Energy optimisation is a cornerstone of a smart cement plant, as it helps in lowering costs and cutting carbon. ICR delves into the different aspects that make a cement plant more energy efficient, accountable and sustainable.
The cement industry is among the most energy-intensive sectors globally, representing a critical frontier for energy efficiency gains. According to the International Energy Agency, global cement production today consumes roughly 100 kWh of electricity per tonne of cement, alongside thermal energy intensity of about 3.6 GJ per tonne of clinker. This energy intensity must fall to below 90 kWh and 3.4 GJ respectively by 2030 to align with Net-Zero trajectories.
India’s cement sector already stands out as relatively energy efficient. According to the OECD, the national average thermal energy consumption hovers at 725 kcal per kg of clinker (˜3.04 GJ/t), and electrical energy usage averages about 80 kWh per tonne of cement, both notably lower than the global averages of approximately 934 kcal/kg clinker and 107 kWh/t cement.
Still, there’s significant room for improvement. The Confederation of Indian Industry’s latest benchmarking shows that while average electrical energy consumption in the Indian cement sector has fallen from 88 kWh/tonne in 2014 to 73.75 kWh/tonne in 2023, the best-performing plants have pushed that down even further—to about 56 kWh/tonne of cement, and 675 kcal/kg of clinker in thermal terms. These figures spotlight the potential—and the urgency—for the rest of the industry to accelerate its energy efficiency trajectory.
Need for Energy Efficiency
Global energy efficiency is rightly dubbed the ‘first fuel’ in the clean-energy transition. According to the International Energy Agency, enhancing energy efficiency is the single most cost-effective and fastest route to cut CO2 emissions while lowering operational costs and strengthening energy security. Efficiency gains alone could fulfil up to 40 per cent of the greenhouse-gas reductions needed to meet Paris Agreement goals, making them indispensable for sectors like cement that are poised for long-term infrastructure growth.
Speaking about the need for cement manufacturers to invest in energy efficiency solutions, MM Rathi, Joint President, Power Management, Shree Cement, says, “Because it directly reduces operating costs, ensures compliance with tightening regulations, and strengthens carbon credentials at a time when financing and markets reward low-carbon players. With mature technologies and strong incentives available, delaying only increases both cost and risk.”
Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, explains, “We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.”
Alex Nazareth, Whole-time Director and CEO, Innomotics India, expounds, “In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.”
In cement manufacturing, energy footprint looms large: production of this indispensable material accounts for 7–8 per cent of global CO2 emissions due to energy-intensive processes and raw-material calcination. A recent report by Reuters confirms that over half of cement’s emissions stem from clinker production, highlighting how inefficient
thermal operations translate directly into climate and cost concerns. In this context, every percentage
point of energy saved not only cuts fuel and electricity costs but also contributes meaningfully to decarbonisation efforts.
With regards to innovations in energy efficiency, Dr Avijit Mondal, Deputy General Manager (DGM), NTPC Energy Technology Research Alliance (NETRA), NTPC, exemplifies, “Cement manufacturing is among the most energy-intensive industrial processes, with continuous high loads from kilns, grinding mills, crushers and conveyors. Integrating a hybrid behind-the-meter microgrid offers a powerful solution to improve energy efficiency, reduce power costs and enhance operational resilience. A typical integrated cement plant can deploy a hybrid system comprising 8-15 MWp of rooftop and ground-mounted solar PV, 8-25 MW of waste heat recovery (WHR) capacity, and a Battery Energy Storage System (BESS) sized for 15-30 minutes of peak plant load. In this configuration, solar PV supplies the daytime base load for processes like grinding and material transport, WHR delivers steady baseload power for kiln and cooler exhaust, and BESS handles ramping and flicker control.”
Barriers to Adoption
Rathi points out that the single biggest barrier is the high upfront capital cost and longer payback periods. According to a study published in PubMed Central, capital limitations are the third most significant barrier to sustainability transformation in the sector—particularly given the hefty investment and slow payback associated with energy projects such as waste-heat recovery systems (WHR) and captive power plants. The report highlights costs of approximately US$2.4 million per MW for WHR systems and US$1 million per MW for captive
power, making rapid returns challenging for many manufacturers.
Suryam shares, “Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output.”
