Concrete

Energy optimisation is an ongoing process

Published

1 week ago

February 12, 2025

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Ashok Dembla, Director, KhD Humboldt, in conversation with Kanika Mathur about the use of technology in the grinding process.

The cement industry, responsible for nearly seven per cent of global CO2 emissions, faces a pressing challenge: balancing growth with sustainability. As companies strive for net-zero emissions, innovations in alternative fuels, carbon capture, and energy efficiency are reshaping the sector. From blended cement to cutting-edge kiln electrification, the industry is moving toward a future beyond carbon. In this interview, ICR explores the evolving technologies and strategies driving cement’s decarbonisation journey.

Tell us about cement beyond carbon.
The cement industry contributes approximately 7 per cent of global carbon dioxide emissions, making it one of the largest industrial contributors to climate change. This places a great responsibility on the industry to reduce emissions and promote sustainability. It becomes a moral obligation for us to work toward carbon neutrality or even carbon negativity to protect the environment and ensure a sustainable future for humanity.
Many companies in the cement industry have already pledged to achieve net-zero emissions by 2050 or beyond. At KHP, our focus is on technological innovation to achieve the vision of cement beyond carbon. Cement remains an essential material for infrastructure development and economic growth, and the challenge is to meet this demand while minimising its carbon footprint.
Currently, conventional methods like producing blended cement, which uses less clinker and more fly ash or slag, have been instrumental in reducing emissions. Additionally, technologies like Waste Heat Recovery (WHR) systems have seen significant adoption in India. WHR systems allow plants to recover and reuse heat, improving efficiency. Another method is the use of Alternative Fuels and Raw materials (AFR). While the industry was at just 4 per cent usage of AFR previously, we have now reached around 7 per cent, with an ultimate goal of surpassing 35 per cent, which is the global benchmark.
However, these conventional methods alone will not suffice to achieve complete decarbonisation. Advanced technologies are being explored, such as capturing carbon dioxide from exhaust gases, improving system efficiencies, and implementing oxy-fuel combustion or electrification of kilns. While these technologies are still in various stages of development, I believe they will become economically viable after 2030. The industry’s focus is on continuous research and development to integrate these technologies into our processes effectively.

How is your technology adapting to changing fuels and raw materials?
The use of alternative fuels and raw materials (AFR) is continuously evolving within the cement industry. As a machinery supplier, we are adapting to these changes by providing advanced solutions for handling and processing AFR. One of our most significant innovations is the PyroRotor, an equipment designed specifically for feeding up to 85 per cent of alternative fuels into the pyroclone, which is far beyond what conventional methods can achieve. This has greatly enhanced our ability to replace traditional fuels with more sustainable alternatives.
In addition, we have developed solutions to address nitrogen oxide (NOx) emissions, a critical environmental concern. Our NOx reduction equipment significantly minimises NOx generation during the production process, helping plants meet stringent regulatory requirements.
Optimisation is another critical focus area. Through digitisation and advanced process control systems like PRO-MAX, we are able to optimise the entire cement production process. This system includes kiln and mill control modules, allowing plants to operate more efficiently and reduce both thermal and electrical energy consumption.
Globally, the industry is also moving toward more advanced technologies, such as increasing oxygen content in fuel firing and capturing carbon dioxide directly from flue gases. While these technologies are already being implemented in some European plants, they require significant capital investment and governmental support. India is also taking steps in this direction, with plans for model plants to showcase the viability of these advanced solutions.

Do any of your solutions have an impact on energy utilisation in cement plants?
Energy utilisation in cement plants involves two main types: thermal energy and electrical energy. On the thermal energy front, significant progress has been made over the past decade. Previously, plants required around 750 kilocalories per kilogram of clinker. Today, this has been reduced to 685 kilocalories or even lower, thanks to continuous improvements in process efficiency.
For electrical energy, we have optimised systems like the roller press, which enhances the efficiency of raw material grinding and cement grinding. These advancements have significantly reduced energy consumption per ton of clinker produced.
Energy optimisation is an ongoing process. By integrating advanced technologies and optimising plant operations, we aim to achieve even greater reductions in energy consumption, contributing to both cost savings and environmental sustainability.

