Concrete

Shaping a Low-Carbon Cement Future

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2 hours ago

November 17, 2025

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ICR explores how India’s cement industry is redefining emission control through advanced filtration, digital process optimisation, and low-carbon innovation.

Cement plants emit four key pollutants—CO2, NOx, SOx, and particulate matter (PM)—each arising from different stages of production. Most CO2 stems from limestone calcination and kiln fuel combustion, and while the sector’s CO2 intensity has remained flat, it must decline by ~4 per cent annually by 2030 to align with net-zero goals, as mentioned in or a report by the IEA. In kilns, thermal NOx dominates due to high flame temperatures (~1,200°C), SO2 originates from sulphur in fuel and raw materials, and PM is released from raw mill handling and clinker grinding—as mentioned in or a report by the EEA Guidebook (2023). At the global level, cement accounts for 6 per cent to 8 per cent of total CO2 emissions, highlighting the need for integrated emission strategies, as mentioned in or a report by the GCCA. India’s installed capacity grew from ~510 MTPA (2019) to ~632 MTPA (2024), reflecting ~4.4 per cent CAGR, as mentioned in or a report by JMK Research (2024). National GHG emissions reached ~4.13 GtCO2e in 2024, with cement responsible for 6 per cent to 7 per cent, largely concentrated among top producers, as mentioned in or a report by CARE Edge ESG (2025).
India’s cement roadmap targets net-zero CO2 by 2070, with milestones tied to efficiency, alternative fuels, SCMs, and carbon capture, as mentioned in or a report by TERI (2025). Policy frameworks are evolving accordingly: Continuous Emission Monitoring Systems (CEMS) for PM, SO2, and NOx are mandated to strengthen compliance and transparency, as mentioned in or a report by the CPCB. Globally, the IEA’s Breakthrough Agenda Report (2025) emphasises that achieving real decarbonisation requires parallel progress in process control, AFR, SCMs, and CCS, since total CO2 emissions remain above 2015 levels and intensity gains have plateaued. For India, the path forward lies in combining strict regulatory oversight with accelerated technology adoption—ensuring each tonne of clinker produced moves closer to compliance, efficiency, and long-term net-zero alignment.

Modern filtration systems: The first line of defence
Cement plants are swiftly moving beyond legacy electrostatic precipitators (ESPs) to high-efficiency baghouses, hybrids, and smart filter media that achieve ultra-low particulate emissions with tighter control. India’s regulatory drive has been crucial—CPCB’s 30 mg/Nm3 PM limit (also enforced by Delhi DPCC) has accelerated retrofits and new installations, as mentioned in or a report by CPCB and DPCC. Modern systems often outperform these standards: a Thermax kiln-raw mill project guaranteed =25 mg/Nm3, while an ESP-to-baghouse conversion in Asia cut dust from 40 to 9 mg/Nm3 (—78 per cent), as mentioned in or a report by Thermax and a peer-reviewed study. Indian majors like UltraTech are scaling this approach—converting hybrid filters to pulse-jet baghouses and upgrading cooler ESPs to further reduce PM, as mentioned in or a report by the company’s environmental filings.
Performance gains now hinge on advanced filter media. Plants using ePTFE/PTFE-membrane bags achieve cleaner filtration and drops from ~50 to ~30 mg/Nm³, while maintaining stable pressure loss, as mentioned in or a report by Orient Cement’s compliance report and an ePTFE study. Nanofiber-laminated felts and electrostatically enhanced baghouses promise lower pressure drop, longer bag life, and reduced fan power, as mentioned in or a report by the US EPA baghouse compendium. Vendors like Intensiv-Filter Himenviro now offer baghouses achieving <10 mg/Nm3 under optimal design and maintenance. The trend is clear: pulse-jet baghouses with advanced membranes and selective ESP upgrades are providing India’s cement sector with the compliance flexibility, energy efficiency, and reliability needed to thrive under its tighter emission regime.

Advanced process optimisation
Digitalisation and AI-based process optimisation have emerged as key levers for emission reduction in cement manufacturing, addressing pollutants at their source rather than at the stack. Across global and Indian plants, AI-driven kiln control systems like ABB’s Expert Optimiser and Carbon Re’s AI for Pyroprocess are redefining precision by integrating real-time data from sensors and APC loops to stabilise combustion, optimise fuel use, and limit NOx and CO formation. As mentioned in or a report by ABB (2024), advanced process control has cut fuel consumption by 3 per cent to 5 per cent and CO2 emissions by up to 5 per cent, while as mentioned in or a report by Carbon Re (2024), European plants achieved 4 per cent lower fuel use and 2 per cent CO2 reduction through AI kiln optimisation.
Indian majors like UltraTech, Dalmia, and Shree Cement are piloting such hybrid models combining process, energy, and environmental data for smarter emission management.
Vijay Mishra, Commercial Director, Knauf India says, “India’s construction materials sector is making steady progress toward circularity, moving beyond the earlier focus on “green buildings” to now addressing lifecycle impacts and resource recovery. While global leaders, particularly in Europe, benefit from mature collection and recycling infrastructure for materials like gypsum, metals, and aggregates, India is still in the early stages of building that ecosystem—but the momentum and policy direction are clearly positive. The country’s massive construction pipeline presents a unique opportunity: even modest gains in material reuse and low-carbon manufacturing could yield enormous environmental benefits. The main challenge remains infrastructure—segregation at site level, recovery logistics, and recycling facilities—but as these improve, the economics of circular materials will become more compelling. Looking ahead, the next decade of emission-conscious manufacturing will be shaped by material circularity, manufacturing efficiency, and digital traceability—turning waste into value, cutting emissions at source, and ensuring every sustainable action can be measured and rewarded. For manufacturers, this balance between innovation and responsibility will define the future of India’s low-carbon construction movement.”
The benefits extend beyond combustion. Real-time monitoring and predictive analytics enable operators to anticipate emission spikes and recalibrate process parameters automatically. As mentioned in or a report by the CII–Sohrabji Godrej Green Business Centre (2023), India’s top plants operate below 70 kWh/t cement (electrical) and 690 kcal/kg clinker (thermal)—benchmarks sustained through digital oversight. Digital twins and AI-driven models now simulate NOx reduction and fuel substitution scenarios, cutting trial errors. As mentioned in or a report by the IEA (2025), digitalisation is among the top three global levers for industrial decarbonisation, capable of reducing cement CO2 emissions by up to 8 per cent by 2030. The future of emission control will depend less on end-of-pipe systems and more on intelligent, adaptive process control that keeps every second of kiln operation cleaner, stable, and efficient.

