Concrete

Charting a Cleaner Future

Published

2 years ago

February 14, 2024

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The Indian cement industry’s commitment to carbon neutrality with the use of carbon capture, utilisation and storage (CCUS) technology is commendable. But it still has ‘miles to go’ before it achieves its sustainability goals. ICR looks at the various aspects of CCUS, and the challenges and opportunities it presents to the cement sector.

In an era where the imperative to combat climate change has become increasingly urgent, the cement industry finds itself at the crossroads of innovation and environmental responsibility. At the heart of this transformative journey lies Carbon Capture, Utilisation, and Storage (CCUS), a suite of technologies designed to intercept carbon dioxide emissions at their source, repurpose them for various applications, and securely store them away from the atmosphere. This paradigm shift in industrial practices is not merely a technological evolution; it represents a conscientious commitment to mitigating the environmental footprint of one of the most significant contributors to global greenhouse gas emissions.

Defining the trifecta of Carbon Capture, Utilisation, and Storage involves a nuanced understanding of each element›s role in reshaping the landscape of industrial sustainability. Carbon capture technologies strive to intercept and capture CO2 emissions at their genesis, preventing their release into the atmosphere. Utilisation ventures beyond mere containment, exploring innovative ways to repurpose captured carbon for constructive applications, fostering a circular economy. Meanwhile, the storage component addresses the crucial need to safely sequester captured carbon, ensuring it remains dormant and harmless.

Dr Paula Carey, Co-Founder & Chief Scientific Officer, Carbon8 says, “The amount of Carbon Dioxide that is captured is limited by the amount of residue available, but the economics of our system means that a profit can be made for every tonne of CO2 captured without the need for subsidies, or large energy penalties or the use of expensive toxic chemicals such as amines. The process results in the sustainable management of an industrial residue that might otherwise be destined for landfill and produces a low carbon product for the construction industry reducing the need for the extraction of natural aggregate.”

The significance of CCUS in addressing climate change cannot be overstated. With the cement industry being a notable contributor to carbon emissions globally, the adoption of CCUS stands as a pivotal step towards achieving climate goals. According to Delhi-based think tank Centre for Science and Environment’s Decarbonising India: Cement sector report, CCUS could be one of the recommended pathways for reducing emissions in the Indian cement sector in the long run but not by 2030, especially after witnessing the slow progress on CCUS in the Indian cement sector.

CCUS TECHNOLOGIES
As the global imperative to combat climate change continues to gain momentum, industries are turning their focus towards innovative solutions to reduce carbon emissions. The cement sector, known for its significant environmental footprint, stands poised for a revolutionary transformation through the adoption of Carbon Capture, Utilisation, and Storage (CCUS) technologies. In this segment, we delve into the intricate realm of CCUS technologies, presenting an insightful overview of the diverse approaches aimed at capturing and managing carbon emissions at cement plants.

According to the Annual Global Climate Report 2023 by National Centers for Environmental Information, the year 2023 was the warmest year since global records began in 1850 at 1.18°C (2.12°F) above the 20th century average of 13.9°C (57.0°F). This value is 0.15°C (0.27°F) more than the previous record set in 2016. The 10 warmest years in the 174-year record have all occurred during the last decade (2014–2023). Of note, the year 2005, which was the first year to set a new global temperature record in the 21st century, is now the 12th-warmest year on record. The year 2010, which had surpassed 2005 at the time, now ranks as the 11th-warmest year on record.

The landscape of carbon capture technologies is a dynamic tapestry of innovation, with various methods vying for prominence in the quest for sustainability. From post-combustion capture, where CO2 is extracted from flue gasses after the combustion process, to pre-combustion capture, which intervenes in the fuel conversion stage, and oxy-fuel combustion, where fossil fuels are burned in oxygen-rich environments—each approach brings its unique set of advantages and challenges. This article endeavors to unravel this technological tapestry, providing a comprehensive understanding of the strengths and limitations inherent in different carbon capture methodologies, and their applicability to the intricacies of cement production.

According to Max Tschurtschenthaler: Global Business Unit Manager, Cement, Process Industries, ABB and Joonas Rauramo: CEO, Coolbrook, “There are huge costs associated with decarbonising the cement industry. According to the Council on Energy, Environment and Water (CEEW), given that the cumulative CO2 emissions from manufacturing 337 Mt of cement were estimated to be around 218 Mt in 2018-19, India will need approximately $334 billion in capital expenses and another $3 billion in annual operating costs to decarbonise the existing cement production in the country.”

