safe and environment friendly disposal. HeidelbergCement group has installed a municipal solid waste feeding system with a storage shed. There are several challenges associated with using municipal waste in kilns. It is highly heterogeneous in nature, which makes it difficult to maintain kiln stability. The main issue is related to size and flowability of municipal waste. Flowability was a bigger issue during waste feeding, due to bigger size up to 300 mm and high moisture content (25-30 per cent) the material frequently stuck up at the hopper discharge chute. To improve this, the hopper chute has been modified and a new shredder machine installed.
This helps to reduce the size of municipal waste less than 50mm. This increases alternative fuel utilisation. A grab crane mechanised system was also installed to ensure continued waste feeding. This technology replaced the previous manual waste feeding system, which was not consistent. Consistent quality and quantity of municipal waste in the vicinity of a cement plant is also a challenge to prepare suitable raw mix/fuel mix. We made agreements with local municipalities to ensure consistent continuous supply of waste. We have a dedicated lab for analysing alternative fuels. To increase Thermal Substitution Rate (TSR) and MSW utilisation, a shredder and grab crane were installed.
NOx Emission Control Technology The ‘clinkerisation’ process is the most important step of cement manufacturing, and the one which requires all our vigilance because of its possible environmental consequences as cement (clinkerisation) processes release nitrogen oxides ( NOx) emissions. In the cement industry normally, 95 per cent of NOx formed is nitric oxide (NO). This gas is colourless and is readily transformed into NO2 in air.
Thermal NOx Formation Thermal NOx is formed at a temperature greater than about 1200°C by direct oxidation of atmospheric nitrogen. Since the flame temperature in cement rotary kilns is about 2000°C, a considerable amount of thermal NO is generated. The thermal reaction between oxygen and nitrogen to form NO takes place in the process. NO formation increases rapidly with temperature and in the presence of excess oxygen. Factors affecting the concentration of NO in the kiln gases are: • Flame temperature • Flame shape • Excess air rate • Maximum material temperature • Material retention time in burning zone • Gas retention time in burning zone
Fuel NOx Formation
NOx also results from the oxidation of nitrogen compounds present in fuel, other than gaseous. The reaction normally takes place at relatively lower temperature, less than 1200°C. Fuel NOx formation normally depends on: • Nitrogen content in the fuel • Volatile content in the fuel • Oxygen level in the combustion zone • Initial NO concentration in the combustion gas • Temperature in the secondary combustion zone
Prompt NOx Formation Prompt NOx is formed by fuel-derived radicals, such as CH reacting with N2 in hydrocarbon flames. The overall contribution of prompt NOx to total NO is relatively less.
Control Techniques Typical NOx emission in older technologies can be as high as 1800 – 2000 mg/Nm3, while the average emission value in modern plants is around 1000 mg/Nm3. NOx emissions reduction from cement plants can be done in two methods.
Primary NOx Reduction methods • Optimisation of clinker burning process. • Automatic kiln control system or expert system. • Use of low NOx burner to allow low primary air and to control flame flow pattern. • Addition of water to the flame or fuel of the main burner. • Staged combustion in precalciner.
In calciner staged combustion, fuel is first burned under reducing conditions to reduce NOx and then the remaining fuel burns under oxidising conditions to complete the combustion. Introduction of raw meal allows control of calciner temperature. Through these mechanisms, both fuel NOx and thermal NOx are controlled.
Secondary NOx Reduction Method In the secondary reduction measure, a separate gas cleaning unit is added. Selective Non Catalytic Reduction (SNCR) system and this technology can reduce NOx up to 80 per cent. In this process NO reacts with NH3. The reagent typically NH3 or urea is injected into the kiln system at a location with an appropriate temperature window (870°C to 1100°C). The temperature is critical, at higher temperatures the reagents will form additional NOx whereas at lower temperatures the reactions proceed slowly, and substantial amounts of unreacted ammonia will escape. HC India installed SNCR systems in their cement plants to reduce the NOX emissions to support UN SDG goals. Nox Emission reduced <700 mg/Nm3 by installing SNCR system.