How do you see the journey toward net zero unfolding, and what is your perspective on this?
The journey toward net zero is both challenging and rewarding. One of the critical areas we have focused on is the increased use of alternative fuels and raw materials (AFR). The technology to utilise AFR is available, but its successful implementation depends on a well-organised system for waste collection and processing.
In India, progress has been made in cities like Indore and Bengaluru, where systems for waste segregation and preparation are more developed. However, there is still a long way to go to make this a common practice across the country. Government support is crucial in this regard, especially in establishing efficient logistics systems to transport waste from its generation point to cement plants for use as fuel.
Collaboration between industries, government bodies, and city administrations is essential to achieve the full potential of AFR utilisation. The ultimate goal is to make the use of AFR economically viable while ensuring that the logistics and supply chain challenges are effectively addressed.
Net zero is not just a technological goal; it is a systemic change that requires the entire ecosystem to work together. While the industry has made significant strides, much work remains to be done to make net zero a reality.

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Concrete

Global Start-Up Challenge Launched to Drive Net Zero Concrete Solutions

Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations

Published

9 hours ago

February 21, 2025

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Start-ups worldwide are invited to contribute to the global cement and concrete industry’s efforts to reduce CO2 emissions and combat climate change. The Global Cement and Concrete Association (GCCA) and its members are calling for applicants for the Innovandi Open Challenge 2025.

Now in its fourth year, the Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations that help decarbonise the cement and concrete industry.

The challenge is seeking start-ups working on next-generation materials for net-zero concrete, such as low-carbon admixtures, supplementary cementitious materials (SCMs), activators, or binders. Innovations in these areas could help reduce the carbon-intensive element of cement, clinker, and integrate cutting-edge materials to lower CO2 emissions.

Thomas Guillot, GCCA’s Chief Executive, stated, “Advanced production methods are already decarbonising cement and concrete worldwide. Through the Innovandi Open Challenge, we aim to accelerate our industry’s progress towards net-zero concrete.”

Concrete is the second most widely used material on Earth, and its decarbonisation is critical to achieving net-zero emissions across the global construction sector.

Concrete

StarBigBloc Acquires Land for AAC Blocks Greenfield Facility in Indore

The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands.

Published

2 days ago

February 19, 2025

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StarBigBloc Building Material, a wholly-owned subsidiary of BigBloc Construction, one of the largest manufacturers of Aerated Autoclaved Concrete (AAC) Blocks, Bricks and ALC Panels in India has acquired land for setting up a green field facility for AAC Blocks in Indore, Madhya Pradesh. Company has purchased approx. 57,500 sq. mts. land at Khasra No. 382, 387, 389/2, Gram Nimrani, Tehsil Kasrawad, District – Khargone, Madhya Pradesh for the purpose of AAC Blocks business expansion in central India. The total consideration for the land deal is Rs 60 million and Stamp duty.

StarBigBloc Building Material Ltd currently operates one plant at Kheda near Ahmedabad with an installed capacity of 250,000 cubic meters per annum, serving most part of Gujarat, upto Udaipur in Rajasthan, and till Indore in Madhya Pradesh. The capacity utilisation at Starbigbloc Building Material Ltd for the third quarter was 75 per cent. The planned expansion will enable the company to establish a stronger presence in Madhya Pradesh and surrounding regions. Reaffirming its commitment to the Green Initiative, it has also installed a 800 KW solar rooftop power project — a significant step toward sustainability and lowering its carbon footprint.

Narayan Saboo, Chairman, Bigbloc Construction said “The AAC block industry is set to play a pivotal role in India’s construction sector, and our company is ready for a significant leap forward. The proposed expansion in Indore, Madhya Pradesh aligns with our growth strategy, focusing on geographic expansion, R&D investments, product diversification, and strategic branding and marketing initiatives to enhance visibility, increase market share, and strengthen stakeholder trust.”

Bigbloc Construction has recently expanded into construction chemicals with Block Jointing Mortar, Ready Mix Plaster, and Tile Adhesives, tapping into high-demand segments. The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands, ensuring superior bonding, strength, and performance.