As a result, the IEA has called for dedicated efforts to reduce carbon emissions in the cement industry, which could include the reduction of clinkerto- cement ratio (including through greater uptake of blended cement) as well as adopting pathbreaking technologies such as electric kilns, carbon capture, utilisation and storage (CCUS) and clinkers made from alternative raw materials” they add.

The adoption of CCUS in cement plants represents a critical juncture in the industry›s evolution towards sustainability. Cement production, notorious for its substantial carbon emissions, now stands on the precipice of change, with CCUS offering a lifeline to curb its environmental impact. By exploring the current landscape of CCUS adoption in cement plants, this article seeks to showcase the tangible efforts and strides made by the industry towards aligning with global climate objectives. From pilot projects to large-scale implementations, the cement sector is poised to redefine its narrative, proving that responsible production practices and environmental stewardship can indeed go hand in hand.

CHALLENGES IN CCUS
As the sector grapples with the imperative to reduce its carbon footprint, a host of technical hurdles loom on the path to seamless integration of CCUS technologies. From the complexities of retrofitting existing cement plants to the energy-intensive nature of certain capture processes, the technical challenges inherent in this paradigm shift require a meticulous examination. This segment aims to dissect the nuanced obstacles that confront the cement industry on its quest for sustainable practices, offering a glimpse into the labyrinth of hurdles that must be navigated to embrace CCUS wholeheartedly.

However, the landscape is not one solely marked by impediments; it is equally defined by the spirit of innovation and the relentless pursuit of solutions. As the cement industry strives to overcome the technical challenges posed by the adoption of CCUS, a wave of innovative solutions and technological advancements is sweeping through the sector. From breakthroughs in capture efficiency to the development of more costeffective storage methods, this article sheds light on the cutting-edge developments that promise to revolutionise the way cement plants approach carbon management. The symbiosis of challenges and solutions forms the crucible in which the future of sustainable cement production is forged, showcasing the industry›s resilience and determination to surmount obstacles on its journey toward a greener tomorrow.

According to the report An affordable, reliable, competitive path to net zero by McKinsey & Company, the net-zero transition and economic empowerment are urgent and simultaneous goals. But there are several ways that the net-zero transitions, if not executed well, could make energy, materials, and other products less affordable than traditional alternatives. Even though wind and solar generate electricity more cheaply than fossil fuels do, they will require additional spending as their share in the overall generation mix rises—for storage; other “firming capacity,” which is electricity that can be used at times when solar and wind are not providing enough energy; and grid infrastructure.

If the costs of technologies, such as batteries, do not decline as expected, or if grids are not designed thoughtfully, the delivered cost of electricity could rise. For materials, decarbonising the production of steel, aluminum, and cement could increase production costs by 15 per cent or more by 2050. If costs of energy and other products were to rise, economic growth could suffer, posing a particular problem for developing countries. And as we mentioned above, the scale of spending needed for the transition could stretch public finances.

ECONOMIC VIABILITY

As the global community intensifies its focus on environmental sustainability, the cement industry finds itself at a pivotal juncture, where economic viability converges with ecological responsibility through the lens of Carbon Capture, Utilisation, and Storage (CCUS). Central to this paradigm shift is a meticulous examination of the economic landscape, exploring the cost implications of integrating CCUS into the intricate tapestry of cement production. This segment delves into a comprehensive cost analysis, deciphering the financial intricacies that cement manufacturers must navigate on their journey towards a more sustainable and carbon-conscious future.

Implementing CCUS in cement production is not merely a technological endeavor; it is an economic calculus that demands scrutiny. From the capital investments required for retrofitting existing facilities to the operational costs associated with capturing, utilising, and storing carbon emissions, a nuanced understanding of the economic implications is essential. This article aims to unravel the complexities, providing insights into the direct and indirect costs that shape the economic viability of CCUS adoption in the cement industry.

Amidst these financial considerations, the landscape is punctuated by a beacon of support in the form of financial incentives and government backing. Recognising the pivotal role that industries play in achieving climate goals, governments worldwide are championing initiatives to encourage CCUS adoption. From tax incentives to grants and subsidies, this article explores the various avenues of financial support that cement manufacturers can leverage, underscoring the collaborative effort required between private enterprises and governments to make sustainable practices not only environmentally sound but economically feasible. The convergence of economic viability and environmental stewardship is a narrative that unfolds in the realm of CCUS, illustrating the profound impact of responsible industry practices on the global stage.