The MIYAWAKI method Air pollution is a global crisis and high concentrations of harmful gases and particles in our atmosphere negatively affect the health of humans, animals, and plants, and also cause global warming. Tree plantation is the natural remedy to control emissions, trees act as earth purification by absorbing toxic gases and releasing oxygen. We need to plant more trees to tackle global warming.
But the challenge lies in availability of space and growth of plants. The Miyawaki method is a solution for this challenge as these method plants grow rapidly and require less space. In the 1980s, Dr Akira Miyawaki introduced a new and innovative reforestation approach in Japan with the challenge to restore indigenous ecosystem, and to maintain the global environment, including disaster prevention and greenhouse gas mitigation. The Miyawaki technique is a unique methodology proven to work worldwide, irrespective of the soil’s agro climatic conditions. A completely chemical free forest in an organic way that sustains itself, supports local biodiversity, and attracts birds and insects. Reconstitution of ‘indigenous forests by indigenous plants’ produces a rich, dense and efficient protective pioneer forest in 2-3 years. This type of planting resulted in quick production of multi layered forest, a soil rich with microbial activity like that of a normal primary forest. It’s a multi-layered green forest, maintenance free and 100 per cent organic with zero pesticides/ chemical fertilisers. The Miyawaki planting method was executed at our colony with a total number of 2,700 plants comprising 31 different plant species. Saplings are planted closely together to promote growth. Around 5-6 saplings per square metre are recommended. This is to facilitate a natural forest pattern. Initially the soil is mixed with manures and irrigated at regular intervals. The plants utilise these resources in the beginning and once they are established, all the resources being given are stopped so that the plants could thrive on their own and survive. The total land area is 0.5 acres (143m x 14m). It was basically an unused waste land with rocks, which is cleared off of all the pebbles, stones, plastic and other domestic waste. The land was dug up one metre in depth and old soil was replaced with red soil, which was thoroughly mixed with paddy husk, vermicompost, red soil and coco peat in 1:1:1:1 ratio for 0.5 acre of land. Thereafter, 2,700 plants were planted.
ABOUT THE AUTHOR:
Vimal Kumar Jain, Director – Technical, HeidelbergCement India, in his career spanning over 32 years, he has gained experience in operations and maintenance and project management from concept to commissioning, in the cement sector. He holds a mechanical engineering degree and a business & operations management diploma.
The Department of Science and Technology (DST) recently unveiled a pioneering national initiative: five Carbon Capture and Utilisation (CCU) testbeds in the cement sector, forming a first-of-its-kind research and innovation cluster to combat industrial carbon emissions.
This is a significant step towards India’s Climate Action for fostering National Determined Contributions (NDCs) targets and to achieve net zero decarbonisation pathways for Industry Transition., towards the Government’s goal to achieve a carbon-neutral economy by 2070.
Carbon Capture Utilisation (CCU) holds significant importance in hard-to-abate sectors like Cement, Steel, Power, Oil &Natural Gas, Chemicals & Fertilizers in reducing emissions by capturing carbon dioxide from industrial processes and converting it to value add products such as synthetic fuels, Urea, Soda, Ash, chemicals, food grade CO2 or concrete aggregates. CCU provides a feasible pathway for these tough to decarbonise industries to lower their carbon footprint and move towards achieving Net Zero Goals while continuing their operations efficiently. DST has taken major strides in fostering R&D in the CCUS domain.
Concrete is vital for India’s economy and the Cement industry being one of the main hard-to-abate sectors, is committed to align with the national decarbonisation commitments. New technologies to decarbonise emission intensity of the cement sector would play a key role in achieving of national net zero targets.
Recognizing the critical need for decarbonising the Cement sector, the Energy and Sustainable Technology (CEST) Division of Department launched a unique call for mobilising Academia-Industry Consortia proposals for deployment of Carbon Capture Utilisation (CCU) in Cement Sector. This Special call envisaged to develop and deploy innovative CCU Test bed in Cement Sector with thrust on Developing CO2 capture + CO2 Utilisation integrated unit in an Industrial set up through an innovative Public Private Partnership (PPP) funding model.
