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Digitalising the value chain could be a game changer

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Ashok Kumar Dembla, President & Managing Director, Humboldt Wedag India, talks about the key areas where carbon emission reduction is feasible and how they are pioneering solutions that would drive sustainability while maintaining operational efficiency.

Tell us about the prominent areas in the cement manufacturing process where carbon emission reduction is greatly possible.
Cement production emerges as one of the highest-emitting industries, accounting for approximately 7 per cent of global CO2 emissions. As the world strives to achieve net-zero emissions by 2050 to combat climate change effectively, rapid decarbonisation of the cement and concrete industry becomes imperative.
The conventional production process of cement relies heavily on fossil fuels, primarily coal, which releases substantial CO2 emissions into the atmosphere. Therefore, reducing the reliance on fossil fuels by substituting them with low-carbon alternative fuels, such as biomass and waste-derived fuels and incorporating alternative raw materials in cement production is the way forward.
Cement manufacturers are already exploring alternatives such as fly ash, metal slag, or calcined clay to replace clinker in their production processes. Blended cement production offers a solution to mitigate carbon emissions and high energy consumption related to clinker production. Replacing a portion of the clinker with fly ash or blast furnace slag, lowers the clinker/cement ratio without compromising the properties of Portland cement.

As technology leaders for the cement industry, what are the products and solutions offered by you that can make cement manufacturing sustainable?
KHD offers a wide variety of technologies that can be utilised to reduce carbon emissions. The technologies are developed with the aim of following decarbonisation pathways set out by Global Cement and Concrete Association to help cement plants become cleaner alongside reducing the operation cost.
Oxyfuel: Oxyfuel technology increases the concentration of CO2 in the exhaust gas and so makes it simpler and less costly to capture. It’s thus currently the most techno-commercially feasible pathway to carbon capture at scale. CO2 concentration of standard cement plant exhaust gases is low (mostly below 20 per cent), which reduces the efficacy of capture technologies. Raising the concentration of CO2 in the exhaust gas is therefore an important step toward establishing commercially viable CCUS solutions at scale and this is where KHD’s oxyfuel combustion concept comes into play.
Clay Calcination: Cement producers around the world are pursuing clay calcination projects as part of efforts to reduce the carbon intensity of their cement but how best to implement these projects depends on a range of site-specific factors.
KHD ProMax®: KHD ProMax is a suite of Cloud-based digital solutions that connects to and delivers real-world optimisation of cement plant equipment and processes. KHD ProMax® is customisable and grows as per the customer’s requirements. We are also continuously developing new functionalities in response to customer’s requests. It begins, however, with a secure connection from the plant to the Cloud via KHD ProMax Edge.
Pyrorotor®: The Pyrorotor® is our most advanced technology for utilising alternative fuels. Its innovative design enables very high thermal substitution rates with almost no fuel pre-processing, even when dealing with low-quality alternative fuels. Available as a modular add-on to any calciner, the Pyrorotor® delivers unmatched fuel flexibility and reduces fuel costs. It also helps cut carbon emissions associated with the combustion of fossil fuels. The results are good for the bottom line and support the pathway
to decarbonisation.
Roller Press: When compared to other grinding options, the roller press is simply the most energy-efficient of the lot. It is also flexible and can be used to grind various feed materials, supporting the use of alternative cementitious materials and the production of lower-carbon composite cements.

Are your solutions customisable as per your customer’s requirements?
Yes, we always understand the basic requirements of the customer and then based on feasibility, we are offering them what best suits them to achieve their goal. For example, the client has to provide the composition and granulometry of AFR and percentage planned to be used along with its calorific Value and moisture, we accordingly design our pyro-process system including the need of by-pass required and design of calciner and PH fan etc. In case a higher percentage of AFR is envisaged, we incorporate the pyro-rotor from the project stage itself.

Which are the key parameters where the cement industry can use decarbonisation consultation?
Consultants can be useful to do complete surveys of availability of alternative fuels and their quality. Accordingly, consultants can make complete feasibility of using AFR keeping logistic costs involved and long-term agreement with producers of AFR. Consultants can also be useful to identify alternative binding materials like slag and fly-ash which are very useful to reduce clinker consumption in final product e.g. slag cement, fly-ash cement etc. However, technology related to preparation of alternative fuels and firing is available with various technology suppliers and consultants have limited role in technology areas.