Raman Bhatia, Founder and Managing Director, Servotech Renewable Power System, states, “Deploying large-scale solar solutions, comes with unique challenges that require careful planning and execution. One of the primary hurdles in such projects is the structural readiness of industrial rooftops, as they must be able to support the weight and scale of the installation while ensuring long-term safety and durability.”
Beyond financial constraints, there remains a glaring awareness and information gap across the industry. A 2017 report by the International Finance Corporation (IFC) identifies several non-financial barriers, including regulatory uncertainty, lack of project-level knowledge, limited access to sustainable energy financing and internal misalignment of priority between expansion projects and energy efficiency initiatives. Despite the strong long-term returns, energy-saving measures are often overshadowed due to lack of clarity, understanding or management focus within cement organisations.
Finally, the skills deficit stands is a major drag on energy efficiency deployment—not just in renewables but across industrial sectors including cement. According to Reuters, India’s clean energy ambitions are being undermined by an acute shortage of skilled professionals. In the solar industry alone, there’s a shortfall of around 1.2 million trained workers, a gap expected to grow by 2027. Without robust technical know-how—whether for installation, operations, digital monitoring or maintenance—cement plants struggle to implement and sustain efficiency technologies effectively.
Digital Transformation of Energy
Digital transformation is reshaping the cement industry, turning traditional analogue plants into data-driven operations. Internet of Things (IoT) and Industrial IoT (IIoT) systems are being deployed across operations to capture real-time data from kilns, mills, conveyors, and control systems. This information integrates into Energy Management Systems (EMS) that monitor consumption, optimise equipment use and quickly flag inefficiencies. Automation tools like VFDs, smart MCCs and sensors enable not just monitoring, but also proactive control of power-intensive assets—unlocking substantial energy savings through real-time adjustments.
Artificial Intelligence (AI) is adding another layer of sophistication. According to industry estimates, AI in cement manufacturing can reduce energy consumption by up to 15 per cent and cut electricity usage by approximately 28 per cent, thanks to real-time monitoring and feedback loops. Moreover, smart cement plant research indicates that AI implementation can lower overall energy use by 22.7 per cent, reduce downtime by 75 per cent and improve clinker consistency by nearly 12 per cent. These gains underline how machine learning and process-optimisation algorithms can deliver both cost and carbon dividends in one go.
Referring to energy-efficient technologies as vital, Rathi states, “They will lower operating costs, enable decarbonisation and accelerate the shift toward digital, circular and low-carbon manufacturing, making energy efficiency the backbone of competitiveness and sustainability.”
Beyond AI, the rise of digital twins and advanced modelling is giving plant managers unprecedented foresight. Simulated virtual replicas of cement lines let operators test energy-saving scenarios without risking real-world performance. According to a report by Ramco, predictive quality analytics and kiln-fuel blending driven by machine learning enable optimal resource utilisation, lowering both energy consumption and emissions. These systems are especially promising where alternative fuels or clinker substitutes are used—helping ensure consistency and efficiency in challenging process conditions.
Citing the example of modern mineral processing with digital technology, Karen Thompson, President, Haver & Boecker Niagara’s North American and Australian Operations, referred to Artificial intelligence (AI) as a practical tool that’s reshaping how quarries operate. “One of the most impactful applications is in predictive analytics. Unplanned downtime not only disrupts production but also leads to increased energy use, emergency repairs and premature equipment disposal — all of which have environmental consequences. Predictive maintenance technologies help mitigate these risks. Tools like condition monitoring and vibration analysis use wireless sensors to continuously assess equipment health,” she states.
Smart energy management tools powered by IIoT are bridging operations, maintenance, and strategic dashboards. ABB’s Ability™ Knowledge Manager, for instance, allows integration of production, downtime, quality, energy, and emissions data into a unified platform—and deliver insights even via mobile access. A leading Indian cement producer implemented the suite across multiple plants, achieving ROI in just eight months, cutting costs by 3-5 per cent and extending asset lifecycles—demonstrating how digital tools are central to modernising
energy management.
The Green Route
In an industry where energy constitutes up to 40 per cent of production costs, unlocking free sources of power can be a game-changer. Waste Heat Recovery Systems (WHRS) tap into high-temperature exhaust—like kiln preheater gases—and convert up to 30 per cent of a plant’s electricity needs into usable power, using steam turbines or Rankine cycles. A report by the Ministry of New and Renewable Energy mentions that the Indian cement sector possesses a WHRS potential of nearly 1.3 GW, which could annually reduce coal use by approximately 8.6 million tonnes and cut 12.8 million tonnes of CO2 emissions.
