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Leading the Green Revolution

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Ajay Kapur, CEO – Cement Business, Adani Group, explores India’s proactive measures, from embracing renewable energy and waste heat recovery to reducing clinker usage and innovatively repurposing industrial by-products, signaling a promising shift towards sustainable cement manufacturing.

Imagine a world without cement – it’s almost like picturing a skyline without its defining structures. As one of the most commonly used building materials, the manufacturing of cement faces significant challenges in decarbonising. Tackling this challenge goes beyond the ordinary, considering that the cement sector is a major player, contributing up to 7-8 per cent of global greenhouse gas emissions. The significance of this issue is particularly pronounced for India, as we currently hold the dual status of the world’s second-largest producer and consumer of cement. The production capacity of the Indian cement sector is poised to grow to more than 700 million tonnes (MT) over the next five years from around 570 MT now. Consumption on the other hand is also set to grow to 450 MT by 2027.
As the Indian economy expands and continues on this growth path to reach $5 trillion in GDP in the near term and emerge as the world’s third largest economy before the end of the current decade, the environmental challenges will also become more formidable.
Most large cement manufacturers in India have already committed to becoming carbon neutral sometime around the middle of this century and this is also going to contribute to India’s Net Zero ambition set for 2070. The road ahead for Indian cement manufacturers is very similar to what the energy sector faces. India’s economic turnaround that started in 1991 also brought home conversations around the rising and unprecedented levels of consumption of energy to fire up the economy, putting the country under the environmental spotlight, too. Cement production is not only energy intensive but also depends on natural mineral resources. The widespread adoption of well-understood and sustainable cement production practices has been a gradual process, gaining momentum over time. Today, the Indian cement sector is ready to meet sustainability challenges head-on through a whole range of measures that covers the entire value chain in cement manufacturing, leading all the way to increasing the share of green cement on the demand side.

Alternative fuel and raw materials
Being an energy-intensive sector, cement manufacturers have started investing in cleaner sources of energy like solar and wind as captive generation units to run their plants. This shift in no small measure is supported by the falling cost of renewable energy India. Between 2010 and now, the cost of solar modules in India have dropped by more than 80 per cent, making it one of the most sought after sources of clean energy for large industrial units including cement. Similar efforts are also on to move finished cement, packed and bulk on more sustainable or green logistics like soya extract-based biofuel powered shipping. Bulk terminals and grinding units along India’s long coastline can enable the movement of clinker and cement through the sea route at the lowest possible cost.
The share of green energy is further enhanced through investments in Waste Heat Recovery Systems (WHRS). These systems not only adhere to the principles of the circular economy but also result in fossil fuels savings. This not only nurtures a more cost-efficient process but also directly impacts the bottom line.
According to the Ministry of New and Renewable Energy (MNRE), the Indian cement Industry has the highest potential to adopt WHRS as an alternative to conventional sources of energy. WHRS installations will continue to grow along with the increase in capacity to manufacture cement, bringing it close to 1.3 GW at current production capacity levels. It is estimated that WHRS would help replace the energy requirement equivalent to 8.6 million tonnes of coal, resulting in emissions savings of 12.8 million tonnes of CO2 by the Indian cement manufacturers.
Cement manufacturers are also cutting down on the ‘clinker factor’ by replacing them with industrial by-products without compromising the quality (strength) of the cement. Cutting down the clinker factor offers two immediate benefits. One, it reduces energy consumption because clinker is produced at ~1400°C (from limestone etc.,) and two, it also softens the environmental impact of by-products like flyash, slag and silica fumes. Manufacturing a tonne of Ordinary Portland cement also releases around 800 kg of CO2. Investments are also made in recycling massive quantities of municipal waste into Refuse Derived Fuel or RDF through its pre- and co-processing facilities, which is then used as energy to run cement kilns. The impact of producing and using RDF not only saves on energy from conventional sources but also helps large cities manage municipal waste in a safe manner. Mega cities like Mumbai are now working with cement companies to manage municipal waste through a symbiotic relationship that benefits manufacturers and city administrators.
Red mud, a waste derived from aluminium production, is also now used in the cement manufacturing process as an alternative raw material. Again, this helps build a circular economy through utilisation of aluminium industry’s by-products in an environmentally sound manner. Other large industrial sectors like pharmaceuticals also tapped for zero residue of their process waste and ETP sludge. Similarly cement manufacturers are also able to process hazardous wastes released by the automobile and automobile ancillary sector such as chromium, zinc and paint sludge, oil residue and cotton waste.
Water management is yet another area that is making cement manufacturing in India more sustainable. Apart from becoming water positive (returning more water than what is consumed) from an operations point of view, a lot is also being done under the larger banner of CSR where cement manufacturers are now active participants in water conservation projects, working along with local rural communities including farmers. Large cement manufacturers in India are also working on conserving biodiversity in their areas of operations including large afforestation projects, which helps in strengthening the water table.

Conclusion
India today has a very robust legislative mechanism to ensure that industrial sectors like cement abide by environmental laws. But cement manufacturers, recognising the growing environmental consciousness among consumers, are actively pursuing higher benchmarks to minimise burden on environmental damage. With the growing consumer centricity that has moved cement from being a commodity to a branded consumer product, manufacturers are now able to offer sustainability as part of the brand value and appeal. Green cement as a product in India is still in its nascent stage with a miniscule share in the overall market. It is expected to grow in coming years as sustainability is an important factor for today’s buyers.
Today’s well-informed consumers also expect manufacturers to play a more responsible role in protecting the environment through sustainable manufacturing practices. The transformation of the Indian cement sector has only begun.

ABOUT THE AUTHOR:
Ajay Kapur, CEO – Cement Business, Adani Group
has over 30 years of expertise in the cement, construction, power and heavy metals sector. He has been extensively involved in several business forums, such as CII, FICCI, and ASSOCHAM.

Concrete

India Sets Up First Carbon Capture Testbeds for Cement Industry

Five CCU testbeds launched to decarbonise cement production

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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.

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Concrete

JK Lakshmi Adopts EVs to Cut Emissions in Logistics

Electric vehicles deployed between JK Puram and Kalol units

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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.

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Concrete

Holcim UK drives sustainable construction

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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.

Image source:holcim

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