Connect with us

Economy & Market

The New Age of Mining

Published

on

Shares

Sustainable mining is redefining how India sources the backbone of its cement industry — responsibly, efficiently, and transparently. ICR explores how innovation, regulation, and community partnership are shaping the next era of mining for a low-carbon future.

India’s vast mineral endowment underpins not just its industrial ambitions but also some of its most carbon-intensive sectors — and yet, the current paradigm of extraction is increasingly unsustainable. In the cement sector alone, limestone mining is critical: about 97 per cent of the limestone produced in India is of cement grade. According to Market Review of Cement Sector, JSW report, India’s cement production rose to 426.29 million tonnes in FY 24, an increase of 8.90 per cent year-on-year, placing ever greater demand on quarrying operations. The Indian Cement Industry Analysis, IBEF states that with this scale of extraction, the environmental consequences are mounting, compelling the industry and regulators alike to rethink mining practices.
The environmental toll of conventional mining — deforestation, soil erosion, disruptions to hydrological systems, dust pollution, and biodiversity loss — is no longer a future risk but a present reality. A study by Mongabay-India tracking Indian coal-mining regions from 1994 to 2022 found that mining had reduced forest cover by 7.32 per cent to 17.61 per cent, and shrunk water bodies by 5 per cent to 10 per cent in many zones. Moreover, water pollution in several mines has often exceeded permissible norms: between 2013 and 2018, eight out of 28 studied mines were found to breach Bureau of Indian Standards limits. These are cautionary signals for sectors deeply reliant on mined materials — like cement — that sustainability cannot remain an afterthought states Assessment of Environmental Impact due to Mining Activities, PRS India.
Alongside environmental imperatives, there is growing social, regulatory, and economic impetus pushing the mining industry toward transformation. The mining sector currently contributes about 2.5 per cent to India’s GDP states the Mining 2025 – India, Chambers practice guide. Meanwhile, ESG norms, community expectations, and climate goals demand that mining operations align with sustainable development principles. As India charts its path toward Net Zero by 2070, the cement industry must engage not only in low-carbon kiln technologies but also in sustainable sourcing of its raw materials. In this article, we explore how sustainable mining — in policy, practice, and innovation — can become a foundation rather than a constraint for India’s
cement future.

Environmental footprint of traditional mining
Traditional mining leaves a deep and lasting scar on the natural environment, often in ways that transcend the boundaries of the lease area. Vegetation is cleared, soil structure is disrupted, and topsoil is often lost irreversibly. According to a recent spatial-analysis study, mining areas in one region expanded from 0.00 per cent in 1991 to 8.97 per cent in 2021, while vegetation cover in the same region fell from 40.17 per cent to 31.20 per cent over the same period according to the ‘An assessment of environmental impacts in mining areas’ report, 2024. In mineral-rich states like Odisha, districts such as Rayagada and Koraput have each lost more than 20 km² of forest cover between 2001 and 2019 due to expansion of mining operations. According to the ‘Mining impacts on
forest cover change in a tropical forest’ study such deforestation not only reduces biodiversity and habitat, but also undermines ecosystem services such as carbon sequestration, soil retention, and local
climate regulation.
Pankaj Agarwal – National Mines Head, Shree Cement says, “Sustainable mining means responsibly extracting resources with minimal environmental impact, while ensuring long-term ecological balance and community well-being. As the cement industry moves toward carbon neutrality, mining must transform through clean energy adoption, electrification, and digital innovation to reduce emissions and boost energy efficiency. Embracing alternative raw materials and circular economy principles will lessen reliance on virgin resources, while integrating carbon capture technologies will help close the emissions loop. Responsible land use, biodiversity protection, and community engagement will ensure mining supports both environmental and social sustainability. In this evolving landscape, mining becomes a key enabler of a greener, more resilient cement industry.”
“Responsible mining is not just about extracting resources, it’s about safeguarding ecosystems, empowering communities and ensuring that every step we take today builds a more sustainable tomorrow. At every stage from exploration to rehabilitation, we must embed environmental stewardship, ethical governance, and social accountability into our operations. This is not only a moral imperative but also a strategic one, ensuring long-term value for all stakeholders” he adds.
The environmental burden extends well beyond land cover changes. Water quality and hydrology are frequently disrupted by sediment runoff, acid mine drainage, and leachates carrying heavy metals and suspended particulates. According to a report by PRS India, Assessment of Environmental Impact due to Mining Activities and its Mitigation, 2021, during 2013–18, pollutants in eight out of 28 studied mines exceeded limits prescribed by the Bureau of Indian Standards. Furthermore, in the state of Karnataka, a 2025 assessment of granite quarrying in Ramanagara district found that surface and groundwater around quarry sites showed evidence of contamination, declining groundwater levels, and increased turbidity. Together with dust emissions, noise, vibration from blasting, and slope failures in overburden dumps, these impacts impose health risks on local communities and degrade ecosystems over a broad footprint.