In May 2024, the board of directors approved fund-raising through SME IPO or Preferential issue to support expansion plans of Starbigboc Building Material subject to requisite approvals and market conditions, Starbigboc Building Material aims to expand its production capacity from current 250,000 cubic meters per annum to over 1.2 million cubic meters per annum in the next 4-5 years. Company is targeting revenues of Rs 4.28 billion by FY27-28, with an expected EBITDA of Rs 1.25 billion and net profit of Rs 800 million. In FY23-24, the company reported revenues of Rs 940.18 million, achieving a revenue CAGR of over 21 per cent in the last four years.

Incorporated in 2015, BigBloc Construction is one of the largest and only listed AAC block manufacturer in India, with a 1.3 million cbm annual capacity across plants in Gujarat (Kheda, Umargaon, Kapadvanj) and Maharashtra (Wada). The company, which markets its products under the ‘NXTBLOC’ brand, is one of the few in the AAC industry to generate carbon credits. With over 2,000 completed projects and 1,500+ in the pipeline, The company’s clients include Lodha, Adani Realty, IndiaBulls Real Estate, DB Realty, Prestige, Piramal, Oberoi Realty, Tata Projects, Shirke Group, Shapoorji Pallonji Group, Raheja, PSP Projects, L&T, Sunteck, Dosti Group, Purvankara Ltd, DY Patil, Taj Hotels, Godrej Properties, Torrent Pharma, GAIL among others.

Concrete

World Cement Association Calls for Industry Action

The cement industry is responsible for 8 per cent of global CO2 emissions

Published

3 days ago

February 18, 2025

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The cement industry is responsible for 8 per cent of global CO2 emissions—a staggering figure that demands urgent action, particularly as 2024 marked the first year the planet surpassed the 1.5°C global warming limit. Recognising this critical juncture, the World Cement Association (WCA) has released a landmark White Paper, “Long-Term Forecast for Cement and Clinker Demand”, which projects a sharp decline in long-term cement and clinker demand. By 2050, annual clinker production is expected to fall below 1 Gt from its current level of 2.4 Gt, with far-reaching implications for global carbon emissions and the viability of carbon capture projects.

WCA CEO Ian Riley underscores the complexity of this challenge:
“Carbon capture remains a vital tool for tackling emissions in hard-to-abate sectors like cement. However, flawed demand assumptions and the fragmented nature of cement production globally could undermine the feasibility of such projects. Industry stakeholders must rethink their strategies and embrace innovative, sustainable practices to achieve meaningful emissions reductions.”

Key Findings from the WCA White Paper
The WCA White Paper provides a comprehensive roadmap for the industry’s decarbonisation journey, highlighting the following critical insights:
1. Declining Cement and Clinker Demand: Global cement demand is expected to drop to approximately 3 billion tonnes annually by 2050, while clinker demand could decline even more steeply, reaching just 1.5 billion tonnes annually.
2. Implications for Carbon Capture and Storage (CCS): With reduced clinker production, the need for CCS is expected to decline, necessitating a shift in investment and policy priorities.
3. Alternative Materials and Clinker-Free Technologies: These innovations hold transformative potential for reshaping demand patterns and cutting emissions.
4. Supply Chain Optimisation: Enhancing logistics and reducing waste are key strategies for adapting to evolving market dynamics.

A Path to Lower Emissions
Clinker production, the largest source of CO2 emissions in cement manufacturing, generates one-third of emissions from fuel combustion and two-thirds from limestone decomposition. According to our white paper, transitioning to lower-carbon fuels could reduce specific fuel emissions per tonne of clinker by nearly 70% by 2050. Overall CO2 emissions from cement production are forecast to decline from 2.4 Gt in 2024 to less than 1 Gt by 2050, even before factoring in carbon capture technologies.

Ian Riley emphasised: “This white paper provides actionable insights to help the cement industry accelerate its decarbonisation journey. By prioritising innovation and collaboration, the industry can achieve substantial emissions reductions and align with global climate goals.”