From capture to co-processing
The cement industry’s decarbonisation pathway now rests on two pivotal levers—Carbon Capture, Utilisation and Storage (CCUS) and Alternative Fuels and Raw Materials (AFR)—each addressing a distinct source of emissions. While process emissions from limestone calcination are unavoidable, CCUS provides a route to capture, reuse, or store CO2, whereas AFR mitigates combustion-related emissions by substituting fossil fuels with renewable or waste-derived alternatives. Together, they form the “dual engine” of deep decarbonisation, capable of reducing total CO2 emissions by over 40 per cent in advanced systems, as mentioned in or a report by the Global Cement and Concrete Association (GCCA, 2024). Globally, CCUS is moving from pilots to commercial reality—as mentioned in or a report by Heidelberg Materials (2024), the Brevik CCS plant in Norway will capture 400,000 tonnes of CO2 annually, while Holcim’s GO4ZERO project in Belgium aims for 1.1 million tonnes by 2029, establishing Europe as the proving ground for full-scale capture. As mentioned in or a report by TERI (2025), India is now developing its own CCUS roadmap, with Dalmia Cement and Carbon Clean partnering on a 500,000 tCO2/year project in Tamil Nadu—the country’s first commercial-scale cement CCUS initiative. Meanwhile, as mentioned in or a report by the NITI Aayog–GCCA policy brief (2024), frameworks are being designed for carbon capture finance corporations and shared storage clusters to accelerate deployment.
Raj Bagri, CEO, Kapture says, “Decarbonising cement production is crucial, but while the focus is often on the main kiln, the surrounding infrastructure, including essential diesel generators remains a source of carbon pollution. These generators provide crucial backup or primary power for on-site operations, contributing to a plant’s overall carbon footprint. Kapture addresses this with a cost- effective, easily retrofittable technology that captures CO2 directly from diesel generator exhaust. Kapture’s innovative approach transforms the captured carbon into a stable, solid byproduct. This material then closes the loop by being sequestered in concrete. By serving as a direct replacement for a portion of virgin clinker, Kapture’s. byproduct actively offsets the hard-to-abate process emissions that dominate the cement industry. This circular economy model provides a powerful solution. It immediately cuts combustion emissions from the auxiliary power source and simultaneously reduces the need for high-carbon raw materials in the concrete mix, Kapture offers the cement industry a pathway to both clean up their power and drastically lower the carbon intensity of their end-product.”
Parallel to carbon capture, the rise of AFR is redefining combustion efficiency and circularity across Indian plants. As mentioned in or a report by the CII–Sohrabji Godrej Green Business Centre (2023), India’s Thermal Substitution Rate (TSR) averages 6 per cent to 8 per cent, with leaders such as UltraTech, ACC, and Geocycle already achieving 15 per cent to 20 per cent through co-processing Refuse-Derived Fuel (RDF), biomass, and industrial waste. This transition reduces dependence on coal and petcoke while diverting thousands of tonnes of waste from landfills. The MoEFCC aims to raise TSR to 25 per cent by 2025, in line with India’s Circular Economy Action Plan, and as mentioned in or a report by the IEA (2023), such substitution can cut specific CO2 emissions by 12 per cent to 15 per cent. Although cost, scale, and infrastructure remain challenges, India’s combined progress in CCUS and AFR signals a powerful shift—toward a future where carbon is captured and reused, waste becomes a valuable fuel, and cement production evolves into a truly circular, low-emission system.

Instrumentation, data transparency, and continuous monitoring
Real-time monitoring has become central to emission management in cement manufacturing, replacing periodic sampling with Continuous Emission Monitoring Systems (CEMS) that track PM, SO2, and NOx continuously. As mentioned in or a report by the CPCB (2024), CEMS installation is now mandatory for all integrated plants in India, with live data streaming to regulatory servers for verification. These systems enhance transparency and allow operators to act before emissions exceed limits. Complementing them, IoT-based sensors for baghouse performance and draft fans are cutting downtime by up to 30 per cent, as mentioned in or a report by Frost and Sullivan (2024). Many states now mandate continuous online air-quality reporting, creating a real-time loop between regulators, operators, and technology providers. As mentioned in or a report by the GCCA (2024/25), leading producers are integrating digital emission platforms that combine CEMS data, process sensors, and ESG metrics, building both compliance and investor confidence. Globally, as mentioned in or a report by the IEA (2025), smart sensors and automated reporting can cut non-compliance events by up to 40 per cent while boosting efficiency. For India, scaling such data-driven frameworks will ensure emission control evolves from a reactive measure to a proactive, intelligence-led sustainability system.