Limestone mining and the cement industry
Limestone is the principal raw material in cement manufacture — indeed, more than 95 per cent of India’s limestone output is consumed by the cement industry. According to a report by JSW, Market Review of Cement Sector, about 97 per cent of the limestone produced in India is cement-grade. Over the past few decades, India has witnessed a surge in limestone extraction to support a rapidly growing cement sector. The Status of Limestone Mining and Cement Industry in India report notes that production increased more than five-fold from 23.8 million tonnes in 1970-71 to over 127 million tonnes by 1999-2000, and this upward trajectory has continued since. As the demand for infrastructure, housing, and urban development accelerates, pressure on limestone quarries intensifies — raising the stakes for mining that is both efficient and ecologically sensitive.
However, the method of extraction — typically opencast or open-pit quarrying — brings with it several environmental challenges that are especially pronounced in limestone mining for cement. Blasting, crushing, and hauling generate large volumes of dust and suspended particulates, which degrade air quality in surrounding habitations and ecological zones. According to a study published in Atmospheric Chemistry and Physics assessing environmental impact, limestone quarrying releases considerable suspended particulate matter and contributes to carbon and other air pollutant emissions. Furthermore, the process of overburden removal and bench formation alters landforms and disturbs soil structure and drainage patterns, increasing susceptibility to erosion and reducing soil fertility in adjacent lands.
Water dynamics and hydrology are also affected by limestone mining, particularly in regions with fractured carbonate bedrock. De-watering and drainage of aquifers, runoff laden with suspended solids and fines, and changes in surface water flow paths can all strain local water resources. In the East Jaintia Hills of Meghalaya, for example, studies have documented observable declines in water availability, contamination of streams, and deterioration of water quality in limestone mining zones sates the ‘Changes in Soil Quality in Limestone Mining Area’ study. Similarly, open-cast mining in Tilakhera, Chittorgarh district (Rajasthan) showed degradation in soil organic carbon, pH, and other fertility indicators up to a depth of 4.5 m beyond the mine boundaries states ‘Impact of open cast Limestone mining activities on soil quality status’. These hydrological and geochemical perturbations often persist long after mining operations cease, complicating restoration efforts.
Ramesh Kumar Ajmera, Founder and Director, Balaji PrimeSteel says, “Water, one of mining’s most critical resources, is being conserved through closed-loop recycling, advanced filtration and dry tailings processing, minimising both consumption and pollution. Meanwhile, waste is no longer just a liability: tailings can be dry stacked and reused in construction, steel slag and fly ash are fed into cement production, and bioleaching extracts residual metals from mine waste. Real-time monitoring with IoT sensors, geographic information system (GIS) and blockchain ensures transparency, ethical sourcing, and early detection of violations. Even post-closure, drones, bioremediation and digital land planning support ecological restoration. While high costs and skill gaps slow adoption, technology ultimately acts as both shield and sword—reducing harm while driving efficiency and profitability in mining’s low-carbon future.”
Given the scale and criticality of limestone supply, the cement industry must embed sustainability into its upstream mining operations. Efficiency in resource usage — such as optimising blasting protocols to reduce waste and flyrock, reclaiming and reusing mine water, preserving topsoil for rehabilitation, and planning quarry layouts to minimise ecological disruption — are no longer optional extras, but essential. A robust Environment Management Plan tailored for limestone quarries, with rigorous monitoring of dust, water, noise, and biodiversity, becomes a baseline expectation states the ‘Environmental Hazards of Limestone Mining and Adaptive Practices’ report. In the subsequent sections, we will examine how technology, rehabilitation, regulation, and innovation can together reimagine limestone mining not merely as an enabler for cement, but as a driver of sustainable industrial development.

