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Green cement: Smart strategy

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As India races to build its future, green cement emerges as a powerful tool to balance growth with sustainability. Through innovative technologies and supportive policies, the cement industry is sculpting a low-carbon pathway for construction—toward climate-resilient infrastructure.

India’s rapid urbanisation and infrastructure development have positioned it as the second-largest cement producer globally. However, this growth comes with environmental challenges, as the cement industry contributes approximately six per cent of the country’s total greenhouse gas emissions. In response, the industry is increasingly turning to green cement—a sustainable alternative that aims to reduce the environmental footprint of construction activities.
According to a report by Ernst & Young Parthenon (published February 2025), India is positioning itself as a pivotal force in the global green hydrogen economy, leveraging hydrogen’s potential as a clean and adaptable energy source to drive its decarbonisation. The National Green Hydrogen Mission, launched in January 2023, encourages the production and utilisation of this clean energy source. Green hydrogen is set to play a vital role in decarbonising sectors like steel, cement, and transportation, significantly reducing the nation’s carbon footprint.
Hard-to-abate industries like steel, cement, power and utilities, oil and gas, auto-OEMs are high energy consuming and high emitting. These industries are pivotal for economic growth and hence its quintessential for them to decarbonise their production processes if India is to meet its emissions-reduction goals. The emission contribution of these sectors is expected to grow in the coming years. EY analysis indicates that the critical manufacturing sectors would reach a mark of ~2 gigaton CO2 emissions annually in the next 15 years.
Green cement minimises emissions by using alternative materials and low-carbon production techniques. Primary raw materials for this include industrial waste products like blast furnace slag and fly ash, reducing the clinker-to-cement ratio and an effort to close the loop across the cement production value chain as well.
Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, says, “The future of green cement in global construction is set for rapid transformation, driven by sustainability goals and evolving industry demands. With stricter carbon regulations and a growing push for green-certified buildings, the shift toward low-carbon materials is accelerating. Green cement offers more than just environmental benefits. Its superior tensile strength and corrosion resistance make it a viable alternative to traditional cement. Builders are increasingly recognising its role in enhancing long-term project value while reducing carbon footprints.”
India’s cement industry, the world’s second-largest, plays a pivotal role in the nation’s infrastructure and economic development. However, it also contributes approximately 5.8 per cent of the country’s CO2 emissions as of 2022. Recognising this environmental challenge, India has committed to achieving net-zero emissions by 2070, with an interim goal of sourcing 50 per cent of its electricity from renewable sources by 2030. The transition to green cement—produced using alternative fuels and raw materials—offers a viable pathway to reduce the industry’s carbon footprint while supporting sustainable growth.

Understanding green cement
Green cement refers to cementitious materials produced using sustainable methods, incorporating alternative raw materials and energy-efficient processes. Unlike traditional Portland cement, which relies heavily on clinker—a primary source of CO2 emissions—green cement utilises industrial by-products such as fly ash, slag and silica fume. These substitutions not only reduce carbon emissions but also enhance the durability and performance of the final product.
The IMARC Group’s report on the India Green Cement Market highlights the pivotal role of alternative raw materials in driving the sector’s growth. In 2024, the market was valued at USD 1.6 billion and is projected to reach USD 2.8 billion by 2033, exhibiting a CAGR of 6.11 per cent during 2025–2033. This growth is largely attributed to the increasing incorporation of industrial by-products such as fly ash, slag and silica fume in green cement production. These materials, by substituting traditional inputs like limestone and clay, not only reduce the reliance on finite natural resources but also lower the carbon emissions associated with cement manufacturing. Additionally, certain green cement formulations have the capability to absorb carbon dioxide during the curing process, further mitigating their environmental impact.
The report also underscores a broader industry shift towards sustainable construction practices in India. The adoption of alternative raw materials aligns with national efforts to reduce the environmental footprint of the construction sector. By leveraging industrial waste products, the green cement industry not only addresses waste management challenges but also contributes to the creation of more sustainable building materials. This approach supports India’s commitment to environmental sustainability and positions green cement as a viable solution for eco-conscious construction projects.

