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Electrifying the Decarbonisation Process

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Max Tschurtschenthaler, Global Business Unit Manager, Cement, Process Industries, ABB and Joonas Rauramo, CEO, Coolbrook, explore the potential of an innovative technology venture set to be deployed in India to replace traditional fossil fuels with renewable electricity in cement production, ultimately reducing carbon emissions and satisfying customer demands.

As the second largest cement producer in the world, the demands on India from the domestic and global markets see a constant surge as cities and countries grow and population rises. Meanwhile, the opportunities for high productivity and sustainable manufacturing are also there for forward-thinking operators.
From India’s infrastructure focus to a higher allocation for affordable rural housing under the Pradhan Mantri Awas Yojana – Gramin (PMAY-G), multiple factors are pushing demand for cement in India. Rating agency Crisil has estimated this demand will lead to an incremental sales volume increase of 30-35 million tonnes (Mt) in the 2023-24, taking the total volume to roughly 425 Mt per year. Globally, the cement industry contributes to CO2 emissions of 7–8 per cent, yet its outputs are essential to modern built environments. It is well-known that reducing carbon emissions in cement production is a challenge, as the kiln’s high temperatures and chemical reactions during limestone calcination make it a complex process to decarbonise.
Between 2015 and 2021, the International Energy Agency (IEA) saw the CO2 intensity of cement production witness an annual increase of about 1.5 per cent. To achieve the net zero emissions globally by 2050 target set by IEA, this intensity needs to be reduced by 3 per cent each year until 2030.
Unfortunately, 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 India’s existing cement production. As a result, the IEA has called for dedicated efforts to reduce carbon emissions in the cement industry, which could include the reduction of clinker-to-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.

RotoDynamic Heater technology
However, there is an upside to these challenges. On the one hand, at the recent COP28, major Indian cement companies reiterated their commitment to reducing emissions in their journey to becoming net zero by relying on CCUS. The Global Cement and Concrete Association (GCCA) also suggested that CCUS is expected to contribute around 36 per cent of net emission reduction in the cement industry by 2050 under the global roadmap to net zero. Similarly, the Indian cement sector is expected to follow suit.
On the other hand, technological innovation makes decarbonisation in the cement industry possible and helps to accelerate development. Specifically, ABB and Coolbrook, a technology and engineering company, have partnered to advance technology to help decarbonise the chemicals, cement and steel industries. These industries are responsible for 70 per cent, or 6000 Mt annually, of industrial CO2 emissions. The cooperation aims to develop innovative solutions to reduce CO2 emissions in these industries, which will help combat climate change.
The said innovation involves Coolbrook’s proprietary RotoDynamic technology, which replaces the burning of fossil fuels in high-temperature industry processes with renewable electricity as the energy source, with ABB’s motors, power electronics and process automation for optimised energy efficiency and operational processes. By developing and scaling up RotoDynamic technology for use in emission-heavy industries such as cement manufacturing, Coolbrook and ABB aim to cut carbon emissions annually by up to 2400 Mt.
Reaching higher temperatures through electrification
The cement production process involves the chemical reaction of limestone with multiple components to produce clinker, which is responsible for around 60 per cent of CO2 emissions. The remaining 40 per cent of emissions are caused during the activation of the chemical process by burning fossil fuels. Heavy industry currently relies on these polluting fuels since traditional electric heaters cannot generate the high temperatures required for the process, which can reach up to 1700°C.
The RotoDynamic Heater (RDH), developed by Coolbrook, can achieve temperatures of up to 1700°C, powered by electricity and without using fossil fuels. This makes it an attractive alternative to fossil-fired furnaces and kilns for producing cement, iron, steel, and chemicals. Unlike traditional electric heating solutions, the RDH is a turbo machine that can internally increase the gas temperature, significantly increasing the temperature. The gas is accelerated to supersonic velocity and then decelerated very quickly in a diffuser, converting electric energy first into kinetic and finally into thermal energy. The acceleration/deceleration process can be performed multiple times, resulting in higher temperatures than existing electric heaters.
Unlike traditional electric heating technologies, the RDH is compact in size and can be retrofitted easily in any brownfield industrial process facility, including cement plants. The RDH can be used in multiple applications, such as pre-heating feedstocks and heat provision to the pre-calciner, where most fuel is used. The electrification unit aims to replace the burner in the main kiln, where temperatures exceed 1700°C.