Technology-Led mining: digitalisation and automation
In recent years, mining operations have begun to embrace digital transformation in a way that reshapes the entire value chain — from exploration and planning through extraction to monitoring and rehabilitation. According to a report by PwC, Transforming India’s Mining Landscape with Autonomous Technology, autonomous mining integrates operational technology (e.g. automated drilling, haul trucks, and control systems) with information technology (data connectivity, analytics, remote operations) to progressively reduce human presence in high-risk zones and enhance precision. In India, the deployment of IoT sensors, AI algorithms and remote control systems is enabling real-time monitoring of blasting, slope stability, dust levels, and equipment health, thereby optimising energy use and lowering downtime states the EY – Transforming India’s Mining Sector through Sustainability and Innovation report.
Prasanajit M, Founder and Managing Director, Shanvi Resources says, “For Shanvi Resources, sustainable mining means profit with proof — measurable ESG outcomes built into every tonne. Data and technology are central to this vision: live orebody models, smart drilling, and analytics-led operations help cut dilution, fuel, and water use, transforming sustainability from a cost centre into a control variable. To the cement industry, the message is clear — co-design your quarries with your miners. Align raw-mix needs, haulage energy, water management, and land rehabilitation from day zero, because shared KPIs deliver both a lower clinker factor and a lower environmental footprint.”
The results of automation and digitalisation are already noteworthy in global practice, and Indian mining firms are beginning to catch up. According to the Automation and Digitalisation Insights 2024 report, over 60 per cent of surveyed mining professionals have confirmed deployment of automation technologies such as autonomous vehicles and remote operating centres, especially in large scale operations. These technologies reduce exposure of workers to hazardous environments, improve operational consistency, and open the way for predictive maintenance and prescriptive optimisation of workflows. Moreover, the use of digital twins and industrial IoT platforms is showing promise: for example, a 2025 study demonstrated how a prototype system combining IoT sensors with a digital twin layer optimised equipment deployment and process throughput in traditional mining setups states the Industrial IoT and Digital Twin in Mining study. The integration of such technologies in India’s cement-linked limestone mining can yield gains in safety, efficiency and environmental control — provided capital investment and skill development go hand in hand.

Afterlife of mined lands
Once mining operations wind down in a quarry, the ‘afterlife’ of that landscape becomes as important as its active years. The objective of reclamation and rehabilitation is to restore ecological function, make the land safe and stable, and wherever possible repurpose it for productive use (like agriculture, forestry, or recreation). According to a report by FIMI, States’ Best Practices in Mining, 2025, several Indian states have begun mandating comprehensive mine closure and post-mining land use plans as part of their lease conditions. Effective reclamation often begins before closure: stacking and preserving topsoil, contouring benches and slopes, installing drainage, and planting pioneer species to check erosion. In India, bio-reclamation efforts by coal/lignite PSUs have resulted in 10,942 hectares being brought under green cover over FY 2019–20 to 2023–24, with 23.64 million saplings planted in and around mines according to a report by the Ministry of Coal.
“Overburden is systematically stacked and used for backfilling or land reclamation. We also plant trees in reclaimed areas, so the land regains its natural balance over time. Compliance is non-negotiable now. We stay aligned with all statutory norms and so that their concerns are addressed beyond just legal requirements” says Anurag Bagaria, Managing Director, KK Bagaria Group.
Yet rehabilitation is no mere matter of planting trees. In limestone mining regions, success depends on matching appropriate germplasm, soil amendments, moisture retention strategies, and long-term monitoring. The Post-mined Land Rehabilitation in India catalogue highlights that more than 50 tree, shrub and grass species have been trialed across different climatic zones, but the choice must suit local soil and rainfall regimes. In highly weathered or rocky overburden zones, techniques such as compost mixing, mycorrhizal inoculation, and vetiver hedges have often been used to stabilise slopes and shield against erosion states the Post-mined Land Rehabilitation in India catalogue. In limestone quarries specifically, legacy studies have shown that a combination of rainwater harvesting structures, soil ameliorants, and strategic planting of grasses and shrubs can yield self-sustaining vegetation even in complex substrate conditions.
Water management is a core pillar of sustainable mining, because without proper control, dewatering, runoff, or contaminated discharges can degrade downstream aquatic systems. According to a report by Saba Shirin et al, Environmental Impact of Mine Water Utilization and Management in Indian Mines, 2018, untreated mine water often exhibits elevated TDS, suspended solids, and abnormal pH levels — risks that demand robust treatment before reuse or discharge. In practice, mines adopt a “zero or minimal discharge” approach, capturing runoff, sedimenting suspended solids, and recycling treated water back into operations. Many mining firms globally now deploy modular treatment systems, reverse osmosis, and constructed wetlands to polish effluent water suitable for dust suppression, process reuse or irrigation states Mining Wastewater Use: Challenges, Opportunities, and Sustainable Approaches, 2023. Crucially, integrating water budgeting in mine planning—forecasting inflows, seepage, and recycling potential—allows operators to reduce freshwater drawdown and maintain ecological flows in surrounding watersheds.
Waste minimisation and byproduct utilisation represent both an environmental solution and a value opportunity for mining in the cement sector. According to a report by EY, Advancing India’s Mining Sector: Strategies for Sustainable Growth, 2024, mining companies are increasingly adopting circular economy principles by converting waste streams into raw materials, backfill, or construction inputs. Tailings, overburden, fines, and quarry dust — often viewed as liabilities — can be converted into blends for aggregates, bricks, or supplementary cementitious materials (SCMs). The Circular Economy in the Indian Extractive Industry article (2025) notes that improved processing and sorting can increase the usable share of mineral output while reducing the volume of residue requiring storage. Some Indian mines already use tailings or reject for backfilling, stabilising dumps, or as road base; others treat wastewater sludge for land application states Mine Waste as Resource: Indian Mining Scenario of Coal, 2021. The challenge lies in ensuring quality, regulatory compliance, transport economics, and consistent supply — but done right, byproduct valorisation transforms a cost centre into a strategic advantage for sustainable mining.