Regulatory framework and global benchmarks
India’s cement industry operates under one of the most stringent emission control regimes among developing nations, with the Central Pollution Control Board (CPCB) setting specific stack emission limits for key pollutants—30 mg/Nm³ for particulate matter (PM), 800 mg/Nm3 for NOx, and 100 mg/Nm3 for SO2 from kiln and clinker cooler outlets, as mentioned in or a report by the CPCB (2024). These norms are comparable to the EU-Best Available Techniques (EU-BAT) reference levels, which stipulate 10–30 mg/Nm3 for PM, 200–800 mg/Nm3 for NOx, and 50–400 mg/Nm3 for SO2, depending on plant design and fuel type—as mentioned in or a report by the European Commission’s BAT Reference Document (BREF, 2023). Meanwhile, US-EPA’s National Emission Standards for Hazardous Air Pollutants (NESHAP) require PM to be maintained below 30 mg/Nm3 for new cement kilns, reinforcing global convergence toward tighter thresholds. India’s 2016 revision of cement emission norms marked a watershed moment, reducing permissible PM levels from 150 mg/Nm3 to 30 mg/Nm3, driving widespread retrofits of ESPs and installation of high-efficiency baghouses across major plants. As highlighted in a TERI policy paper (2025), nearly 80 per cent of India’s integrated cement capacity now complies with these upgraded standards, supported by Continuous Emission Monitoring Systems (CEMS) and regular digital reporting to state pollution control boards—placing India’s emission control framework among the most advanced and transparent in the Global South.

Building a low-emission, high-performance industry
India’s cement sector stands at a defining crossroads—where growth and sustainability must advance together. With production projected to exceed 600 million tonnes by 2028, as mentioned in or a report by JMK Research (2024), India’s leadership in emission control will shape global low-carbon manufacturing. Over the past decade, regulatory reform, CPCB’s 30 mg/Nm3 PM limits, continuous monitoring, and ESP-to-baghouse conversions have brought India close to EU and US benchmarks. The next leap requires integrated decarbonisation—linking AI-driven optimisation, renewable energy, alternative fuels, and carbon capture. As mentioned in or a report by the IEA (2025), digital technologies can reduce CO2 emissions by up to 8 per cent by 2030, while CCUS and AFR could cut process-related emissions by 40 per cent to 50 per cent. Meanwhile, R&D in LC³ and belite cements, combined with circular-economy co-processing, is reshaping both the chemistry and carbon profile of Indian cement. Policy incentives, carbon finance, and strong industry–academia collaboration will be key to making India a pioneer in green cement.
Ultimately, emission control is becoming a strategic advantage, not just compliance. The future cement plant will be a hybrid of automation, accountability, and adaptive design, where digital twins optimise processes and every gram of carbon is tracked. By coupling robust policy frameworks with investment in skills, digital infrastructure, and collaborative innovation, India can redefine sustainable heavy industry. The goal now is not incremental change but transformational adoption, where every avoided emission strengthens both the planet and profitability. With its evolving ecosystem of technology, regulation, and intent, India’s cement sector is poised to become a global benchmark for low-emission, high-performance manufacturing and a model for industrial decarbonisation.

Carbon Emissions in Ready-Mix Concrete

This case study, published in Case Studies in Construction Materials (Elsevier, Jan 2025) by Zuojiang Lin, Guangyao Lyu, and Kuizhen Fang, examines carbon emissions in C30–C80 ready-mix concrete in China and explores CO2 reduction through SCMs, transport optimisation, and manufactured sand use.

This study analyses the carbon emissions of C30–C80 ready-mixed concrete using a large-scale mix proportion dataset from across China. The research applies a life-cycle assessment (LCA) based on IPCC and ISO 14040 standards to calculate total emissions, covering raw material production, transportation, manufacturing, and concrete delivery. The findings reveal that average carbon emissions range between 262.61 and 401.78 kgCO2e/m3, with cement accounting for about 90 per cent of embodied emissions. The study establishes that emission variations primarily arise from differences in cement dosage and raw material composition rather than energy use in manufacturing or transport.
The study identifies Supplementary Cementitious Materials (SCMs)—such as fly ash, ground granulated blast furnace slag, and silica fume—as major contributors to CO2 reduction. By partially replacing cement, SCMs lowered total emissions by 5 per cent to 30 per cent while maintaining equivalent strength levels. However, around 11 per cent of samples showed negative reduction rates, indicating that improper SCM selection or inconsistent material quality can offset benefits. The relationship between SCM substitution rates and CO2 reduction was found to be positively correlated but weakly linear, with considerable data dispersion due to mix variability.
Transport distance was also evaluated as a significant but secondary factor influencing emissions. The study found that CO2 reduction benefits from SCMs remained stable until transport distances exceeded 4166 km, beyond which the gains were nullified. For every additional 100 km of SCM transport by truck, the carbon reduction rate decreased by only 0.45 per cent. Comparatively, long-distance transport of aggregates from 100 km to 500 km increased concrete’s carbon emissions by over 10 per cent. This highlights the higher sensitivity of total emissions to aggregate logistics than SCM transport.
Lastly, the study analysed manufactured sand (MS) as a substitute for natural fine aggregates (NFA). While MS reduces transport-related emissions due to shorter sourcing distances, it increases total production energy consumption and can reduce concrete strength. When 50 per cent to 100 per cent of NFA was replaced with MS, total CO2 emissions remained largely unchanged. The authors conclude that SCMs offer clear and stable low-carbon benefits, whereas MS requires technological optimisation to realise its potential. Overall, the research provides quantitative evidence supporting low-carbon labelling standards for China’s concrete industry and underscores the importance of balancing strength, sourcing, and sustainability.

