Economy & Market

Cut Cement Carbon

Published

5 months ago

November 20, 2025

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India’s cement sector stands on the threshold of a green transformation — balancing rapid growth with deep decarbonisation. The journey ahead demands innovation across materials, fuels and processes, backed by strong policy and collaboration. ICR explores how industry stakeholders are looking at scaling sustainable solutions fast enough to build a truly Net Zero cement future.

India’s cement industry stands at a pivotal crossroads. As the world’s second largest producer of cement, the country accounts for nearly 8 per cent of global installed capacity. A report by the India Brand Equity Foundation (IBEF) mentions that India’s cement production reached approximately 453 million tonnes in FY 2024–25, up from 426.3 million tonnes the previous year, reflecting steady growth driven by infrastructure and housing demand. This scale of activity underpins the nation’s development ambitions — yet it also magnifies the urgency of decarbonisation in a sector that is both energy and carbon intensive.
Globally, cement production is responsible for around 7–8 per cent of total manmade CO2 emissions. According to a 2024 report by the Global Cement and Concrete Association (GCCA), India’s cement sector contributes about 5.8 per cent of the country’s total CO2 emissions, primarily from the calcination process during clinker production and the use of fossil fuels in kilns. The same report notes that Indian producers are targeting a reduction in emission intensity from 0.68 tonnes of CO2 per tonne of cement in 2020 to 0.56 tonnes by 2030, with further improvements expected by 2047. These figures highlight the scale of transformation required even as domestic demand continues to surge.
At the same time, India’s market structure and resource base provide strong foundations for this transition. A report by IBEF highlights that nearly 98 per cent of India’s cement capacity lies in the private sector, supported by abundant limestone reserves and robust investment in new grinding and waste heat recovery capacities. However, achieving growth alongside sustainability will demand a deep shift — one that integrates smarter technology, low carbon material innovations, automation, and carbon capture at scale. The coming decade will test how effectively India can balance the ‘3 Cs’ of decarbonisation: Cut emissions, Cement innovations, and Carbon capture and utilisation.

The policy push
India’s industrial decarbonisation journey is gathering momentum, and the cement sector has become a key focus area. At the heart of the effort is the Perform, Achieve and Trade (PAT) scheme, a market-based instrument implemented under the National Mission for Enhanced Energy Efficiency (NMEEE). A report by the Cement Manufacturers’ Association (CMA) mentions that cement plants in PAT Cycle-I and Cycle-II overshot their energy savings targets by 81.6 per cent and 48.6 per cent respectively, signalling early success in improving energy efficiency.
Dr SB Hegde, Global Industry Expert, says, “Green hydrogen can transform cement production by eliminating the 32 per cent of emissions from burning coal in kilns, cutting ~0.32 million tonnes of CO2 annually for a one million tonne per annum (MTPA) plant (IEA, 2020). Combined with alternatives like fly ash for clinker and carbon capture, it could reduce emissions by 66 per cent to 95 per cent by 2050. Unlike biomass, which some plants use to cut emissions by 10 per cent but struggle with unreliable supply (UltraTech, 2024), hydrogen burns consistently at 1400–1500°C, like a steady flame in a gas stove. India’s National Green Hydrogen Mission (NGHM), targeting 125 GW of renewable energy by 2030, supports this shift (MNRE, 2023).”
In parallel, broader regulatory evolution is underway. According to an article by the Climate Policy Lab, India is set to replace the PAT scheme with the Carbon Credit Trading Scheme (CCTS) by 2026, covering nine industrial sectors including cement. This shift recognises that simply improving energy efficiency is not sufficient; the industry must move towards intensity and absolute emission targets, a step reinforced by India’s net zero commitment at COP26 for 2070.
Beyond regulatory mandates, industry led initiatives are driving the transition. The Global Cement and Concrete Association (GCCA) India and domestic trade bodies are collaborating to embed sustainability practices across the value chain, supporting innovations in blended cements, alternative fuels, and logistics decarbonisation. Such strategic initiatives amplify the policy push and help bridge the gap between regulation and action.