Green initiatives in mining
Energy efficiency and carbon reduction in mining are no longer aspirational goals but strategic imperatives. According to a report by EY, Advancing India’s Mining Sector: Strategies for Sustainable Growth, one of the three core pillars for decarbonising mining in India is energy efficiency, alongside electrification and the shift to decarbonised fuels. By reducing specific energy consumption in mining machinery, optimising haulage routes, and using variable-speed drives and waste heat recovery systems, mines can materially lower their emissions footprint. In India’s broader industrial sector, energy efficiency programmes achieved savings of 53.60 Mtoe in 2023-24, equivalent to roughly 6 per cent of the country’s primary energy supply. When applied to mining operations, similar gains translate to reductions in fuel use, maintenance costs, and greenhouse gas emissions—especially valuable in energy-intensive sectors like limestone and cement feedstock extraction.
Pukhraj Sethiya, India Managing Director, ReVal Consulting says, “The most underrated driver of sustainable mining is community engagement. While technology and regulations often dominate discussions, the long-term viability of mining truly depends on earning and maintaining a social licence to operate. Employing local people, building cooperative supply chains, and ensuring post-mining land use that benefits surrounding communities can significantly reduce operational risks and strengthen social resilience. These practices move sustainability beyond compliance, embedding it in the very fabric of regional development and stakeholder trust. When communities thrive alongside mining operations, sustainability becomes both a moral and commercial imperative.”
“Consulting plays a pivotal role in accelerating ESG adoption by bridging ambition with execution. By integrating ESG principles into mine design, conducting materiality assessments, and quantifying life-cycle impacts, consultants help organisations turn sustainability into a measurable business advantage. They enable miners to navigate complex regulations, access green finance, and enhance investor confidence while improving operational efficiency. As climate risks, investor scrutiny, and global supply-chain benchmarks redefine the economics of mining, sustainability has shifted from being a choice to a strategic necessity. In cement-linked mining, in particular, responsible and data-driven ESG integration is now the true benchmark of long-term competitiveness” he adds.
Biodiversity conservation and supply-chain greening are complementary but distinct fronts in sustainable mining. Mining activities, particularly for construction minerals, have been flagged among the serious threats to local biodiversity through habitat loss, fragmentation, pollution, and hydrological disruption. According to a report by CONBIO / C-Bio (2024) on mining threats in high-level biodiversity conservation policies, the mining of construction minerals causes direct and indirect impacts on biodiversity via erosion, traffic, pollution and water stress. To counter this, mining operations must develop biodiversity action plans, set aside ecological buffers, and use corridors or “green bridges” to maintain habitat connectivity. Meanwhile, the role of green supply chains becomes critical: adopting green procurement, optimising transport logistics, and ensuring traceability of raw materials can reduce emissions and ecological footprints beyond the mine. A study on green practices in Indian mining supply chains observed that firms are increasingly adopting eco-friendly transport, waste handling, and supplier audits as part of a Green Supply Chain Management (GSCM) framework. Together, energy-efficient mining, biodiversity safeguards, and green supply chains form a triad that can lift mining from being seen as a burden to being a contributor to sustainable value creation.