Reducing CO2 in Cement Production

This case study, published in Industrial & Engineering Chemistry Research (ACS Publications, Sept 2024) by Franco Williams and Aidong Yang, investigates CO2 reduction in cement manufacturing through alternative clinker compositions and CO2 mineralisation, achieving up to 45.5 per cent energy and 35.1 per cent CO2 savings in simulations.

This study investigates strategies for reducing CO2 emissions in cement production, which currently contributes around 8 per cent of global anthropogenic CO2. Using Aspen Plus V12.1 process simulations, seven clinker production scenarios were analysed — including Ordinary Portland Cement (OPC), three variants of High-Ferrite Clinker (HFC), Belite-Ye’elimite-Ferrite Clinker (BYF), Calcium Silicate Cement (CSC), and a hybrid option combining OPC with a Supplementary Cementitious Material (SCM) produced via CO2 mineralisation. The objective was to quantify differences in energy demand and CO2 emissions under natural gas–fuelled conditions and assess the decarbonisation potential of each composition.
The simulations revealed that alternative clinkers significantly outperform OPC in both energy efficiency and carbon footprint. OPC clinker production required 1220.4 kWh/t, emitting 741.5 kgCO2/t clinker, while CSC clinker achieved the lowest total energy intensity at 665.1 kWh/t, corresponding to a 45.5 per cent energy reduction and 35.1 per cent CO2 reduction. This efficiency stems from CSC’s low CaCO3 input (989.7 kg/t clinker) and sintering temperature of 1250°C, compared to OPC’s 1271.5 kg/t and 1500°C. The BYF clinker followed with 31.3 per cent energy savings and 27.5 per cent CO2 reduction, while HFC variants achieved moderate reductions of 3.1 per cent to 6.4 per cent in CO2 emissions.
For the SCM + OPC scenario, 25 per cent of the clinker was replaced with SCM derived from CO2 mineralisation. Despite a higher total energy requirement (1239.6 kWh/t) due to capture and mineralisation energy, this option delivered the greatest CO2 reduction—up to 44.8 per cent relative to OPC. The benefit was attributed to CO2 absorption during mineralisation and reduced clinker mass. However, the study noted that the energy intensity of mineralisation (1.30 kWh/kg SCM) exceeded that of clinker production (1.22 kWh/kg), indicating that this strategy’s effectiveness depends on access to low-carbon electricity sources.
Geographical variations also influenced the overall carbon footprint. When accounting for electricity grid emissions, Brazil showed the lowest total CO2 output (482.7 kgCO2/t) for SCM-integrated cement due to its green energy mix, compared to 601.6 kgCO2/t in China and 556.1 kgCO2/t in the United States. For CSC clinker, total reductions were 35.7 per cent, 36.0 per cent, and 35.3 per cent respectively across these countries. This emphasises that decarbonisation gains are highly dependent on the carbon intensity of local power grids.
Supporting simulations demonstrated that lowering sintering temperatures alone (to 1350°C or 1250°C) could reduce total energy consumption by 7 per cent to 17.5 per cent and CO2 emissions by 1 per cent to 2.6 per cent. However, these results are modest compared to the full compositional changes in alternative clinkers, confirming that reducing CaCO3 content in the raw meal contributes more significantly to CO2 mitigation. The decomposition of CaCO3 releases 0.44 kg CO2 per kg CaCO3 and requires 179.4 kJ/kmol of heat; hence, formulations with reduced limestone and alite (C3S) contents inherently lower both emissions and energy demand.
In conclusion, the study establishes that Calcium Silicate Cement (CSC) is the most energy-efficient clinker alternative, while SCM-integrated OPC achieves the highest CO2 reduction potential under green-energy conditions. The authors highlight that the decarbonisation of electricity supply is crucial for maximising the benefits of CO2 mineralisation-based SCMs. These results underscore that altering clinker chemistry and incorporating CO2 utilisation pathways are practical, high-impact strategies for achieving deep decarbonisation in the cement industry and align with global net-zero goals.

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A Legal Push for Low-Carbon Cement

Concrete

A Legal Push for Low-Carbon Cement

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2 hours ago

November 17, 2025

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As India’s cement industry reports yet another quarter of strong earnings on the back of improved realisations, stable prices and steady demand, the sector now stands at a pivotal crossroads. The optimism around growth is undeniable with improvement in capacity utilisation, continued infrastructure momentum and rebounded profitability. Yet, amid this performance surge, a new and defining chapter in India’s decarbonisation journey has begun.
On October 8, 2025, the Union Government notified the Greenhouse Gases Emission Intensity Target Rules, 2025, marking the first legally binding emission-intensity limits for heavy industries. Of the 282 units identified across cement, aluminium, pulp and paper, and chlor-alkali, a staggering 186 belong to the cement sector. This is an unmistakable signal that the industry will anchor India’s next phase of industrial climate action.
The move compels cement manufacturers to reduce their CO2 emissions per tonne of output against a 2023–24 baseline, in alignment with India’s ‘Net Zero by 2070’ vision. While many players have already invested in low-clinker technologies, alternative fuel, and renewable energy, this regulation adds legal teeth to what was previously a voluntary or market-driven transition.
It also introduces a new dimension to competitiveness. With the EU’s Carbon Border Adjustment Mechanism (CBAM) looming large, Indian producers must now quantify, manage and mitigate carbon costs more rigorously or risk losing ground in global trade.
The coming quarters will therefore test the sector’s ability to balance profitability with sustainability, growth with green responsibility. Can India’s cement producers turn compliance into competitive advantage? Can the sector lead the way in building not just infrastructure, but also a lower-carbon future? The answers, as always, will lie in how swiftly the industry moves from chasing volumes to mastering value.

