Concrete

Energy optimisation is an ongoing process

Published

1 year ago

February 12, 2025

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Ashok Dembla, President and Managing 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 KHD, 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

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

6 days ago

June 5, 2026

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

Concrete

Building a Greener Future Together

Published

6 days ago

June 4, 2026

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

1 week ago

June 1, 2026

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.