Case studies
To understand how these principles translate into practice, it’s essential to look beyond policy and theory. In the following section, we explore a series of mining case studies that highlight how different organisations—both in India and globally—are integrating sustainability into their operations. From innovative water reuse systems and biodiversity restoration projects to digital mine planning and community-driven rehabilitation, these examples demonstrate that responsible mining is not only achievable but also commercially rewarding.

Conclusion
The path toward sustainable mining in India demands more than compliance — it calls for a transformation of intent, policy, and practice. The future will be shaped by how effectively policy frameworks integrate sustainability at every stage of mining — from exploration to post-closure rehabilitation. India’s National Mineral Policy (2019) already lays the groundwork by emphasising environmental and social responsibility, but translating policy into practice requires strong institutional capacity, inter-departmental coordination, and transparent monitoring. Strengthening the Star Rating system for mining leases, expanding District Mineral Foundations for equitable community development, and enforcing stricter Environment Management Plans will help close the implementation gap. Equally vital is aligning India’s mining roadmap with its Net Zero 2070 commitments, ensuring that the extraction feeding core industries such as cement becomes low-carbon, circular, and regenerative.
The next phase of sustainable mining will be defined by innovation and collaboration. Advancements in remote sensing, real-time environmental monitoring, green chemistry for beneficiation, and AI-driven resource modelling are already redefining what “responsible extraction” means. But technological innovation must move hand-in-hand with collaboration — between government, academia, private industry, and communities. Mining companies must work alongside environmental scientists and local stakeholders to design site-specific solutions that balance resource utilisation with ecological and social regeneration. In doing so, India has an opportunity not only to secure the raw materials that fuel its economic ambitions but also to demonstrate how a nation rich in minerals can mine responsibly, sustainably, and with foresight for generations to come.

– Kanika Mathur

Case Study 1

Sustainable Mining – a Case Study in Canadian Practice

D H Steve Zou and Cui Lin, Mineral Resource Engineering, Dalhousie University, Halifax, Canada, present a case study that explores how sustainable practices, regulatory frameworks and community-driven reclamation transformed a Canadian coal mine into a model of responsible mineral development.

The case study begins with a clear definition of sustainability in mineral resource development.
Mining is essential for modern life, but mineral resources are finite and extraction disturbs the land. Therefore, sustainability means extracting resources responsibly, reclaiming disturbed land, and minimising environmental impact. Every tonne of mineral extracted reduces
what is left for future generations, which makes careful planning critical.

Three pillars of sustainable mining
The study frames sustainability around three aspects: (a) maximise recovery of resources without waste, (b) minimise or remove footprints through reclamation, and (c) limit environmental pollution by proper waste management. Achieving these goals requires planning, technology and cooperation among mining companies, governments and engineers.

Responsibilities of stakeholders
Mining companies must avoid the practice of only extracting high-grade ores, leaving behind lower grades. They must also develop comprehensive reclamation and waste disposal plans. Governments play a regulatory role, ensuring compliance through inspections, enforcement, and closure planning. Engineers carry ethical responsibility, ensuring no economically recoverable ores are wasted, and effluents meet environmental standards.

Canada’s regulatory framework
Canada has evolved strong regulations over time. Provincial governments are responsible for mining regulations within their jurisdictions, while the federal government oversees projects affecting Crown land or the environment. For new mines, companies must submit reclamation and closure plans, along with financial assurance, before permits are granted. Inspections by professional engineers ensure compliance, with penalties for violations.

National programmes supporting sustainability
The Mining Association of Canada launched the Towards Sustainable Mining (TSM) program in 2004, requiring members to operate in socially, economically, and environmentally responsible ways. This industry-wide initiative formalised sustainability as a core practice, ensuring alignment with community and regulatory expectations.

Case study overview
The featured case study is of a coal mine located within 300 meters of a residential area. Historical mining in the 1800s and early 1900s had removed much of the high-grade coal and left unknown underground workings. To recover the remaining deposits, modern surface mining techniques were used. Given its proximity to the town, blasting was not allowed, making noise and dust control priorities.

Mining operations and waste handling
The coal seams, dipping 20°–25° and lying within 80m depth, were mined using a modified open-pit method. Operations progressed east to west, with waste rocks from new pits used to backfill older ones. Topsoil was stripped and stored for later reclamation. Waste rock volume exceeded pit capacity, so excess was stored on the southern side, later integrated into reclamation plans.

Progressive reclamation approach
Unlike traditional methods where reclamation happens after closure, this mine carried out progressive reclamation. Once a pit was filled with waste rock, it was topped with soil and sod. This minimised long-term disturbance and reduced environmental risks like acid drainage. By the end of operations, the disturbed land was contoured to match natural surroundings.