Concrete

Humboldt Wedag India Marks 25 Years of Excellence

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2 hours ago

November 17, 2025

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Humboldt Wedag India celebrated the landmark event at TechConnect 2025 in Goa.

Humboldt Wedag India commemorated a remarkable milestone — 25 years of operations in India — through its flagship event, TechConnect 2025, held over two days in the scenic city of Goa. The event served as both a celebration and a platform for meaningful dialogue on the future of cement manufacturing. The gathering saw participation from nearly 75 delegates representing leading cement groups across the globe. The presence of the management board, founder members, and long-standing partners added to the significance of the occasion, reflecting the company’s enduring relationships and shared journey of growth.
TechConnect 2025 featured a series of panel discussions, interactive sessions and technology-focused presentations, offering valuable insights into emerging trends in the cement industry. The discussions revolved around energy efficiency, process optimisation, Operational Excellence and ‘cement beyond carbon’ — key themes that are shaping the industry’s evolution. Experts from KHD Germany and India along with representatives from partner companies and clients, exchanged perspectives on innovative solutions, operational best practices and successful project outcomes achieved in recent years. A highlight of the event was the release of two special publications: A commemorative book chronicling Humboldt Wedag India’s 25-year journey, capturing milestones, partnerships and contributions to the Indian cement sector. A booklet featuring the company’s recent technical publications, underlining its commitment to knowledge sharing and continuous innovation.
Beyond the formal sessions, TechConnect 2025 offered participants the opportunity to network, share experiences, and explore collaborative possibilities for the future. The event not only celebrated Humboldt Wedag India’s legacy but also reaffirmed its dedication to driving sustainability, efficiency, and innovation in the cement industry.
With the resounding success of TechConnect 2025, Humboldt Wedag India continues to strengthen its position as a trusted technology partner, shaping the next era of smart and sustainable cement manufacturing.

Concrete

Cementing Change: India’s Innovation Blueprint

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3 hours ago

November 17, 2025

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ICR delves into the groundbreaking innovations transforming India’s cement industry — from carbon capture and digitalisation to sustainable engineering and material resilience. Discover how technology and collaboration are shaping a low-carbon, competitive future.

India’s cement industry is at a pivotal turning point—evolving from traditional production methods to an era defined by advanced technology, sustainability, and operational reinvention. According to a report by the India Brand Equity Foundation (IBEF), demand growth of 6 per cent to 7 per cent is projected for FY25, following a robust 7 per cent to 8 per cent YoY increase in the last quarter of FY24. This momentum, driven by urbanisation, infrastructure expansion, and policy pushes like the PM Gati Shakti National Master Plan, underscores the need for the industry to evolve not just in capacity but in how it innovates, optimises, and decarbonises. Meanwhile, a report by ResearchAndMarkets estimates the Indian cement market will reach US $18.39 billion by 2025 at a 6.6 per cent CAGR, while the green-cement segment is expected to grow from US $2.31 billion (2024) to US $3.28 billion (2030)—clear signs that innovation has shifted from aspiration to necessity for competitiveness and carbon compliance. Amid this growth and environmental urgency, path-breaking innovations are transforming every link in the cement value chain—from carbon capture and digitalisation to sustainable packaging, data-driven manufacturing, and energy optimisation. As plants embrace Industry 4.0 and embed sustainable engineering at their core, the industry is transitioning from volume-led expansion to value-led transformation. The trajectory is clear: India’s cement producers are no longer just making cement—they are redefining it, building a low-carbon foundation for the nation’s next phase of infrastructure and sustainable growth.

CCUS: Cement’s Net-Zero Catalyst
For hard-to-abate process emissions in cement, Carbon Capture, Utilisation and Storage (CCUS) has moved from concept to large-scale implementation. Global first-of-a-kind projects are proving commercial viability: Heidelberg Materials’ Brevik CCS facility in Norway will capture ~400,000 tCO2/year (~50 per cent of the plant’s emissions), with its evoZero cement already pre-sold for 2025, as reported by Reuters. Similarly, Holcim’s GO4ZERO project in Belgium targets ~1.1 MtCO2/year capture by 2029, part of a broader 5 MtCO2/year ambition supported by the EU Innovation Fund. India is preparing to follow this trajectory—Dalmia Cement, in partnership with Carbon Clean, is developing a 500,000 tCO2/year CCUS plant in Tamil Nadu, aligning with its carbon-negative 2040 goal, as mentioned in company releases and an ADB analysis. Policy mechanisms are also emerging: the Global CCS Institute/GCCA policy brief (2024) proposes a Carbon Capture Finance Corporation and innovative funding tools to de-risk early projects, while NITI Aayog’s CCUS roadmap highlights the urgent need for large-scale demonstrations. Together, these moves signal that CCUS is shifting from research to reality, and India aims to be part of this global transformation.
Dr SB Hegde, Global Industry Expert say, “The cement industry’s path to net zero requires a phased and coordinated innovation roadmap. In the near term (2025–2030), emphasis must be on energy efficiency, clinker substitution, AFR, WHR, and digital optimisation, which are already proven and cost-effective. The next decade (2030–2040) will see wider adoption of electrification and carbon capture technologies, supported by renewable energy and green hydrogen. By 2040–2050, advanced low-carbon clinkers, carbon-negative binders, and circular material use will dominate, enabling deep decarbonisation. Together, these phases form a realistic pathway to cut CO2 emissions by over 70 per cent while ensuring competitiveness and resilience.”
Beyond capture, CO2 utilisation is equally vital—turning emissions into economic value through mineral carbonation, CO2-cured concrete, and carbonated aggregates. Europe’s Northern Lights project under Norway’s Longship program has already begun receiving CO2 shipments from Brevik, with plans to scale to ~5 MtCO2/year, as mentioned in the Financial Times. For India, where geological storage mapping and pipeline infrastructure are still evolving, near-site utilisation in construction materials or chemical feedstocks can bridge the economic gap until storage clusters—such as those planned along the west coast—are operational. The strategic path forward involves modular, retrofit-friendly capture systems, integration with energy efficiency and AFR initiatives, and the use of offtake and CFD-style instruments to offset early costs. As a report by TERI emphasises, India’s net-zero pathway by 2070 hinges on CCUS alongside clinker substitution, alternative binders, and renewable integration. The opportunity for Indian cement lies in acting early—turning CCUS from an obligation into a competitive advantage in the race for sustainable manufacturing.