Market dynamics: Growth and projections
The Indian green cement market has witnessed significant growth, valued at US$ 2.31 billion in 2024 and projected to reach US$ 3.28 billion by 2030, growing at a CAGR of 5.85 per cent. This upward trajectory is driven by increasing environmental awareness, government initiatives promoting sustainable construction, and the rising demand for eco-friendly building materials.
A key driver of the Indian green cement market is the growing environmental awareness among consumers, builders and developers. Heightened by visible climate change impacts, media coverage, and educational initiatives, this awareness has fuelled demand for eco-friendly construction materials that reduce the carbon footprint. Green cement, with its lower embodied carbon, reduced energy consumption during production, and responsible use of raw materials, is increasingly preferred over traditional alternatives. Certifications such as Leadership in Energy and Environmental Design (LEED) and recognition from the Green Building Council of India (GBCI) have further incentivised the use of sustainable materials, motivating developers to
adopt green cement in order to meet regulatory and client expectations.
Manoj Rustagi, Chief Sustainability Officer, JSW Cement says, “In India, in the last couple of years, there have been many policy interventions which have been initiated. One of them, namely the carbon market is under notification; others like Green Public Procurement, Green Cement taxonomy and National CCUS Mission are in the advanced stages and are expected to be implemented in the next couple of years.”
This shift aligns with India’s broader sustainability goals. The country, one of the world’s largest producers of renewable energy, had achieved over 175 GW of renewable energy capacity—including solar and wind power—by 2024. With an ambitious target of reaching 500 GW by 2030, the focus on reducing environmental impact across sectors, including construction, is stronger than ever. As a result, green cement is emerging as a crucial component in India’s transition toward sustainable infrastructure and development.

Environmental impact: Reducing the carbon footprint
Traditional cement production emits approximately 0.66 tonnes of CO2 per tonne of cement. By adopting green cement technologies, this emission intensity can be reduced to 0.53 tonnes, representing a significant step toward decarbonising the sector. Moreover, the utilisation of industrial waste materials not only mitigates environmental pollution but also conserves natural resources.
Ganesh W Jirkuntwar, Senior Executive Director and National Manufacturing Head, Dalmia Cement (Bharat), says, “Low carbon cement not only matches but, in some cases, exceeds the durability of traditional cement. It offers superior resistance to chemical attack, chloride penetration and sulphate exposure, making it particularly well-suited for marine and industrial environments. Cements made with materials like fly ash or slag can achieve compressive strength comparable to that of Ordinary Portland Cement (OPC), though they may exhibit a slower initial strength gain that improves significantly over time.”
The Council on Energy, Environment and Water (CEEW) report, Evaluating Net-zero for the Indian Cement Industry, underscores the significant environmental impact of cement production in India. In the fiscal year 2018-19, the industry produced 337 million tonnes of cement, resulting in approximately 218 million tonnes of CO2 emissions. Notably, 56 per cent of these emissions stemmed from the calcination process during clinker production, 32 per cent from fuel combustion for process heating, and the remaining 12 per cent from electricity consumption. The report emphasises that while energy efficiency measures can reduce emissions intensity by 9 per cent, and the use of renewable energy and alternative fuels can contribute an additional 13 per cent reduction, a substantial 67 per cent of emissions would still need to be addressed through carbon management solutions such as carbon capture, utilisation and storage (CCUS).
Financially, the transition to a net-zero cement industry is substantial. The report estimates a requirement of US$ 334 billion in capital expenditure and an additional US$ 3 billion in annual operating costs to achieve full decarbonisation. However, it also highlights that implementing decarbonisation measures with negative mitigation costs can reduce emissions intensity by 20 per cent and even lower the cost of cement by 3 per cent. Further reductions up to 32 per cent in emissions intensity can be achieved without increasing current production costs by adopting efficient technologies and practices. Nevertheless, achieving net-zero emissions would necessitate the adoption of more expensive technologies like CCUS, which could increase the cost of cement by 19 to 107 per cent, depending on the specific methods employed.
Radhika Choudary, Co-Founder and Director, Freyr Energy, says, “Solar-powered plants amplify the environmental benefits of green cement by ensuring that its production processes—from raw material handling to kiln operations—are powered by clean energy. This reduces greenhouse gas emissions across every stage of the cement’s lifecycle. In addition, leveraging solar energy aligns with emerging green building certifications and sustainability frameworks, making the final product more attractive to eco-conscious developers and construction companies. By adopting solar energy holistically, cement manufacturers not only meet regulatory standards but also position themselves as industry leaders in climate-resilient infrastructure.”