Cutting emissions at the source
In the race to decarbonise, the first frontier for the Indian cement industry lies in boosting energy efficiency across plant operations. Upgrading to six stage preheater kilns, optimising cooler and fan systems, and capturing waste¬ heat recovery (WHR) are all core tactics. A report by the Cement Manufacturers’ Association mentions that the theoretical energy demand for clinker production ranges between 1,650 to 1,800 MJ per tonne of clinker, while drying raw materials adds another 200 to 1,000 MJ per tonne. For manufacturers, that means every percentage point of thermal or electrical energy saved translates directly into lower CO2 emissions — a pragmatic and cost-effective route to ‘cut.’
MM Rathi, Joint President – Power Management, Shree Cement, says, “Innovation is transforming the way cement is produced and used, bringing efficiency, strength, and sustainability together. Modern high efficiency plants now run kilns capable of producing up to 13,500 tonnes of clinker per day. With advanced coolers and pyro systems, they achieve energy use as low as 680 kilocalories per kilogram of heat and just 42 kilowatt-hours of power per tonne of clinker. By capturing waste heat, these plants are also able to generate 30–35 kilowatt-hours of electricity per tonne, bringing the net power requirement down to only 7–12 kilowatt-hours—a major step forward in energy efficiency.”
Reduction of the clinker to cement ratio remains a strategic lever in lowering both process emissions (from limestone calcination) and thermal fuel consumption. In India, the average ‘clinker factor’ is estimated at about 0.73 (i.e., 73 per cent of cement is clinker) as per recent modelling. According to a study by the Council on Energy, Environment and Water (CEEW), India’s average clinker ratio stands at 0.73 compared with a global average of 0.77. If India’s cement sector can move towards ~0.56 by 2070 as envisioned in some roadmap scenarios, the implication for emissions reduction is substantial. This shift is supported by the increasing uptake of supplementary cementitious materials (SCMs) and innovative binder systems.
Alternative raw materials such as fly ash, slag and calcined clay offer meaningful pathways to absorb clinker substitution and lower embedded emissions. For instance, ternary blends that combine limestone with calcined clay or slag are gaining traction in India. One recent paper notes that a calcined clay limestone composite cement (LC3) can cut the CO2 footprint by around 30 per cent compared to conventional Portland cement. Moreover, the standards in India (for example IS 18189) now allow ternary blends with calcined clay limestone up to about 20 per cent replacement. These materials not only help reduce the clinker content but also align resource use and circular economy imperatives.
Dr Avijit Mondal, Scientist, NTPC Energy Technology Research Alliance (NETRA), states, “The cement industry’s decarbonisation journey is both a technological and policy challenge. A mix of regulatory frameworks, carbon pricing, green financing and stakeholder collaboration will be essential to accelerate adoption of the 3Cs. For India, which is expected to remain the second largest producer and consumer of cement, the 3Cs framework aligns with national goals of Net Zero by 2070. As power and cement sectors increasingly converge through ash utilisation, renewable integration, and CCU the scope for cross industry partnerships is immense.”
Finally, the intertwining of material and energy efficiency is mediated through smarter process controls, automation and digitalisation — especially in grinding, raw mix preparation and kiln operations. Real time monitoring of power, kiln stability, clinker quality and alternative fuel admixture enables plants to operate closer to their thermodynamic minima. While the technology and cost curve are improving, what remains critical is industry wide scale up of these practices across India’s 600 plus integrated and grinding only units. The challenge is to ensure that improved efficiency and lower clinker factors translate into tangible CO2 savings in the near term, rather than being deferred into ‘future promise’.

Alternative fuels and co-processing
The traditional reliance on coal and petroleum coke in kiln operations is giving way to more sustainable fuel streams, as the Indian cement industry embraces alternative fuels and co-processing of waste. Within the energy intensive process of cement manufacture, where combustion can account for 30 per cent to 40 per cent of CO2 emissions, substituting fossil fuels with refuse derived fuel (RDF), biomass and industrial byproducts offers a compelling route to ‘cut’. A recent industry overview notes that only around 4 per cent of total energy input in the Indian cement industry currently comes from alternative fuels — up from about 0.6 per cent in 2010. This underscores that while the option is technically proven, scaling remains a major hurdle.
Raju Ramchandran, Senior Vice President and Head Manufacturing – Eastern Region, Safety and Sustainability, Nuvoco Vistas, says, “The journey to decarbonise cement and concrete touches every link in the value chain — from sourcing raw materials to producing clinker, from pouring concrete on construction sites to rethinking design with reuse, recycling and 3D printing in mind. Each stage offers an opportunity to reduce emissions through innovation and collaboration.”
The practical application of RDF and biomass in kiln operations is increasingly supported by policy and infrastructure. For instance, in the State of Karnataka the updated waste management rules require that cement plants within a 400 km radius of an RDF facility meet at least 15 per cent of their fuel needs through RDF by 2031. This shift not only reduces dependence on imported fossil fuels but also converts municipal solid waste and non-recyclable combustible fractions into high value fuel inputs — advancing circular economy objectives. However, the path is not without challenge: the heterogeneity in waste fuel properties can disrupt feeding systems in kilns, and the logistics of sourcing, processing and transporting fuels remain complex.
Ulhas Parlikar, Director MRAI and Global Consultant, explains, “The co-processing strategy of AFRs in India supports national waste management goals such as reducing landfill, incineration of hazardous and municipal wastes, and enabling safe resource recovery. Cement kilns are uniquely positioned to help address the country’s growing urban and industrial waste challenge, aligning climate goals and circular economy priorities. Many plants manufacturing clinker in India that belong to Adani Group, UltraTech, Dalmia, Shree, JK, JK Lakshmi, Nuvoco Vista, Vicat, Heidelberg, Ramco, KCP, Nagarjuna, Chettinad and others are operating at a reasonable scale of AFR utilisation. Some of these plants have even achieved a TSR level of more than 35 per cent. Some of these cement plants that have reached the higher levels of chlorine have also set up the chlorine bypass systems.”
Beyond substitution, co-processing waste as fuel and raw material unlocks additional value. For example, industrial byproducts such as tyre derived fuel (TDF) or processed biomass residues may replace traditional coal-based energy inputs, while providing safe disposal routes for otherwise difficult waste. The dual benefit of waste to energy and emission reduction is clearly recognised in global industry studies. Nevertheless, tapping this potential at scale in India requires standardised fuel quality, consistent supply chains, and investment in pre-processing infrastructure — all of which are emerging priorities for the next decade.