Digital transformation
From quarry to kiln to bagging, Indian cement plants are rapidly shifting from manual set-points to sensor-driven, AI-supervised operations. Advanced Process Control (APC) and machine learning now fine-tune dozens of variables in real time—stabilising the pyroprocess, optimising fuel use, and minimising quality variance. As mentioned in ABB’s Expert Optimiser materials, these systems typically deliver 3 per cent to 5 per cent energy savings and 3 per cent to 5 per cent production gains while cutting emissions—results that have converted skeptics into advocates. For Indian operators navigating volatile fuel mixes and ambitious Thermal Substitution Rate (TSR) goals, such optimisations provide tangible, repeatable ROI. India already holds a global efficiency edge—as reported by the CII–Sohrabji Godrej Green Business Centre (2023), the top 10 plants operate below 70 kWh/t cement and 690 kcal/kg clinker, with best-achieved benchmarks of 56.1 kWh/t and 675 kcal/kg, underscoring the impact of digitisation on sustaining world-class performance.
Tushar Kulkarni, Business Head – Minerals – Cement & Mining, Innomotics India says, “India’s cement industry has long been at the forefront of adopting cutting-edge industrial technologies—ranging from Intelligent MCCs and MV/LV drive systems to full-scale plant DCS automation—placing it among the global leaders in energy-efficient and digitally enabled manufacturing. These initiatives have translated into significant gains in energy reduction and operational efficiency across plants. The sector is now entering a new phase of transformation, embracing innovations like AI-driven process optimisation (AI Pyro, AI Mill), electrification of kilns, and Carbon Capture, Utilisation & Storage (CCUS). Encouragingly, several of these technologies are already under feasibility assessment or pilot implementation, reflecting the industry’s readiness to leverage advanced automation and electrification as key enablers of decarbonisation.”
“However, scaling these innovations industry-wide still faces tangible barriers. Many plants continue to operate with legacy systems that lack seamless data connectivity or structured historians, making AI model training and deployment difficult. Challenges such as non-standardised data formats, limited transparency of AI model performance, and uncertainty in calculating ROI often slow down investment decisions. Strengthening data infrastructure, building trust in AI outcomes, and upskilling teams in digital analytics will be crucial to unlocking the full potential of smart drives, advanced predictive control, and electrification. In the coming years, AI-based optimisation tools and CCUS technologies are poised to become game changers—helping India’s cement sector strike the balance between industrial productivity and its low-carbon future” he adds.
The next leap lies in scaling the digital flywheel—integrating process, maintenance, and logistics data into unified platforms powered by AI and predictive analytics. Plants combining APC, predictive maintenance, and digital twins will achieve steadier clinker quality, lower specific energy, and reduced downtime while preparing for CCUS-ready, low-carbon operations. With six-stage preheaters globally averaging 717–812 kcal/kg, India’s continuous optimisation keeps it at the efficient end of this spectrum. The lesson is clear: Industry 4.0 isn’t a parallel initiative—it’s the operating system of tomorrow’s path-breaking cement plant, where automation, data, and intelligence drive both sustainability and competitiveness.

Data-driven decisions
Across Indian cement plants, production is becoming data-rich and model-driven, with IoT sensor networks, AI models, and APC systems working in tandem to optimise kiln stability, fuel mix, and quality in real time. As mentioned in Holcim’s program page and a Global Cement report, the company’s Plants of Tomorrow initiative has deployed 2,100+ digital applications across 40+ countries, with AI software expected in ~100 plants by 2028. Indian leaders already operate at world-class efficiency, achieving ~56.1 kWh/t cement (electrical) and ~675 kcal/kg clinker (thermal), benchmarks maintained through data analytics and condition-based maintenance, as reported by the CII–Sohrabji Godrej Green Business Centre (2023). Downstream, digital control towers and route analytics have helped UltraTech cut average lead distance to ~400 km and logistics costs by ~2 per cent YoY. As mentioned in reports by the GCCA (2024/25) and the World Economic Forum (2024), digitalisation is now a central pillar of the global net-zero cement strategy, proving essential for an industry that contributes ~6 per cent of global CO2 emissions to maximise efficiency from kiln to dispatch.