Technological innovations driving green cement
Advancements in technology are central to the production of green cement in India. Innovations include the use of alternative raw materials such as fly ash, slag, and calcined clay, which reduce the reliance on traditional clinker and lower CO2 emissions. Additionally, energy-efficient manufacturing processes and the adoption of renewable energy sources are contributing to more sustainable cement production. By embracing these technological advancements, India’s cement sector can progress towards its decarbonisation goals, aligning with national and global sustainability targets.

Several technological advancements are propelling the adoption of green cement in India:

  • Alternative raw materials: Incorporating fly ash, slag, and other industrial by-products reduces reliance on clinker and lowers CO2 emissions.
  • Energy-efficient processes: Implementing waste heat recovery systems and optimising kiln operations enhance energy efficiency and reduce greenhouse gas emissions.
  • Carbon capture, utilisation and storage (CCUS): CCUS is emerging as a critical strategy for decarbonising India’s cement sector. Given that cement production is responsible for a significant share of industrial CO2 emissions, integrating CCUS technologies can substantially mitigate environmental impacts. The Global Cement and Concrete Association (GCCA) and the Global CCS Institute have identified potential CO2 storage sites across India, including saline formations and depleted oil and gas fields, which could be instrumental in implementing CCUS at scale.

Implementing CCUS in India requires a collaborative approach involving industry stakeholders, policymakers, and financial institutions. Developing supportive policy frameworks and financing mechanisms is essential to facilitate the deployment of CCUS technologies. Moreover, establishing CO2 hubs and infrastructure for transportation and storage will be crucial to the success of CCUS initiatives in the cement industry.
Dr Yogendra Kanitkar, VP – Research and Development, Pi Green Innovations, says, “CCUS is highly critical. If you are exporting to carbon-sensitive markets, you are likely to be hit with a carbon tariff. The Carbon Border Adjustment Mechanism (CBAM) is one such example. Even within India, the Carbon Credit Trading Scheme (CCTS) has been notified, and around 283 entities have been obligated to reduce their CO2 footprints. So, it’s extremely important for Indian industries to wake up to this reality. If you want to remain competitive in foreign markets, adopting CCUS is non-negotiable.”

Policy framework and government initiatives
The Indian government has introduced several policies to promote sustainable construction practices:

  • Perform, Achieve, and Trade (PAT) Scheme: Encourages industries to improve energy efficiency and reduce emissions.
  • National Action Plan on Climate Change (NAPCC): Outlines strategies for promoting sustainable development and reducing carbon emissions across various sectors.
  • Incentives for green buildings: Provides tax benefits and subsidies for adopting eco-friendly construction materials and practices.

These initiatives aim to align the cement industry with India’s commitment to achieving net-zero emissions by 2070.

Challenges and barriers to adoption
Despite the promising outlook, several challenges hinder the widespread adoption of green cement:

  • Cost implications: The initial investment for green cement technologies can be high, deterring small and medium-sized enterprises. The cost for decarbonising India’s cement industry amounts to more than US$330 billion in capital expenses and over US$3 billion in annual operating expenses, according to a report by Ernst & Young Parthenon (published February 2025)
  • Lack of awareness: Limited knowledge about the benefits and availability of green cement among consumers and builders affects demand.
  • Regulatory hurdles: Inconsistent regulations and standards across states can create confusion and impede adoption.
  • Supply chain constraints: Ensuring a consistent supply of alternative raw materials like fly ash and slag is crucial for sustained production.

Future outlook: Strategies for sustainable growth
To overcome these challenges and promote the adoption of green cement, the following strategies can be implemented:

  • Research and development: Investing in R&D to develop cost-effective and efficient green cement technologies.
  • Public-private partnerships: Collaborations between government bodies and private companies can facilitate knowledge sharing and resource pooling.
  • Education and training: Conducting awareness campaigns and training programs for stakeholders in the construction industry.
  • Standardisation of regulations: Establishing uniform standards and certifications for green cement to streamline adoption.