Energy efficiency and emissions
Coolbrook’s RotoDynamic Heater unit has an exceptional efficiency of up to 95 per cnet in converting electricity to heat, resulting in negligible losses from excess heat generation. The absence of combustion eliminates the need to burn fuel, thereby minimising sulphur oxide, nitrogen oxide, and particle emissions produced during manufacturing.
Reducing the carbon footprint of hard-to-abate sectors like cement requires investment in specific technologies and integrating clean energy into emissions-heavy processes. Coolbrook’s RDH solution generates heat powered by renewable energy sources, reducing dependence on imported fuels and bypassing supply chain and logistics issues, thereby reducing operational expenses.
KPMG has estimated that Coolbrook’s technologies could reduce CO2 emissions by over 2000 Mt annually, equivalent to about 7 per cent of human-made CO2 emissions or approximately 30 per cent of industrial CO2 emissions. The RDH project aims to replace the burning of industrial fossil fuels globally. Testing of the technology began at Coolbrook’s pilot facility in the Netherlands in December 2022 and during 2023 completed the first test phases and demonstrated the technology’s capabilities for industrial use in high-temperature process heating. The technology is now moving forward to industrial scale projects at customer sites. The tests exceeded the level of 1,000°C, which is already several hundred degrees above the temperature range of conventional resistive heaters.

Performance management
While Coolbrook’s RotoDynamic technology offers the potential for decarbonising cement industry processes, ABB brings a range of expertise to such partner relationships; automation, electrification, digital solutions, motors, drives. As the turbine technologies generate more heat the faster they run, they require particular controls over speed. ABB can enable stable temperatures throughout the cement production process with variable speed drives and motors that can be adapted to the size and application of each RDH unit, as well as a control system that can be seamlessly integrated into the existing cement plant’s system and provide advanced data analytics.
Preventing unscheduled downtime is also critical to maximising asset life and optimising production and quality control. ABB’s motor and drive solutions are connected to monitoring equipment that continually assesses performance and alerts the operator to potential failures, facilitating predictive maintenance.

Making progress on the journey
According to a cement sector-specific report by the Delhi-based think tank Centre for Science and Environment, CCUS is being recommended as one of the pathways for reducing emissions in the Indian cement sector. This is why India is already interested in the ABB/Coolbrook RDH solution, even as we see a push to develop domestic wind, solar and hydropower capacity to reduce reliance on fossil fuels and promote energy independence.
This strategy focuses on reducing CO2 emissions in the long run instead of prioritising short-term cost savings. Customers are willing to pay more upfront for electrification solutions that meet environmental targets and the growing demand for CO2-free products. Hence, ABB and Coolbrook’s pre-engineered and pre-fabricated electrification technologies can potentially revolutionise the decarbonisation of heavy industries.
In conclusion, these technologies replace polluting fossil fuels with renewable electricity, leading to cleaner, safer, and more efficient production of essential materials like concrete. Manufacturers can use these technologies to meet emissions targets, protect their license to operate, and meet the growing demand for green cement.

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.

India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.

Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:

  • September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
  • December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
  • August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
  • April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
  • Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
  • Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
  • Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
  • Orient Cement: It would serve as a principal manufacturing facility following the merger.

Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:

  • By FY 2026: Reach 118 MTPA
  • By FY 2028: Target 140 MTPA

These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).

Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.

Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.

Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.

Challenges potentially include:

  • Integration challenges across systems, corporate cultures, and plant operations
  • Regulatory sanctions for pending mergers and new capacity additions
  • Environmental clearances in environmentally sensitive areas and debt management with input price volatility

When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.

Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.

About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.

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Concrete

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

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PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.

Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

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Concrete

Driving Measurable Gains

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Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.

Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.

Beyond energy efficiency, the retrofit significantly improved operational parameters:

  • Lower thermal stress on equipment
  • Extended lubricant drain intervals
  • Reduction in CO2 emissions and operational costs

These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.

Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:

  • Enhanced component protection
  • Extended oil life under high loads
  • Stable performance across fluctuating temperatures

By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.

Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.

A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

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