Sustainable engineering
Sustainable engineering in India’s cement sector is advancing beyond efficiency gains toward holistic life-cycle design, where plant layout, raw materials, and product use all align with low-carbon goals. As mentioned in TERI’s roadmap, the industry must cut CO2 intensity to ~0.35 tCO2/t cement by 2050, down from 0.62 in 2010, while as per the OECD report, new plants should target ˜70 kWh/t (electrical) and ˜680 kcal/kg clinker (thermal). On the materials front, Limestone Calcined Clay Cement (LC³) and similar low-carbon binders can reduce emissions by 30 per cent to 40 per cent versus OPC. According to the Department of Science and Technology, cement and brick production currently emit 200–250 MtCO2 annually, underscoring vast decarbonisation potential. Sustainable engineering is thus no longer conceptual—it’s materialising through plant retrofits, alternative binders, and integrated design strategies that link sourcing, production, and construction into a single, optimised low-carbon chain.
Utssav Gupta, Director, Supertech Fabrics says, “India’s cement industry, as the second-largest producer globally, has made remarkable progress in adopting advanced filtration and emission control technologies. The country now enforces some of the most stringent environmental norms among developing economies, and new plants are being commissioned with state-of-the-art filtration systems that rival international benchmarks. More importantly, there is a visible intent among manufacturers to retrofit and upgrade older units, reflecting a strong national commitment to sustainability. As a material-producing nation, India’s openness to embracing innovation has allowed advanced filtration solutions to gain acceptance swiftly. This mindset shift—where manufacturers and end-users alike are eager to align with global best practices—positions India not as a follower but as a fast-rising leader in environmental performance and technological adaptability within the cement sector.”
“When it comes to modernising emission control systems, the challenge is not the lack of technology but the need for stronger instrumentation and data transparency. Real-time monitoring and consistent data sharing between OEMs, operators, and material suppliers remain critical to fine-tuning systems and achieving peak efficiency. Broader adoption of connected instrumentation could help perform deeper root cause analyses, enabling more precise optimisation and accountability. On the technology front, filtration science itself is undergoing a transformation—driven by material innovation that enhances both performance and longevity of filters. The next wave of filtration technologies will not only reduce particulate emissions but also improve plant sustainability and energy efficiency—marking another leap forward in India’s journey toward cleaner, smarter, and more resilient cement production” he adds.

Energy optimisation
Indian plants are squeesing megawatts from every °C of kiln heat while hard-wiring renewables into their grids. Waste-heat recovery (WHR) has scaled rapidly—installed capacity in India rose from ~240 MW to ~1,289 MW over the last decade, with leaders adding triple-digit megawatts in just a few years; UltraTech reports 351 MW of WHR capacity in FY 2024–25, while Ramco commissioned a new 10 MW WHRS in September 2025, signalling steady brownfield gains, as mentioned in a report by the CII–Sohrabji Godrej Green Business Centre and as mentioned in company/press updates. On the consumption side, global pathways raise the bar: the IEA’s NZE trajectory targets average kiln thermal intensity < 3.4 GJ/t clinker and electricity < 90 kWh/t cement by 2030—benchmarks that Indian best-performers are already approaching or beating, as mentioned in a report by the IEA.
The fuel and power mix is tilting greener at scale. UltraTech has publicly set 85 per cent “green energy” in the total energy mix by 2030 (with an interim 60 per cent by FY26) and surpassed 1 GW of installed renewable capacity—tying energy optimisation directly to cost and carbon, as mentioned in company disclosures. Shree Cement lifted green power to ~56 per cent to 66 per cent with ~582–586 MW of RE capacity (solar, wind, WHR), as mentioned in broker/market reports. Meanwhile, the switch to alternative fuels remains a major lever: industry assessments show Thermal Substitution Rate (TSR) adoption is rising but uneven across firms, with availability and pre-processing still the bottlenecks—yet TSR is pivotal to hitting sector targets, as mentioned in a report by CARE Edge ESG.

Reinventing packaging and storage
Moisture remains the silent enemy of bagged cement, driving a shift from stitched sacks to block-bottom, valve bags made of coated polypropylene (PP) that resist humidity, burst less, and run seamlessly on automated lines. Designs like AD*STAR® offer higher strength, moisture protection, and recyclability within PP streams, as mentioned in Starlinger’s overview, while Indian brands such as Bharathi Cement highlight tear resistance, micro-perforation, and near-zero bursting. Recycling infrastructure is expanding too—as mentioned in a report by the India Plastics Pact (2023), 819 mechanical recycling units now process recovered PP, supporting EPR-linked sack take-back programs under CPCB’s 2023–24 inventory. On the dispatch front, plants are deploying automatic bagging, robotic palletising, and warehouse control systems to reduce breakage and boost loading efficiency, as reported in automation case studies. With bulk loading, silo telemetry, and RFID-enabled yards improving traceability, India’s cement logistics are evolving toward moisture-resistant, recyclable packaging and end-to-end automation, ensuring every bag reaches the site intact—with its strength and brand promise preserved.
Frank Ormeloh, Business Unit Manager – Cement, Haver & Boecker says, India’s cement industry presents a fascinating paradox when it comes to integrated digital and hardware adoption. Despite the country’s global reputation for software excellence, the current level of integration between digital and mechanical systems in cement plants remains modest. Most investments still lean toward mechanical upgrades—from material handling to process machinery—while digital adoption lags behind. Yet, the potential for digital transformation is immense. Digital tools, from AI-based control systems to predictive analytics and smart mesh technologies, often come with lower cost thresholds and higher ROI compared to conventional mechanical retrofits. The industry’s growing openness to innovation, combined with India’s strong IT foundation, suggests a major opportunity to elevate operational intelligence through integrated digital-hardware ecosystems.”
“The true obstacles, however, are not technological but commercial and cultural. The prevalent “lowest price possible” mindset still overshadows the “maximum profit possible” philosophy needed to scale advanced mesh, AI, and robotic systems. To accelerate adoption, pioneers within the sector must step forward—those willing to demonstrate that smart, data-integrated plants are not only more efficient but also more sustainable, safe, and investor-attractive. HAVER & BOECKER envisions this transformation through Operation & Maintenance (O&M) partnerships, where experts co-manage packing facilities alongside customers, aligning technical excellence with business value. Proven in India’s chemical sector, this service-driven model aims to bring cement producers closer to “Perfect Flow,” redefining the material not as a low-cost commodity but as a high-value, innovation-driven product that embodies efficiency, sustainability, and long-term profitability” he adds.