Commenting about viable renewable energy solutions, Ghosh says, “Cement industry is a continuous process industry with high power intensity. It requires green, reliable and cost-effective power solutions. Historically, cement plants have preferred the group captive model given the scale of power requirement. From a green power solutions perspective, round-the-clock solutions with a mix of solar, wind and battery storage (or PSP storage) are best suited to meet the power needs of the cement industry. With reduction in battery CAPEX and further learning curves, we see the cost effectiveness of RTC solutions continues to improve in the near term. An important element to make this competitive is to size the configuration based on very granular analytics, such as optimisation of the battery cycling rate through the life of the plant.”
“Most energy efficiency measures are also value accretive. In fact, if you were to draw the marginal abatement cost curve – you will find that >50 per cent of measures to reduce carbon footprint also being in cost reduction, which is a win-win. This is true not just for cement plant operations but across the value chain including logistics. For example, reducing the per tonne per kilometre (PTPK) costs also help in significant carbon footprint reduction which can be achieved by improving packing efficiencies, route optimisation, etc. Hence, energy efficiency helps improve the cost competitiveness in heavy industries and is not contrarian in nature,” he added.
Narrowing down on solar energy, Bhatia shares, “Our patented peak-shaving technology is designed to optimise energy usage efficiency by reducing costly demand spikes that are common in energy-intensive operations. In industries like cement manufacturing, where power consumption can suddenly surge due to heavy machinery, these peaks often translate into higher demand charges on electricity bills. By intelligently managing when and how energy is drawn from the grid and dispatching battery energy storage (BESS) during peak grid usage, we ensure smoother load profiles, lower costs and mitigate tariff exposure.”
Despite its promise, WHRS adoption isn’t universal. A report by ICRA indicates that Indian cement producers plan to invest around Rs.1,400–1,700 crore by FY2022 to add 175 MW of WHRS capacity, which brings the cumulative installed base to 520 MW—covering only about 16 per cent of their power needs. However, the low marginal power cost from WHRS—at just around Rs.1-1.5 per kWh compared to Rs.4.5–5 for captive thermal power—delivers an estimated 14-18 per cent reduction in power expenses, boosting operating margins by 1.1-1.4 percentage points.
Parallel to WHRS, alternative fuels and raw materials are creating dual efficiencies by cutting both energy demand and raw-material inputs. According to CMA, India’s sector-wide Thermal Substitution Rate (TSR) has grown from 0.6 per cent in 2010 to 4 per cent in 2017, with some plants achieving TSR levels of 25-35 per cent using Refuse-Derived Fuel (RDF), agro-waste, sludge and other residues. These co-processing strategies lower dependence on fossil fuels and reduce environmental impacts — moving both raw materials and energy into a more circular usage cycle.
Looking ahead, the synergy between efficiency gains and circular economy gains positions cement firms for long-term competitiveness. WHRS delivers an immediate reduction in operational cost and carbon footprint, while alternative fuel and raw-material integration opens pathways for regulatory resilience, lower input costs and brand differentiation in a sustainability-conscious market. Yet realising their full potential requires overcoming technical challenges, scaling effective logistics and embracing policy frameworks that support both waste valorisation and energy innovation.
Energy Audits
Energy audits serve as foundational tools in the pursuit of operational efficiency within the cement sector, spotlighting precisely where energy is being wasted and where savings can be unlocked. A detailed study by the National Council for Cement and Building Materials (NCB) revealed that kilns are sometimes operated with heat consumption as high as 850 kcal/kg clinker, whereas the industry’s best-performing plants function around 675-685 kcal/kg clinker. Energy audits helped bridge this gap by pinpointing inefficiencies like cooler losses and false air entry—in one case, a reduction of just five kcal/kg clinker yielded annual cost savings of approximately Rs.45-50 lakh for a 1 Mtpa plant. A report by NCB underscores this: energy audits can deliver substantial returns by diagnosing hidden inefficiencies and guiding corrective actions.