ENVIRONMENTAL IMPACT
In the ever-evolving discourse on environmental conservation, the cement industry finds itself at the forefront of a transformative narrative, catalysed by the integration of Carbon Capture, Utilisation, and Storage (CCUS) technologies. Central to this narrative is a profound examination of the environmental impact, where the echoes of reduced carbon emissions reverberate through the concrete jungles of manufacturing. This segment embarks on a journey into the heart of sustainability, exploring the tangible reductions in carbon emissions achieved through the implementation of CCUS in cement production. As the cement industry grapples with its status as a significant contributor to global carbon emissions, the promise of substantial reductions becomes a beacon of hope in the fight against climate change. CCUS not only intercepts carbon emissions at their source but actively seeks to mitigate their release into the atmosphere. This article unfolds the environmental benefits, presenting a comparative analysis that illuminates the stark contrast between conventional cement production and the greener landscape sculpted by CCUS. From decreased atmospheric pollution to a measurable reduction in the industry’s overall carbon footprint, the environmental impact of CCUS stands as a testament to its potential as a transformative force in achieving sustainable manufacturing practices.

Within this exploration lies a broader question: What if the cement industry were to continue its trajectory without the integration of CCUS? The comparison draws a vivid contrast between a future marked by unrestrained carbon emissions and the alternative reality of a more sustainable industry, embracing CCUS as a cornerstone of its environmental responsibility. Through this lens, the environmental impact of CCUS emerges not merely as a reduction in numbers but as a profound shift towards a future where industry and ecology coexist harmoniously, proving that the pursuit of progress need not come at the cost of our planet›s well-being.

CARBON UTILISATION
In the dynamic landscape of Carbon Capture, Utilisation, and Storage (CCUS), the spotlight extends beyond the mere interception and storage of carbon emissions. It converges upon the transformative concept of Carbon Utilisation, an innovative frontier where captured carbon becomes a valuable resource rather than a mere byproduct. This segment embarks on an exploration into the realm of possibilities, unraveling the myriad ways in which captured carbon can be harnessed to not only enhance sustainability in cement production but also create tangible value across diverse industries.

Traditionally viewed as an environmental challenge, carbon emissions are now being reimagined as a resource with the potential for multifaceted applications. Within the confines of cement production, the concept of carbon utilisation extends beyond containment, exploring how captured carbon can be integrated into the very fabric of manufacturing processes. This article delves into the intricacies of utilising captured carbon within cement production, examining how it can enhance the efficiency and reduce the environmental impact of this critical industry.

Moreover, the canvas of carbon utilisation extends beyond the boundaries of cement plants, presenting a myriad of opportunities to create value in other industries. From the production of synthetic fuels to the development of innovative building materials, the captured carbon becomes a versatile asset with the potential to revolutionise various sectors. This exploration not only unveils the technical possibilities but also underscores the economic incentives for industries to actively participate in the carbon utilisation revolution. The integration of carbon utilisation within the CCUS framework transcends the narrative of mitigation; it becomes a testament to the transformative power of innovation, where environmental responsibility converges with economic opportunity to redefine the landscape of sustainable industry practices.

STORAGE OPTIONS
As the cement industry endeavors to mitigate its carbon footprint through the adoption of Carbon Capture, Utilisation, and Storage (CCUS), the spotlight turns towards the crucial facet of carbon storage—a process that extends beyond mere capture and demands a thoughtful consideration of methods, sites, and safety protocols. This segment delves into the nuanced realm of storage options, unveiling the diverse methods employed to securely sequester captured carbon and emphasising the paramount importance of site evaluation and safety considerations in ensuring the success of CCUS initiatives.

The myriad methods of carbon storage present a mosaic of possibilities, ranging from geological storage in depleted oil and gas reservoirs or deep saline formations to enhanced oil recovery where captured carbon is injected to extract additional hydrocarbons. This article embarks on an exploration of these storage options, dissecting their unique strengths, limitations, and the factors that influence their applicability in the context of the cement industry. Each method represents a piece of the puzzle in the broader CCUS framework, contributing to the collective effort to safely and effectively manage the carbon emissions intercepted at their source.