Conclusion
The transition to green cement represents a transformative opportunity for India’s cement industry to align economic growth with environmental responsibility. As the country continues to urbanise and expand its infrastructure, the adoption of sustainable practices becomes not just desirable, but essential. Green cement offers a viable pathway to reduce the carbon intensity of construction through innovative technologies, alternative raw materials, and energy-efficient production processes. With the support of robust policy frameworks like the National Green Hydrogen Mission and Perform, Achieve and Trade (PAT) Scheme, the industry is well-positioned to meet the dual goals of reducing greenhouse gas emissions and maintaining its critical role in national development.
However, realising the full potential of green cement requires a coordinated, multi-stakeholder approach involving government, industry, academia, and financial institutions. Addressing cost barriers, improving supply chain logistics, and raising awareness among end-users are essential for scaling adoption. As India targets net-zero emissions by 2070, with interim renewable energy and efficiency milestones, green cement will play a pivotal role in the nation’s decarbonisation journey. By investing in innovation, standardisation, and education, India can emerge as a global leader in sustainable construction and set a powerful precedent for other developing economies facing similar climate and infrastructure challenges.

– Kanika Mathur

Concrete

Efficient Cooling Solution Boosts Gearbox Uptime

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Efficient Oil Cooling for Gearbox in the Cement Industry. How a High-Performance Plate Heat Exchanger Ensured Thermal Stability and Operational Continuity.

Contributed by: Narendra Joshi and Sourabh Mishra

Application: Gearbox Oil Cooling
Objective: To maintain optimal oil temperature in high-viscosity lubrication systems for gearboxes in cement plants, ensuring uninterrupted operations and minimizing production losses due
to overheating.
Challenge: A prominent cement manufacturing company’s conventional cooling systems were failing to maintain the oil temperature within the optimal range, jeopardizing equipment performance and leading to avoidable downtime.

Background with the Existing System
In heavy-duty industrial applications, particularly in the cement industry, gearboxes are critical components that must operate under high mechanical loads and harsh conditions. These gearboxes rely on lubrication systems where oil plays a dual role, lubrication and heat dissipation. A recurring challenge in such setups is managing the temperature of the gearbox oil. When oil heats beyond a critical limit, its viscosity drops, reducing its ability to form a protective film. This leads to increased friction between components, heat generation, and eventual damage to gearbox components — directly impacting plant uptime and production output.

Delivering Sustainable Heat Transfer Solution with HRS FUNKE High Efficiency Heat Exchanger
This system was selected for its:

  • Excellent thermal performance, ensuring rapid and efficient oil cooling even with high-viscosity fluids.
  • Leakage-proof operation, with no cross-contamination between cooling water and lubrication oil.
  • Robust design, capable of withstanding high operating pressures and variable flow conditions.

The plate exchanger was custom configured based on the oil’s properties, desired outlet temperature, and ambient heat load, ensuring that the oil remained within the specified viscosity range necessary for maintaining gearbox operation and lubrication integrity.

Performance Benefits Delivered

  • Oil temperature control and maintained consistently within target range
  • Viscosity stability and prevented breakdown of lubrication film
  • Equipment reliability and reduced risk of gearbox overheating or failure
  • Production continuity and eliminated unplanned stoppages
  • Long-Term savings and lower maintenance costs and extended oil life

Solution: To address the problem, HRS Process Systems Ltd recommended the installation of a Funke Plate Heat Exchanger a compact, high-efficiency thermal solution engineered specifically for industrial lubrication oil cooling.

Conclusion: The customer achieved precision oil temperature control, ensuring that the gearboxes operated at optimal conditions. This not only safeguarded the mechanical integrity of the gearbox but also directly contributed to higher plant uptime and improved production efficiency in heavy industries like cement manufacturing.

(Communication by the management of HRS Process Systems Ltd)

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How Upgrades Can Deliver Energy Savings Across the Cement Process

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Jacob Brinch-Nielsen, Vice President of Professional Services, FLSmidth Cement, brings together recommendations from experts across the flow sheet to demonstrate the role of upgrades in optimising the cement manufacturing process.