Complementing audits, benchmarking empowers cement producers to realistically gauge their energy performance against industry leaders. According to the latest CII benchmarking manual, while
average electrical consumption stands at 73.75 kWh/MT cement, the top 10 plants operate at an impressively efficient 56.14 kWh/MT. Similarly, thermal benchmarks show a gap—from the sector average of 726 kcal/kg clinker to best-in-class levels around 675 kcal/kg. These metrics allow companies to set ambitious yet achievable targets, fostering continuous improvement and motivating strategic investments in efficiency technologies.
Data plays a crucial role in this process.
Debabrata Ghosh, Head of India, Aurora Energy Research, states, “Advanced analytics has several use cases to enhance cement plant performance in improving quality, increasing throughput and reducing cost thereby improving margins/ realisations. Use cases differ by part of the process. Availability of granular and high-quality data captured real time through effective information systems is the primary requisite. Typically, use cases with low effort and high impact should be prioritised to capture low hanging fruits. Structural, big-ticket solutions typically bring about medium term impact on either/ all the three metrics.”
Skill Development for Efficiency
India’s hammering of energy efficiency in manufacturing hinges critically on skilled manpower—a resource that remains alarmingly sparse. According to a Reuters report titled ‘Skills shortage hobbles India’s clean energy aspirations,’ the renewable sector faces a skill gap of approximately 1.2 million workers, projected to rise to 1.7 million by 2027, severely impacting deployment and operational effectiveness of technologies like solar, wind and energy-efficient systems. As clean-energy integration grows, this shortage threatens to stall progress across sectors—including cement—where specialised knowledge in automation, digital monitoring and system optimisation is increasingly indispensable.
Within the cement industry itself, the urgency for upskilling is clear. A recent industry snapshot by ZIPDO Education reveals that 48 per cent of workers feel unprepared for the digital transformation of their plants, while 53 per cent lack basic digital literacy, and 58 per cent report shortages in AI and data analytics skills. However, the same report also signals momentum: 72 per cent of cement firms anticipate expanding digital training programs by 2025, and 80 per cent deem reskilling essential to meet sustainability goals. These figures underscore both the magnitude of the gap and the growing recognition that skill development is no longer optional—but foundational to staying energy-competitive.
OEMs, EPCs and Cement Producers Collaboration
Strategic collaboration between Original Equipment Manufacturers (OEMs), Engineering-Procurement-Construction (EPC) firms and cement producers is proving to be a game-changer in operational efficiency. For instance, a case highlighted in Indian Cement Review recounts how JK Cement’s switch to Mobil SHC™ 632 premium lubricants—not just designed but optimised in coordination with OEM partners—enhanced gearbox efficiency by about 0.8 per cent, saved 263 litres of oil, and delivered cost savings of US$18,764 (Rs.13.1 lakh) annually. This partnership model underscores how nuanced inputs from technical suppliers, paired with operational insights from plant engineers, can translate directly into energy and cost gains.
Similarly, EPC collaborations are demonstrating real traction in energy optimisation. At a leading cement producer’s site in Rajasthan, EPC partner Thermax implemented a blend of operational and capital interventions—like Variable Frequency Drives (VFDs) and auto-control flow logics—for both captive power and WHRS. The results were tangible: cost savings of Rs.7.24 million from capex and Rs.1.88 million from opex in the captive plant, plus Rs.870,000 and Rs.190,000 respectively in the WHR facility. This affirms how EPC-led evaluation and targeted upgrades can yield substantial efficiency returns.
Long Term ROI
In the long run, energy-efficient systems are not merely cost-saving tools—they are strategic investments with powerful paybacks. According to an ICRA report, Indian cement companies planned to deploy 175 MW of Waste Heat Recovery Systems (WHRS) by FY 2021–22, involving a total investment of Rs.1,400–1,700 crore. This investment is expected to widen operating margins by 1.10-1.40 per cent, as WHRS-powered electricity costs just Rs.1.3-Rs.1.5 per kWh, compared to Rs.4.5-Rs.5 per kWh for conventional captive thermal power. Furthermore, Global Cement’s market analysis reveals that WHRS-generated power typically comes in at just US$0.02/kWh, significantly lower than the ~US$0.70/kWh from coal-based captive plants, which allows for around 15 per cent savings in power costs when covering 25 per cent of capacity.