Amidst the technical intricacies of storage methods, the critical importance of site evaluation and safety considerations emerges as a paramount concern. Identifying suitable storage sites involves a comprehensive assessment of geological, hydrological, and environmental factors to ensure the long-term stability and containment of captured carbon. Safety considerations, both in terms of the integrity of storage structures and the potential environmental impact, become the linchpin of successful CCUS implementation. This article navigates through the intricacies of site selection and safety protocols, underscoring the industry’s commitment to not only mitigating carbon emissions but doing so with the utmost responsibility and adherence to rigorous safety standards. In the dynamic landscape of CCUS, carbon storage becomes the silent guardian, ensuring that captured emissions find a secure and sustainable sanctuary beneath the Earth›s surface.

CONCLUSION
In the evolution towards a sustainable future, the integration of Carbon Capture, Utilisation, and Storage (CCUS) in the cement industry marks a transformative paradigm shift. Through overcoming technical challenges, navigating economic considerations, and prioritising environmental impact, the industry demonstrates a commitment to responsible innovation. The reduction in carbon emissions and the repurposing of captured carbon showcase the tangible benefits of this shift. With a focus on secure storage solutions and safety considerations, the cement industry is not just mitigating its environmental impact but actively shaping a narrative of resilience and progress. As CCUS becomes a cornerstone of industry practices, it reflects a collective effort towards a greener, more harmonious coexistence between industrial progress and environmental stewardship.

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Concrete

Dalmia Bharat launches Weather 365 in East India

New water-repellent cement targets weather-resilient housing demand

Published

5 hours ago

May 15, 2026

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Dalmia Bharat Cement has launched Weather 365, a super-premium water-repellent cement brand for retail markets in West Bengal and Bihar. The product is designed to address rising demand for durable and weather-resistant construction materials in Eastern India.

Weather 365 offers protection against seepage, dampness and moisture damage, especially in regions exposed to heavy rainfall, humidity and changing weather cycles. The cement is suited for roofs, columns and foundations, and uses uniform water-repellent technology to reduce water penetration, steel corrosion, efflorescence and damp patches.

The company said the product will be available in water-resistant and tamper-proof BOPP packaging. It will also provide on-site technical support through engineering and technical services teams to guide customers on construction practices and long-term building performance.

Positioned in Dalmia Bharat Cement’s premium portfolio, Weather 365 targets homeowners, contractors and builders seeking stronger concrete, improved paint life and better structural durability. The launch supports the company’s strategy to expand premium construction solutions in key Eastern India markets.

Concrete

Filtration Technology is Critical for Efficient Logistics

Published

7 hours ago

May 15, 2026

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Niranjan Kirloskar, MD, Fleetguard Filters, makes the case that filtration technology, which has been long treated as a routine consumable, is in fact a strategic performance enabler across every stage of cement production and logistics.

India’s cement industry forms the core for infrastructure growth of the country. With an expected compound annual growth rate of six to eight per cent, India has secured its position as the second-largest cement producer globally. This growth is a result of the increasing demand across, resulting in capacity expansion. Consequently, cement manufacturers are now also focusing on running the factories as efficiently as possible to stay competitive and profitable.
While a large portion of focus still remains on production technologies and capacity utilisation, the hidden factor in profitability is the efficiency of cement logistics. The logistics alone account for nearly 30 per cent to 40 per cent of the total cost of cement, making efficiency in this segment a key lever for profitability and reliability.
In the midst of this complex and high-intensity ecosystem, filtration often remains one of the most underappreciated yet essential enablers of performance.

A demanding operational landscape
Cement production and logistics inherently operate in some of the harshest industrial environments. With processes such as quarrying, crushing, grinding, clinker production, and bulk material handling expose the machinery to constant high temperatures, heavy loads, and dust, often the silent destructive force for engines.
The ecosystem is abrasive, and often one with a high contamination index. These challenging conditions demand equipment such as the excavators, crushers, compressors, and transport vehicles to perform and perform efficiently. The continuous exposure to contamination across every aspect like air, fuel, lubrication, and even hydraulic systems causes long-term damage. Studies have also shown that 70 to 80 per cent of hydraulic system failures are directly linked to contamination, while primary cause of engine wear is inadequate air filtration.
For engines as heavy as these, even a minor contaminant has a cascading effect; reducing efficiency, performance and culminating to unplanned downtime. Particles as small as 5 to 10 microns, far smaller than a human hair (~70 microns), can cause significant damage to critical engine components. In an industry where margins are closely linked to operational efficiency, such disruptions can significantly affect both cost structures and delivery timelines.