Material resilience
A new generation of low-carbon binders is redefining cement’s material resilience by cutting emissions without compromising performance. Limestone Calcined Clay Cement (LC3) reduces CO2 by ~40 per cent while matching or exceeding OPC strength, lowering the clinker factor to ~50 per cent or less, as mentioned in or a report by RMI’s 2024 “Business Case for LC3” and the LC3 Global Assessment. Composition-level innovations such as Calcium Silicate Cement (CSC) further show up to 45.5 per cent energy and 35.1 per cent CO2 reductions versus OPC, owing to reduced limestone demand and lower sintering temperatures, as mentioned in or a report by Williams and Yang (2024). Beyond emissions, alkali-activated concretes (AAC) deliver ~54 per cent to 61 per cent lower CO2 and ~39 per cent to 70 per cent lower embodied energy, while maintaining high strength under thermal stress, as noted in peer-reviewed studies (2024–2025). For India, reducing the clinker factor through high-quality SCMs and alternative binders remains central, as mentioned in or a report by the GCCA Net Zero Progress Report (2024/25) and CII–GBC benchmarking data. The message is clear: material resilience now means lower embodied carbon, longer service life, and regionally optimised composites tailored to India’s diverse heat, moisture, and chloride conditions.
Jignesh Kundaria, CEO and Director, Fornnax says, “India’s cement industry has made significant progress in adopting IoT and predictive analytics, though maturity remains uneven across the sector. Leading manufacturers are integrating digital tools for process optimisation, equipment health monitoring, and real-time insights, but adoption is still in the early-to-mid stage compared to Europe, where digital ecosystems are more advanced. Encouragingly, Indian plants increasingly recognise that data drives efficiency, sustainability, and competitiveness, marking a cultural shift toward digitisation. The main barriers lie in infrastructure: many plants still use legacy systems incompatible with modern automation, making integration complex and costly. A shortage of digital talent and high upfront costs further slow progress. Yet the outlook is strong—modular, interoperable, and retrofit-friendly solutions are steadily lowering adoption barriers and enabling a scalable, cost-effective transition toward intelligent, data-driven cement operations across India..”

Human–tech synergy
The cement industry’s digital transformation is as much about people as it is about technology—where human expertise evolves alongside AI, digital twins, and robotics. As plants automate and adopt AI-based process control, job roles are shifting from manual operation to analytical decision-making. According to a report by Deloitte (2024), over 60 per cent of global manufacturers now prioritise reskilling in data analytics, IoT, and automation. India mirrors this trend—as mentioned in CII’s 2024 Future of Work in Manufacturing study, cement and heavy industry players are allocating up to 3 per cent of annual operational budgets to digital training, with UltraTech and ACC establishing in-house digital academies for process engineers and maintenance teams.
Dijam Panigrahi, Co-founder and COO, GridRaster says “The core of Industry 5.0 is the human operator. By having Spatial AI systems safely take over repetitive, monotonous, or highly dangerous tasks, plant personnel are liberated to focus on the highest-value work: complex process management, troubleshooting, and continuous process optimisation. This fosters a human-machine collaboration that drives innovation, enhances safety and ensures sustainability. Spatial AI is not merely a theoretical leap in digital twin technology; it is a concrete, actionable technology that is delivering immediate, impactful change on the plant floor. By simplifying complexity and driving setup time down to minutes, this technology is the essential accelerator that makes advanced industrial automation truly accessible to all cement manufacturers, marking the definitive arrival of the human-centric, high-efficiency world of Industry 5.0.”
As mentioned in a report by the NSDC (2025), over 75,000 workers in India’s materials and infrastructure sectors will require advanced digital skills by 2030. The GCCA calls this “digital sustainability”—training workers to manage systems that cut emissions and energy use, not just boost output. In practice, kiln engineers interpret AI dashboards, maintenance teams conduct predictive analytics, and logistics managers optimise CO2-efficient routes. The cement plant of the future is, therefore, a human–machine collaboration hub, where workforce adaptability is as critical as the algorithms driving efficiency and sustainability.

Conclusion
As India’s cement sector enters its next growth phase, the challenge is no longer scale but sustainability at scale. The nation already leads in energy efficiency and alternative fuels, yet the next leap demands embedding innovation into every tonne of cement—through CCUS, low-clinker blends like LC3, AI-driven process control, and green logistics. Supported by the National Green Hydrogen Mission, PAT scheme, and 2030 renewable targets, India’s ecosystem is aligning toward low-carbon, globally competitive manufacturing that exports not just cement but expertise. Achieving this will require deep collaboration among industry, academia, and policymakers, focusing on scalable CCUS, mineral carbonation, and regionally suited binders. As led by the GCCA and CMA, shared R&D platforms and policy-backed decarbonisation clusters—akin to Europe’s CCS hubs—can fast-track progress, while green bonds, blended finance, and carbon credits can de-risk early adoption. Ultimately, path-breaking innovation is India’s passport to a net-zero construction future—where digital intelligence, sustainable engineering, and circular materials converge to make every plant a lab for efficiency and every engineer an innovator. With bold collaboration and steadfast execution, India can transform its cement industry from a top emitter into a cornerstone of global green growth.

– Kanika Mathur