Beyond direct savings, integrating energy-efficient technologies like WHRS or advanced refractories contributes materially to carbon footprint reduction, bolstering ESG performance and potentially unlocking regulatory or market advantages. A detailed case study published by Indian Cement Review in 2024 notes that upgrading kiln burning zones with high-insulation refractories can reduce fuel consumption by 6 per cent, translating into annual savings of roughly `3.5 crore for a 6,000 TPD kiln. The switch also results in an estimated 0.1 tonne of CO2 reduction per tonne of clinker, highlighting how operational efficiencies can create both cost and carbon dividends.
Conclusion
Energy efficiency in cement manufacturing is no longer just a choice—it is an imperative for competitiveness, compliance, and climate responsibility. From waste heat recovery systems to digital transformation and advanced refractories, the sector has already demonstrated that operational savings and carbon reductions can go hand in hand. According to ICRA, WHRS investments alone can expand operating margins by 1.10-1.40 per cent for Indian cement players, showing that the financial case for efficiency is robust. These tangible benefits are proving that efficiency measures are not incremental improvements but transformative enablers for long-term resilience.
At the same time, the industry must overcome barriers such as high upfront costs, limited awareness and skill gaps. Energy audits, benchmarking practices and collaborations between OEMs, EPC contractors and cement producers are emerging as essential tools to bridge these gaps. As noted in multiple case studies, even relatively modest upgrades—such as switching to high-performance refractories—can yield significant savings in fuel costs and emissions reductions. These wins create a strong foundation upon which deeper decarbonisation strategies can be built.
Looking ahead, the integration of emerging technologies—AI, IoT and smart energy management—will further optimise cement operations. Combined with alternative fuels, raw materials and large-scale carbon capture, these innovations are positioning the industry to drastically lower its energy intensity and carbon footprint. The pace of adoption will determine how quickly the sector transitions from incremental efficiency gains to systemic decarbonisation. With India expected to double its cement demand by 2030, scaling these solutions is both a necessity and an opportunity.
The future of cement lies in aligning energy efficiency with the global net-zero agenda. By 2050, achieving net-zero cement production will require a mix of aggressive efficiency measures, deep electrification, large-scale use of alternative fuels and breakthrough technologies such as CCUS. The journey is complex, but the direction is clear: energy efficiency is not only the first step but also the cornerstone of a sustainable cement industry. Those who act decisively today will not only cut costs and carbon but also secure their place as leaders in a net-zero future.– Kanika Mathur
Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.
Surat (Gujarat)
Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.
Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.
Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.
The Limla Cement Plant is expected to support a phased increase in sales volumes across Gujarat. It will also help Nuvoco supply neighbouring markets in Western Maharashtra and release cement capacity from its northern plants, which can consequently be redirected towards markets in North India. The plant will manufacture a full portfolio comprising Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. It will additionally produce the complete Nuvoco Duraguard range, including the premium Nuvoco Duraguard Microfibre product. The acquisition is also expected to generate operational synergies with Nuvoco’s existing plants at Nimbol and Chittorgarh in Rajasthan, improving logistics optimisation and market reach across important regional markets.
The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.
Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”
He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”
Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.
Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.
Indian Cement Review (ICR) and Fuller Technologies brought industry, policy and technology leaders together to discuss how cement innovation can drive green construction at scale, writes Rakesh Rao.
India is building at a pace few countries can match. Highways, airports, housing, logistics parks, industrial corridors and urban infrastructure are reshaping the country’s economic geography. But beneath this growth story lies a difficult question: can India continue to build at scale without locking itself into a high-carbon future?
That question formed the core of an online panel discussion titled “Driving Green Construction Through Cement Innovation”, organised by Indian Cement Review (ICR) in association with Fuller Technologies as the Presenting Partner on June 25, 2026. The webinar brought together experts from cement technology, R&D, global industry platforms, building performance policy and international development cooperation to examine how low-carbon cement and material innovation can accelerate India’s green construction transition.
The discussion came at a crucial time. India has committed to achieving net-zero emissions by 2070 and reducing the carbon intensity of its economy by 45 per cent by 2030. At the same time, the country’s construction sector is expanding rapidly, driven by urbanisation, infrastructure development, housing demand and industrial growth. Cement, as one of the most widely used construction materials, sits at the heart of this transition. It is indispensable to development, but also central to the challenge of reducing embodied carbon in buildings and infrastructure.