Dust management: A persistent challenge
Dust is a natural by-product in cement operations. From drilling and blasting in the quarries to packing in plants, this fine particulate matter does occupy a large space in operations. Dust concentration levels in quarry and crushing zones often create extremely high particulate exposure for equipment. These fine particles, when enter the engines and critical systems, accelerates the wear and tear of the component, affecting directly the operational efficiency. Over time every block fall; engine performance declines, fuel consumption rises, and maintenance cycles shorten. In this case, effective air filtration is the natural first line of defence. Advanced filtration systems are designed to capture high volumes of particulate matter while maintaining consistent airflow, ensuring that engines and equipment operate under optimal conditions.
In high-dust applications, as in cement production, even the filtration systems are expected to sustain performance over extended periods without the need of frequent replacement. This becomes crucial in remote quarry locations where access to frequent maintenance may be limited.

Fluid cleanliness and system integrity
Beyond air filtration, fluid systems also play a crucial role for equipment reliability in cement operations. Fuel systems are required to remain free from contaminants for efficient working of combustion and injection protection. Additionally, lubrication systems also need to maintain the oil purity to reduce friction and prevent any premature wear of moving parts. The hydraulic systems, which are key to several heavy equipment operations, are especially sensitive to contamination.
If fine particles or water enters these systems, it can lead to reduced efficiency, erratic performance, and eventual failure of the system. Modern filtration systems are designed with high-efficiency media capable of removing extremely fine contaminants, with advanced fuel and oil filtration solutions filtering particles as small as two to five microns. Multi-stage filtration systems further ensure that fluid performance is maintained even under challenging operating conditions.
Another critical aspect of fuel systems is water separation. Removing moisture helps prevent corrosion, improves combustion efficiency and enhances overall engine reliability. Modern water separation technologies can achieve over 95 per cent efficiency in removing water from fuel systems.

Ensuring reliability across the value chain
Filtration plays a critical role across every stage of cement logistics:
• Quarry operations: Equipment operates in highly abrasive environments, requiring strong protection against dust ingress and hydraulic contamination.
• Processing units: Crushers, kilns, and grinding mills depend on clean lubrication and cooling systems to sustain continuous operations.
• Material handling systems: Pneumatic and mechanical systems rely on clean air and fluid systems for efficiency and reliability.
• Transportation networks: Bulk carriers and trucks must maintain engine health and fuel efficiency to ensure timely deliveries.
Across these operations, filtration plays a vital role; as it supports consistent equipment performance while reducing the risk of unexpected failures.
Effective filtration solutions can reduce unscheduled equipment failures by 30 to 50 per cent across heavy-duty operations.

Uptime as a strategic imperative
In cement manufacturing, uptime is currency. Downtime not only delays the production, but it also greatly impacts the supply commitments and logistics planning. With the right filtration systems, contaminants are kept at bay from entering the
critical systems, and they also significantly extend the service intervals.
Optimised filtration can extend service intervals by 20 to 40 per cent, reducing maintenance frequency while maintaining consistent performance across demanding operating conditions. Filtration systems designed for heavy-duty applications sustain efficiency throughout their lifecycle, ensuring reliable protection with minimal interruptions. This leads to improved equipment availability, lower maintenance costs, and more predictable operations, with well-maintained systems capable of achieving uptime levels of over 90 to 95 per cent in challenging cement environments.

Supporting emission and sustainability goals
With the rising environmental awareness, the cement industry too is aligning with the stricter norms and sustainability targets. In this scenario, the operational efficiency is directly linked to emission control.

Air and fuel systems that are clean enable
much more efficient combustion. They also reduce emissions from both the stationary equipment and transport fleets. Similarly, with a well-maintained fluid cleanliness, emission systems function better. Poor combustion due to contamination can increase emissions by 5 to 10 per cent, making clean systems critical for compliance.
Additionally, efficient and longer lasting filtration systems significantly reduce any waste generation and contribute to increased sustainable maintenance practices. Extended-life filtration solutions can reduce filter disposal and maintenance waste by 15 to 20 per cent. Smart and efficient filtration in this case plays an important role in meeting the both regulatory and environmental objectives within the industry.