As a unique initiative and one of its first kind in India, DST has approved setting up of five CCU testbeds for translational R&D, to be set up in Academia-Industry collaboration under this significant initiative of DST in PPP mode, engaging with premier research laboratories as knowledge partners and top Cement companies as the industry partner.
On the occasion of National Technology Day celebrations, on May 11, 2025 the 5 CCU Cement Test beds were announced and grants had been handed over to the Test bed teams by the Chief Guest, Union Minister of State (Independent Charge) for Science and Technology; Earth Sciences and Minister of State for PMO, Department of Atomic Energy, Department of Space, Personnel, Public Grievances and Pensions, Dr Jitendra Singh in the presence of Secretary DST Prof. Abhay Karandikar.
The five testbeds are not just academic experiments — they are collaborative industrial pilot projects bringing together India’s top research institutions and leading cement manufacturers under a unique Public-Private Partnership (PPP) model. Each testbed addresses a different facet of CCU, from cutting-edge catalysis to vacuum-based gas separation.
The outcomes of this innovative initiative will not only showcase the pathways of decarbonisation towards Net zero goals through CCU route in cement sector, but should also be a critical confidence building measure for potential stakeholders to uptake the deployed CCU technology for further scale up and commercialisation.
It is envisioned that through continuous research and innovation under these test beds in developing innovative catalysts, materials, electrolyser technology, reactors, and electronics, the cost of Green Cement via the deployed CCU technology in Cement Sector may considerably be made more sustainable.
Secretary DBT Dr Rajesh Gokhale, Dr Ajai Choudhary, Co-Founder HCL, Dr. Rajesh Pathak, Secretary, TDB, Dr Anita Gupta Head CEST, DST and Dr Neelima Alam, Associate Head, DST were also present at the programme organized at Dr Ambedkar International Centre, New Delhi.
JK Lakshmi Cement, a key player in the Indian cement industry, has announced the deployment of electric vehicles (EVs) in its logistics operations. This move, made in partnership with SwitchLabs Automobiles, will see EVs transporting goods between the JK Puram Plant in Sirohi, Rajasthan, and the Kalol Grinding Unit in Gujarat.
The announcement follows a successful pilot project that showcased measurable reductions in carbon emissions while maintaining efficiency. Building on this, the company is scaling up EV integration to enhance sustainability across its supply chain.
“Sustainability is integral to our vision at JK Lakshmi Cement. Our collaboration with SwitchLabs Automobiles reflects our continued focus on driving innovation in our logistics operations while taking responsibility for our environmental footprint. This initiative positions us as a leader in transforming the cement sector’s logistics landscape,” said Arun Shukla, President & Director, JK Lakshmi Cement.
This deployment marks a significant step in aligning with India’s push for greener transport infrastructure. By embracing clean mobility, JK Lakshmi Cement is setting an example for the industry, demonstrating that environmental responsibility can go hand in hand with operational efficiency.
The company continues to embed sustainability into its operations as part of a broader goal to reduce its carbon footprint. This initiative adds to its vision of building a more sustainable and eco-friendly future.
JK Lakshmi Cement, part of the 135-year-old JK Organisation, began operations in 1982 and has grown to become a recognised name in Indian cement. With a presence across Northern, Western, and Eastern India, the company has a cement capacity of 16.5 MTPA, with a target to reach 30 MT by 2030. Its product range includes ready-mix concrete, gypsum plaster, wall putty, and autoclaved aerated fly ash blocks.
Holcim UK has released a report titled ‘Making Sustainable Construction a Reality,’ outlining its five-fold commitment to a greener future. The company aims to focus on decarbonisation, circular economy principles, smarter building methods, community engagement, and integrating nature. Based on a survey of 2,000 people, only 41 per cent felt urban spaces in the UK are sustainably built. A significant majority (82 per cent) advocated for more green spaces, 69 per cent called for government leadership in sustainability, and 54 per cent saw businesses as key players. Additionally, 80 per cent of respondents stressed the need for greater transparency from companies regarding their environmental practices.