Moderated by Nitika Krishan, Senior Urban Infrastructure and Sustainable Policy Consultant, the panel featured:
Dr Hemantkumar Aiyer, VP and Head R&D, Nuvoco Vistas Corp Ltd;
Devika Wattal, Innovation Lead, Global Cement and Concrete Association (GCCA);
Dr Sunita Purushottam, MD, GBPN India (Global Buildings Performance Network); and
Vaibhav Rathi, Senior Technical Advisor, GIZ (the German Agency for International Cooperation)
Setting the tone for the discussion, Nitika Krishan underlined the scale of the challenge before the sector. “The question before us is no longer whether we build, but how we build sustainably,” she said. She pointed out that construction accounts for nearly 40 per cent of global energy-related carbon emissions when both operational and embodied carbon are considered. Cement production, she added, remains one of the hardest industrial processes to decarbonise.
For India, this is not merely an environmental issue. It is a development issue, a competitiveness issue and increasingly, a market issue. As one of the world’s largest cement producers and among the fastest-growing construction markets, India’s material choices will influence the carbon trajectory of its built environment for decades. As Krishan observed, sustainability solutions in economies such as India must not remain limited to laboratory success. They must be scalable, commercially viable and practical at national level.
The innovation gap: From technology to market
Experts believe that there is a need to bridge the innovation gaps for making decarbonisation in cement and concrete scalable. Devika Wattal of GCCA, explained, “The starting point must be the core cement manufacturing process itself. The first and foremost is the heart of our process, the heart of cement manufacturing. How do we reduce clinker? That is always a topic where industry is working very intrinsically.”
Clinker reduction remains one of the most important pathways for lowering emissions in cement. Since clinker production is energy-intensive and chemically emits carbon dioxide, reducing the clinker factor through supplementary cementitious materials (SCMs), blended cements and new chemistries can have a significant impact. Wattal also noted that carbon capture, utilisation and storage (CCUS) will have a role, though it may not be the first lever for all markets.
However, she stressed that innovation cannot stop at technology development. A solution that works in the lab must also be adaptable to industry, scalable in production and acceptable in construction practice. “It is important for that innovation to be adaptable, to be scalable, and so that it can be executed in real time,” she said.
Wattal also called for stronger enabling systems around innovation. These include performance-based standards, product-level embodied carbon databases and clearer frameworks for evaluating green materials. Without these, low-carbon cement products may struggle to compete with conventional materials in procurement and design.
R&D must balance carbon, cost and performance
Bringing in the R&D perspective into the discussion, Dr Hemantkumar Aiyer of Nuvoco Vistas emphasised that low-carbon cement development cannot be treated as a single-variable exercise. Cement must perform in real construction conditions. It must deliver strength, durability, consistency and cost competitiveness, while also reducing carbon.
“The root of understanding and balancing all these aspects lies in materials, and knowing the materials,” he said.
According to Dr Aiyer, R&D teams must understand the variability of raw materials such as fly ash, slag and clinker. Different sources produce different material behaviours. This makes mix optimisation, material characterisation and processing-property relationships critical. When performance is affected, cement manufacturers must understand how strength enhancers, admixtures and other performance chemicals interact with the material system.
He also linked material science with process efficiency. Clinkerisation takes place at extremely high temperatures, around 1,400 to 1,450 degrees Celsius. Any improvement in raw mix design, process control or energy optimisation can, therefore, help reduce emissions and cost. Dr Aiyer pointed to artificial intelligence-based optimisation, Cement 4.0 tools and advanced software as important enablers for real-time process and material control.
“The more you understand the materials, the more you can control it,” he said.
LC3: The promise is proven, the sequencing is not
Limestone calcined clay cement, commonly referred to as LC3, has attracted global attention because it can reduce clinker content significantly by using calcined clay and limestone while maintaining performance in many applications. Kiranmai Sanagavarapu of Fuller Technologies said the technology itself has already moved beyond proof of concept. Fuller Technologies has worked with calcined clay technology for nearly two decades and has seen plants running in France and Ghana. These plants, she said, are meeting local and national specifications, while the economics are beginning to make sense.
“The calciner is performing, the economics is stacking up, it is making business sense to produce,” she said.