Advancements in filtration technology
Over the years, there has been a significant evolution in the filtration technology to meet the modern industrial applications.
Key developments include:
• High-efficiency filtration media capable of capturing very fine particles without restricting flow
• Compact and integrated designs that combine multiple filtration functions
• Extended service life solutions that reduce replacement frequency and maintenance downtime
• Application-specific engineering tailored to different stages of cement operations
Modern multi-layer filtration media can improve dust-holding capacity by up to two to three times compared to conventional systems, while maintaining consistent performance. These advancements have transformed filtration from a basic maintenance component into a critical performance system.

Adapting to diverse operating conditions
The cement industry of India operates across diverse geographies. Spanning across regions with arid regions with higher dust levels, to the coastal areas with higher humidity, challenges of each region pose different threats to the engines. Modern filtration systems are thus tailored to address these unique challenges of each region.
Indian operating environments often range from 0°C to over 50°C, with some of the highest dust loads globally in mining zones.
Additionally, filtration technology can also be customised to variations which then align the system design with factors like dust load, temperature, and equipment usage patterns. Equipment utilisation levels in India are typically higher than global averages, making robust filtration even more critical. This approach ensures optimal performance and durability across different operational contexts.

Impact on total cost of ownership
Filtration has a direct and measurable impact on the total cost of ownership of equipment.
Effective filtration leads to:
• Lower wear and tear on critical components
• Reduced maintenance and repair costs
• Improved fuel efficiency
• Extended equipment life
• Higher operational uptime
Effective filtration can extend engine life by 20 to 30 per cent and reduce overall maintenance costs by 15 to 25 per cent over the equipment lifecycle. These benefits collectively enhance productivity and reduce lifecycle costs. Conversely, inadequate filtration can result in frequent breakdowns, increased maintenance expenditure, and reduced asset utilisation.

Building a more efficient cement ecosystem
With the rising demand across various sectors, the cement industry is expected to expand at an unprecedented rate. This growth is forcing the production to move towards a more efficient and resilient system of operations. This requires attention not only to production technologies but also to the supporting systems that enable consistent performance. Filtration must be viewed as a strategic investment rather than a routine consumable. By ensuring the cleanliness of air and fluids across systems, it supports reliability, efficiency, and sustainability.

The road ahead
The future of cement logistics will be shaped by increasing mechanisation, digital monitoring, and stricter environmental standards. The industry is also witnessing a shift towards predictive maintenance and condition monitoring, where filtration performance is increasingly integrated with real-time equipment diagnostics.
In this evolving landscape, the role of filtration will become even more critical. As equipment becomes more advanced and operating conditions more demanding, the need for precise contamination control will continue to grow. From quarry to construction site, filtration technology underpins the performance of every critical system. It enables equipment to operate efficiently, reduces operational risks, and supports the industry’s broader goals of growth and sustainability. In many ways, it is the unseen force that keeps the cement ecosystem moving, quietly ensuring that every link in the value chain performs as expected.

About the author
Niranjan Kirloskar, Managing Director, Fleetguard Filters, is focused on driving innovation, operational excellence, and long-term business growth through strategic and people-centric leadership. With a strong foundation in ethics and forward-thinking decision-making, he champions a culture of collaboration, accountability, and technological advancement.

Concrete

Cement’s Next Fuel Shift

Published

9 hours ago

May 15, 2026

admin

Jignesh Kindaria highlights how Thermal Substitution Rate (TSR) is emerging as a critical lever for cost savings, decarbonisation and competitive advantage in the cement industry.

India is simultaneously grappling with two crises: a mounting waste emergency and an urgent need to decarbonise its most carbon-intensive industries. The cement sector, the second-largest in the world and the backbone of the nation’s infrastructure ambitions, sits at the centre of both. It consumes enormous quantities of fossil fuel, and it has the technical capacity to consume something else entirely: the waste our cities cannot get rid of.
According to CPCB and NITI Aayog projections, India generates approximately 62.4 million tonnes of municipal solid waste annually, with that figure expected to reach 165 million tonnes by 2030. Much of this waste is energy-rich and non-recyclable. At the same time, cement kilns operate at material temperatures of approximately 1,450 degrees Celsius, with gas temperatures reaching 2,000 degrees. This high-temperature environment is ideal for co-processing, ensuring the complete thermal destruction of organic compounds without generating toxic residues. The physics are in our favour. The infrastructure is not.
Pre-processing is not the support act for co-processing. It is the main event. Get the particle size wrong, get the moisture wrong, get the calorific value wrong and your kiln thermal stability will suffer the consequences.