Lessons and broader implications
This Canadian case study demonstrates that sustainable mining is achievable through careful planning, progressive reclamation and community involvement. By integrating environmental protection, waste management, and social benefits into the mining lifecycle, the project left behind usable land and community infrastructure rather than scars. It exemplifies best practice, showing how the mining industry can support both present needs and future generations.

Case Study 2

Sustainable Mining in Practice

This case study published in Journal of Cleaner Production, Elsevier, 2024, investigates sustainable mining practices by evaluating how modern mining operations can integrate environmental responsibility, technological innovation and socio-economic benefits.

Mining remains a cornerstone of industrial growth, yet it poses significant environmental and social challenges. The authors focus on sustainable frameworks that balance mineral demand with ecological and community priorities.

Background context
Globally, mining activities are linked to high energy use, biodiversity loss, water contamination, and greenhouse gas emissions. The case study highlights that the mining sector contributes around four per cent to seven per cent of global greenhouse gas emissions, stressing the urgent need for sustainable interventions. The challenge lies in meeting mineral demand for industries like cement, steel and renewables while cutting environmental impact.

Research objectives
The case study aims to analyse integrated approaches that reduce mining’s environmental footprint. Key objectives include waste reduction, energy efficiency, carbon neutrality pathways, and restoration of ecosystems post-mining. The paper positions sustainability not just as compliance but as a core business strategy, shaping competitiveness and long-term viability.

Methodology
The study combines life cycle assessment (LCA), carbon accounting, and field data from Chinese mining operations to evaluate sustainability indicators. Parameters such as energy consumption, CO2 emissions, water use, and land restoration progress were quantified to understand the true impact of mining activities and the benefits of greener alternatives.

Data insights – emissions
Findings show that average carbon emissions from coal mining activities range between 1.4 to 2.6 tonnes of CO2 per tonne of coal produced, depending on depth, technology, and energy source. Electrification of equipment, renewable integration, and efficiency upgrades were shown to reduce emissions by 15 per cent to 25 per cent, proving that measurable reductions are achievable through targeted interventions.
Data insights – energy and water
The study highlights that traditional coal mines consume about 30–40 kWh of electricity per tonne of coal. Modernisation, including automation and optimised ventilation systems, reduces this figure by nearly 20 per cent. In terms of water, operations averaged 1.2–2.0 m³ per tonne, with closed-loop recycling cutting water demand by up to 50 per cent. These numbers underscore the role of process redesign in sustainability.

Land and ecological restoration
Post-mining reclamation is another focal point. In the case project, progressive reclamation restored over 65 per cent of disturbed land within operational phases, instead of waiting until closure. Vegetation recovery rates exceeded 70 per cent survival in replanted zones, showing how planned rehabilitation can return land to productive or recreational use while mining is still active.

Community and social impact
The study notes that mining companies adopting sustainable practices enjoy stronger community trust. In the featured project, investment in local water treatment and public green spaces created shared value. Job creation was paired with training in renewable and environmental technologies, aligning workforce development with sustainability goals.

Policy and governance
Regulation plays a central role. The authors stress that strict government policies in China—including carbon neutrality targets for 2060—are accelerating the shift toward sustainable mining. Financial assurance for reclamation, environmental audits, and penalties for violations is shaping corporate behaviour.

Conclusion
The case study demonstrates that sustainable mining is practical and beneficial. By integrating emission reduction, water conservation, land reclamation and community engagement, mining can reduce its ecological footprint while ensuring long-term resource availability. The findings suggest that a structured, data-driven approach to sustainability enhances resilience, meets ESG expectations, and sets benchmarks for the global mining industry.

Concrete

Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint

Published

on

By

Shares

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.

Continue Reading

Concrete

Green Construction Through Cement Innovation

Published

on

By

Shares

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:

  • Kiranmai Sanagavarapu, Director, Low Carbon Solutions, Fuller Technologies;
  • 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

Participate in Cement Expo 2026 and discover how next-gen infrastructure can be built with innovations in cement.

Continue Reading

Concrete

Indian Railways Plans Green Fly Ash Transport Network

Published

on

By

Shares

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.

Continue Reading

Video Thumbnail

    SIGN-UP FOR OUR GENERAL NEWSLETTER


    Trending News

    SUBSCRIBE TO THE NEWSLETTER

     

    Don't miss out on valuable insights and opportunities to connect with like minded professionals.

     


      This will close in 0 seconds