But if the technology is viable, why has adoption not scaled faster? For Sanagavarapu, the answer lies in project sequencing. Too often, clay characterisation happens after equipment is specified. This, she warned, is a backward approach because calciner design depends on clay mineralogy, kaolinite content, iron levels, reactivity, moisture and other variables.
“If you don’t know what your deposit looks like before you commit for the equipment, you are, in a way, going blind into designing,” she said.
She also identified permitting and plant integration as major bottlenecks. Environmental clearances, mining permissions and local regulatory approvals must begin early. Similarly, calcined clay must be integrated into existing grinding, blending and logistics systems from the design stage, not treated as an afterthought during commissioning.
India already has IS 18189:2023 standard for LC3, but Sanagavarapu pointed out that the standard is not yet visible enough in procurement documents. “The gap between what is technically being permitted and what the procurement is asking is the single biggest bottleneck,” she said.
In her view, successful scale-up depends on getting the sequence right: clay characterisation first, permitting in parallel, standards aligned with construction, and integration built into plant design.
India’s LC3 journey: Progress, but demand remains thin
Providing details of India’s LC3 commercialisation experience, Vaibhav Rathi of GIZ noted that JK Cement carried out the first commercial production of LC3 at its Rajasthan plant, followed by JK Lakshmi Cement three months later. These initiatives were supported by the International Climate Initiative of the Government of Germany, with IIT Delhi contributing deep institutional knowledge on LC3 research and BIS certification.
Rathi said India’s early experience has produced clear lessons. One of the biggest was the need to build capacity among regulators. While BIS certification existed, State Pollution Control Boards were unfamiliar with the technology and unsure about the approval pathway.
“The capacity building is not just needed amongst the producer and the users of the cement, but also the regulators who are working with this technology for the first time,” he said.
He also highlighted the need for better information on China clay deposits. Since China clay is currently classified as a minor mineral, centralised data on availability, quality and location is limited. If cement manufacturers are to adopt LC3 at scale, stronger mineral intelligence will be important.
The third issue is demand. LC3 has already been used in projects such as Palava City in Mumbai and Noida International Airport, but these remain limited examples. “It is in a chicken and egg situation,” Rathi said. “Cement companies are saying we need more demand, and users are saying there is not enough cement available.”
Public procurement, he suggested, could help break this cycle. If agencies such as CPWD and other public bodies begin testing, accepting and specifying LC3, it could create the market confidence needed for cement companies to invest in production and storage.
Building codes must catch up with innovation
Dr Sunita Purushottam of GBPN India argued that material choices will determine built environment emissions over the long term, but India’s current policy signals remain fragmented. Although LC3 has received BIS recognition, she pointed out that building codes, municipal bylaws, schedules of rates and sustainability codes do not yet provide uniform guidance on low-carbon cement.
“The current cement regulations are largely prescriptive and favouring traditional materials,” she said. This limits the ability of alternative materials to compete on performance, durability and emissions.
Dr Purushottam also raised the issue of taxation. Cement, including LC3, currently falls under the same GST bracket as conventional cement. A differentiated tax structure, she argued, could help accelerate market adoption. “In order for the market to demand LC3, that differentiation in the GST could go a long way,” she said.
She noted that green building certifications such as IGBC and GRIHA are already creating demand for low-carbon materials by assigning points for embodied carbon and sustainable material use. However, she said large-scale adoption will require regulatory mandates, particularly through building codes and state-level notifications.
She also cautioned that low-carbon cement alone does not solve the entire building performance problem. A material may reduce embodied carbon, but the operational carbon of a building depends on thermal performance, design, insulation and energy use. “The energy part has two elements,” she said. “One is the embodied carbon of the material itself, and the other is the operational carbon.”
Collaboration is the bridge between invention and impact
Wattal said GCCA sees innovation as a strategic priority and works through platforms that connect industry with academia and start-ups. “There is no way we will decarbonise our sector without innovation,” she said.
However, she stressed that research must be connected to actual industry challenges. Innovations developed in isolation may fail when they encounter real-world barriers such as raw material variability, plant integration, cost, standards and finance. Start-ups, too, need industry mentorship and scale-up pathways.
Wattal also flagged the importance of finance. Even strong technologies may struggle to attract investment if there is no common understanding of bankability. “We have always put projects into, is this a bankable project? But the definition of a bankable project has never been defined,” she said.