The regulatory push is real
The Solid Waste Management (SWM) Rules 2026 mandate that cement plants progressively replace solid fossil fuels with Refuse-Derived Fuel (RDF), starting at a 5 per cent baseline and scaling to 15 per cent within six years. NITI Aayog’s 2026 Roadmap for Cement Sector Decarbonisation targets 20 to 25 per cent Thermal Substitution Rate (TSR) by 2030. Beyond compliance, every tonne of coal replaced by RDF generates measurable carbon reductions which is monetisable under India’s emerging Carbon Credit Trading Scheme (CCTS). TSR is no longer a sustainability metric. It is a financial lever.
Yet our own field assessments across multiple Indian cement plants reveal a sobering reality: the primary barrier to scaling AFR adoption is not waste availability. It is the fragmented and under-engineered pre-processing ecosystem that sits between the waste and the kiln.

Why Indian waste is a different engineering problem
Indian municipal solid waste is not the material that imported shredding equipment was designed for. Our waste streams frequently exceed 40 per cent to 50 per cent moisture content, particularly during monsoon cycles, saturated with abrasive inerts including sand, glass, and stone. Plants relying on imported OEM equipment face months of downtime awaiting proprietary spare parts. Machines built for segregated, low-moisture waste fail quickly and disrupt the entire pre-processing operation in Indian conditions.
The two most common failures we observe are what I call the biting teeth problem and the chewing teeth problem. Plants relying solely on a primary shredder reduce bulk waste to large fractions, but the output remains too coarse for stable kiln combustion. Others attempt to use a secondary shredder as a standalone unit without a primary stage to pre-size the feed, leading to catastrophic mechanical failure. When both stages are present but mismatched in throughput capacity, the system becomes a bottleneck. Achieving the 40 to 70 tonnes per hour required for meaningful coal displacement demands a precisely coordinated two-stage process.

Engineering a made-in-India answer
At Fornnax, our response to these challenges is grounded in one principle: Indian waste demands Indian engineering. Our systems are built around feedstock homogeneity, the holy grail of kiln stability. Consistent particle size and predictable calorific value are the foundation of stable kiln combustion. Without them, no TSR target is achievable at scale.
Our SR-MAX2500 Dual Shaft Primary Shredder (Hydraulic Drive) processes raw, baled, or loosely mixed MSW, C&I waste, bulky waste, and plastics, reducing them to approximately 150 mm fractions at throughputs of up to 40 tonnes per hour. The R-MAX 3300 Single Shaft Secondary Shredder (Hydraulic Drive), introduced in 2025, takes that primary output and produces RDF fractions in the 30 to 80 mm range at up to 30 tonnes per hour, specifically optimised for consistent kiln feeding. We have also introduced electric drive configurations under the SR-100 HD series, with capacities between 5 and 40 tonnes per hour, already operational at a leading Indian waste-processing facility.
Looking ahead, Fornnax is expanding its portfolio with the upcoming SR-MAX3600 Hydraulic Drive primary shredder at up to 70 tonnes per hour and the R-MAX2100 Hydraulic drive secondary shredder at up to 20 tonnes per hour, designed specifically for the large-scale throughput that higher TSR ambitions require.

The investment case is now
The 2070 Net-Zero target is not a distant goal for India’s cement sector. It starts today, with decisions being made on the plant floor.
The SWM Rules 2026 are already in effect, requiring cement plants to replace coal with RDF. Carbon credit markets are opening up, and coal prices are not going to get cheaper. Every tonne of coal a cement plant replaces with waste-derived fuel saves money on one side and generates carbon credit revenue on the other. Pre-processing infrastructure is no longer just a compliance requirement. It is a business investment with a measurable return.
The good news is that nothing is missing. The technology works. The waste is available in every Indian city. The government has provided the policy direction. The only thing standing between where the industry is today and where it needs to be is the commitment to build the right infrastructure.
The cement companies that move now will not just meet the regulations. They will be ahead of every competitor that waits.

About the author
Jignesh Kundaria is the Director and CEO of Fornnax Technology. Over an experience spanning more than two decades in the recycling industry, he has established himself as one of India’s foremost voices on waste-to-fuel technology and alternative fuel infrastructure.