Improving energy efficiency in material transport
Pneumatic conveying offers a cleaner and more contained alternative to mechanical conveying. However, pneumatic systems can also be energy-intensive, with inefficiencies arising from air leakage, pressure losses, and outdated equipment designs. Optimising these systems can significantly reduce energy consumption and operating costs.
“One major challenge is maintaining efficient air-to-material ratios, as excessive air use leads to unnecessary power consumption,” explains Emilio Vreca, Manager of PT Product Engineering “Leaks in piping and inefficient compressors further compound energy losses. To address these issues, upgrading to the latest pneumatic conveying solutions can yield substantial improvements.”
The latest pump design—the Fuller-Kinyon® (FK) ‘N’ Pump—provides power savings of up to 15 per cent thanks to an improved seal, while an extended barrel and screw design have improved volumetric efficiency by more than 15 per cent. Similarly, the latest generation Ful-Vane™ Air Compressor has been engineered for increased energy efficiency, with an improved inlet area for capturing larger air flows and compatibility with variable frequency drives.

Optimising energy efficiency in packing and dispatch
Even minor inefficiencies in bagging and palletising can lead to higher maintenance demands, increased material waste, and unnecessary energy use. Reducing these inefficiencies is yet another lever to improve overall plant performance and sustainability.
Upgrading rotary packers enhances weighing accuracy, reduces spout-to-spout variations, and lowers reject rates, improving both product consistency and energy efficiency. Similarly, replacing pneumatic drive systems in palletisers with electric alternatives eliminates compressed air dependency, leading to more precise bag handling and reduced energy demand. These targeted upgrades help streamline operations while minimising environmental impact.
A key development in dust control is the FILLPro™ Dust Reduction Kit for GIROMAT® EVO. “By refining material flow and fluidisation, FILLPro reduces dust emissions at the source, improving bagging efficiency and plant cleanliness,” explains Gabriele Rapizza, Proposal Engineer. “This reduces material loss, prevents blockages, and cuts down on maintenance, helping plants achieve a more stable and energy-efficient packing operation.”

How services contribute to increased energy efficiency
In the past, many viewed the role of the supplier as a “sell-and-move-on” model. Things have certainly changed. As cement producers face challenging markets, heightened competition, and increasingly ambitious decarbonisation targets there is little room to tolerate inefficiencies within the plant. The paradigm has shifted such that the value of expert services is as essential as the initial equipment supplied. Furthermore, as digital solutions progress at speed, a fluid, long-term partnership gives cement plants the best platform to take advantage of the latest tools.
Whether it’s an audit to identify why energy efficiency has decreased from one year to the next, or even an optimisation package preparing your plant for carbon capture solutions – we are believers in the principle that there is always more we can do to improve efficiency. For example, our Online Condition Monitoring Services (OCMS) provide continuous monitoring of critical equipment such as the kiln, mills, cooler and fans, aggregating data and utilising advanced algorithms to identify potential trouble spots. As the OEM and an experienced full solutions provider, we can support these services with expert advice, not only alerting you to a problem but also providing recommendations as to how to remedy it or attending site to support you in person.

Small upgrades, big impact
Energy efficiency is a critical factor, influencing both operational costs and sustainability goals. While large-scale innovations such as carbon capture will play an essential role in long-term decarbonisation (and steal the headlines), incremental mechanical upgrades offer an immediate pathway to lower energy consumption with minimal disruption.
By optimising key process areas — grinding, dosing, combustion, cooling, and material transport — you can achieve measurable energy savings while improving performance and flexibility. These solutions provide a strong return on investment and pave the way for a more sustainable cement industry.

Part 3 of 3. Read Part 1 in the May issue of Indian Cement Review and Par 2 in the June issue of the Indian Cement Review magazine.

(Communication by the management of the company)

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Star Cement launches ‘Star Smart Building Solutions’

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Star Cement has launched ‘Star Smart Building Solutions,’ a new initiative aimed at promoting sustainable construction practices, as per a recent news report. This venture introduces a range of eco-friendly products, including tile adhesives, tile cleaners and grouts, designed to enhance durability and reduce environmental impact. The company plans to expand this portfolio with additional value-added products in the near future. By focusing on sustainable materials and innovative building solutions, Star Cement aims to contribute to environmentally responsible construction and meet the evolving needs of modern infrastructure development.

Image source:https://www.starcement.co.in/

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