For India, she saw strong potential in its academic and start-up ecosystem, but said the challenge lies in alignment and prioritisation. The country has the research base, industrial capacity and market size. What it now needs is a coordinated route from innovation to deployment.
There is a practical concern for cement manufacturers: how can existing plants be adapted for lower emissions without compromising reliability or commercial viability?
Kiranmai Sanagavarapu addressed, “The reliability risk in calcined clay retrofit is definitely real, but it is almost always self-inflicted. The risk arises when a new process is added to an existing circuit without properly redesigning grinding and blending configurations.”
Existing cement plants, she explained, can take two broad routes. The first is external sourcing of calcined clay combined with mill optimisation. This requires lower capital investment and can potentially move in 12 to 18 months if other conditions are in place. It may reduce emissions by around 20 to 30 per cent. The second route is integrated calcination on site, which requires higher capital expenditure and longer lead times, but provides greater control over quality, supply and emissions reduction potential.
For Sanagavarapu, the principle is simple: low-carbon retrofits must be designed with intent. “Design it with an intent properly from the start. Start in the market conditions where the economics are already working,” she said.
Circularity: The overlooked advantage
According to Vaibhav Rathi, fly ash and slag are already well established in cement and construction (C&D), but construction and demolition waste remains underutilised. “C&D waste is a growing business opportunity which not many have taken up,” he said. India’s continuous construction and demolition activity creates huge volumes of waste, much of which contributes to air pollution, land degradation and material inefficiency. With the right processing and standards, this waste can be converted into useful construction products.
Rathi also pointed out that LC3 has a circular economy dimension that is often overlooked. It can use low-grade kaolin-rich clay left behind after high-grade clay is extracted for other applications. “LC3 is not only a low-carbon solution, but also a circular economy solution,” he said.
At the same time, he cautioned that LC3 in India is not yet cheap because it has not reached scale. Site-specific techno-commercial feasibility studies, supported jointly by development agencies and industry, could help companies assess whether LC3 production makes technical and financial sense at a given location.
Dr Purushottam added that India must address both low-carbon cement and construction waste together. “Both low-carbon cement and C&D waste go hand in hand. India does not have an option but to work on both,” she said.
Dr Aiyer called for policy shifts from both government and industry, including preferential purchasing of sustainable materials, minimum supplementary cementitious material requirements in public and public-private projects, and faster regulatory implementation. “If we can fast-track the regulatory standards and their implementation on the ground, that is the way to go,” he said.
From green ambition to green construction
Cement innovation is no longer only about chemistry. It is about systems. Low-carbon cement will scale only when technology, standards, procurement, finance, regulation, education and construction practice move together.
LC3 and other low-carbon technologies have shown promise. India has early commercial examples, strong research capability and growing market interest. But mainstream adoption will depend on whether demand can be created, regulators can be capacitated, standards can be embedded in procurement, and manufacturers can see a clear business case.
For a country building at India’s scale, the opportunity is enormous. Cement will continue to be central to infrastructure and urban development. The challenge now is to ensure that the cement used in India’s growth story carries a lower carbon burden.
Rakesh Rao
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Specialised rail logistics will move fly ash from power plants to infrastructure industries.
New Delhi
Indian Railways is planning a large-scale green logistics initiative to transport fly ash from thermal power plants to industries where it can be reused in infrastructure and construction activities.
The initiative was discussed during a review meeting chaired by Union Minister for Railways Ashwini Vaishnaw. Union Ministers of State for Railways V Somanna and Ravneet Singh Bittu were also present.
India generates nearly 340 million tonnes of fly ash every year from thermal power plants. The proposed initiative aims to create an efficient rail-based transport system using specialised containers and dedicated logistics arrangements to move fly ash safely from power plants to end-use industries.
Fly ash is widely used in road construction, cement manufacturing, brick production, concrete, blocks and boards. By improving its movement through the railway network, the initiative is expected to support better utilisation of this industrial by-product while reducing environmental concerns linked to storage and disposal.
The move also aligns with India’s circular economy goals by converting waste from thermal power generation into a useful raw material for the construction and infrastructure sectors. Wider availability of fly ash can help reduce material costs in areas such as bricks and cement, supporting more affordable infrastructure and housing development.
Through this initiative, Indian Railways aims to provide a cleaner, safer and more organised transport solution for fly ash, turning an environmental challenge into an infrastructure resource.
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