Tell us more about the carbon capture technology for cement plants.
The type of fuel used in cement manufacture directly impacts on CO2 emissions, with coal accounting for around 60 per cent to 70 per cent of CO2 emissions from cement installations. Therefore, the large amount of carbon dioxide emitted during the cement manufacturing process accounts for 5 per cent of the total emissions of CO2 from stationary sources worldwide and is a cause of great concern and must be tackled in order to comply with current legislation.
Several technologies are available and have been proposed for the separation of CO2 from the flue gases from new and existing plants with retrofit capture units.
Amine-Scrubbing: Amine-based carbon capture is a regenerative process using an amine solvent to remove CO2 from flue gas. Reversing the reaction releases pure CO2 for capture and frees up the solvent for re-use. The technology uses an amine solvent to scrub CO2 from the flue gas. The flue gas is initially fed into an absorption column, where the solvent selectively removes the CO2. The CO2-rich solvent is then fed into a desorber column, where it is heated to release the CO2, which is captured before being sent for geological storage or onward use. This regeneration process is highly energy intensive, however, posing an economic and environmental challenge.
The regenerated solvent is cooled and returned to the absorption column.
Oxy-firing: In oxy-firing technology, the combustion air is replaced by reasonably pure oxygen from an air separation unit (ASU), with the CO2-rich flue gas being recycled to moderate the flame temperature. Because of the high percentage of CO2 in flue gas originating from the calcination process, combustion in a CO2/O2 atmosphere looks like the best option for CO2 reduction in a cement plant. The main advantage of oxy-firing for cement plants is the low oxygen consumption with only 1/3rd of the amount of oxygen needed per tonne of CO2 captured compared to a coal-fired boiler.
Calcium looping: Calcium looping technology is also known as the regenerative carbon cycle. This process works on two reversible chemical reactions: carbonation and calcination. It removes CO2 from the flue gases of a cement plant using a Calcium oxide (CaO) sorbent.
These are still under evolution phase and all stakeholders are actually pushing the stakes.

How important is it for cement plants to become modernised and digitally equipped today?
Digitalisation can help achieve material cost savings, reduce inventory carrying costs, increase equipment uptime and availability, reduce maintenance planning time and costs, improve health, safety and environmental (HSE) compliance, enable faster real time decisions, data driven problem solving, and establish clear linkages to initiatives, performance, and accountability. While digitalisation serves numerous advantages, care needs to be administered while implementing the solutions to realise its true potential. It becomes critically important to define the objectives at the beginning- starting small through pilot projects and scaling up gradually through a designated reference factory.
Digitalisation is imperative for a highly commoditised and competitive industry of cement. Steep decline in the cost of computing technology, data storage and network bandwidth have streamlined the implementation of pilot projects and scaling up technological solutions. Digitalising the value chain could be a game changer for the cement companies and improve profitability while realising a sustainable competitive advantage.

What are the major challenges that you face in context to providing decarbonisation solutions?
Decarbonising cement and concrete production face several challenges and barriers that hinder the transition to low-carbon practices. Technological challenges and research gaps exist, as developing and scaling up innovative technologies for carbon capture, alternative materials and energy-efficient processes requires further research and development. Investment and financing constraints pose another barrier, as the upfront costs of adopting decarbonisation technologies and implementing sustainable practices can be substantial. Resistance to change and industry practices rooted in traditional methods and established norms can impede the adoption of new technologies and practices. Additionally, a lack of awareness and education among industry stakeholders about the benefits and feasibility of decarbonisation can slow down progress. Overcoming these challenges requires collaborative efforts, increased research funding, supportive policies and educational campaigns to drive the necessary transformation in the cement and concrete industry.

How do you envision the future of carbon emissions from the cement industry?
The cement and concrete industry have established new targets to lower and even eliminate emissions, such as those set by the Global Cement and Concrete Association (GCCA). These targets aim for a 20 per cent reduction of CO2 per metric ton of cement and a 25 per cent reduction of CO2 per cubic meter of concrete by 2030 compared to 2020 levels. The GCCA calls for complete decarbonisation by 2050. All the parties involved are maximising their resources and approach to achieve these benchmarks.

  • –Kanika Mathur

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Adani’s Strategic Emergence in India’s Cement Landscape

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3 days ago

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September 16, 2025

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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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1 month ago

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August 16, 2025

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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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Driving Measurable Gains

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1 month ago

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August 16, 2025

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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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