Innovating low carbon binders
Global and Indian research and industry activity around low carbon binders has moved from laboratory curiosity to commercial pilot and early rollout. LC3 and other ternary blends are receiving particular attention because they offer substantial clinker substitution without compromising strength or durability. A report by the Global Cement and Concrete Association (GCCA) notes that new low carbon binders such as LC3 can reduce embodied CO2 by around 30 per cent to 40 per cent compared with ordinary Portland cement, and several Indian manufacturers have announced plans to commercialise these formulations. Complementary market studies also point to brisk growth in ‘green cement’ demand in India — the India green cement market was valued in the low billions of US dollars in 2024 and is projected to grow at a mid-single digit CAGR through the decade. These figures underpin why major projects and infrastructure clients are starting to specify low carbon cements as part of sustainability procurement.
Gaurav K Mathur, Director and Chief Executive, Global Technical Services, opines, “Energy consumption is a significant concern in cement production, with a substantial portion of it attributed to the friction and heat generated by moving components in machinery. Lubrication management plays a pivotal role in optimising energy efficiency within all manufacturing plants. Advanced lubricants with superior friction reducing properties contribute to lower energy consumption by minimising resistance in moving parts and ultimately play important role in machine reliability.”
Geopolymer cements and alkali activated binders present another promising avenue, particularly where industrial byproducts (fly ash, GGBS) are locally abundant. Recent Indian academic work has showcased geopolymer mixes that can cut CO2 emissions by a large margin — in some laboratory studies by as much as 50 per cent to 80 per cent relative to conventional OPC, depending on the precursor and activator chemistry. While these numbers are impressive, practical deployment requires overcoming standardisation, supply chain and curing practice barriers; nevertheless, pilot projects and institutional testbeds in India are accelerating technology readiness and building the case for wider acceptance in structural applications.
Jigar Shah, Head – Application Engineering, ACM SBU, Henkel Adhesive Technologies India says, “Ash buildup—especially in high humidity environments—is a recurring challenge for maintenance teams. It clings to the inner walls of hoppers and silos, chokes flow paths, and forces shutdowns that no one has time for. And when the monsoon rolls in, the problem only intensifies. Ash particles are fine, abrasive and hygroscopic. They absorb moisture from the air, especially during the rainy season, and form stubborn layers on metal surfaces. Over time, this buildup narrows flow paths, increases system pressure, and eventually brings operations to
a standstill.”
Technology innovation in formulations goes hand-in-hand with process and digital innovations on the plant floor. Automation, advanced process control (APC), and AI driven optimisation are enabling plants to maintain kiln stability with higher rates of alternative raw materials and fuels, while improving energy efficiency and reducing reject rates. According to the Cement Manufacturers’ Association, predictive maintenance and real time monitoring can recover 5 per cent to 20 per cent of productive capacity lost to poor maintenance and can materially reduce fuel and power consumption when integrated with WHR and kiln control systems. Likewise, industry consultancy analyses show that AI enabled predictive maintenance can cut downtime by 20 per cent to 30 per cent and trim maintenance costs by 10 per cent to 15 per cent, savings that translate directly into lower operational CO2 intensity.
Taken together, these technological strands — new binder chemistries, expanded use of SCMs, and smarter plant operations — create a mutually reinforcing pathway to lower carbon intensity. Yet scale up remains the central test: moving from pilot batches of LC3 and geopolymer concrete to sustained commercial production requires changes in standards, investment in calcination and grinding lines optimised for alternative blends, and digitised quality control regimes. If Indian producers can synchronise material innovation with automation and process control, the industry can materially bend the emissions curve while meeting the country’s infrastructure needs.

CCUS: The next frontier
Carbon capture is rapidly moving from theory to pilot scale reality for the cement sector, driven by a suite of technologies tailored to the industry’s unique emission profile. Options under active development include chemical solvent scrubbing (amine systems), oxy fuel combustion (which produces a CO2 rich flue gas stream), solid sorbents, calcium looping and indirect calcination that decouple calcination from fuel combustion — each with different energy, space and integration requirements for an existing kiln. Several international demonstration projects have shown the technical feasibility of these routes, and the Global Cement and Concrete Association (GCCA) places CCUS as a central lever that could account for a large share of sectoral emission reductions by mid-century.
Nathan Ashcroft, Director, Low Carbon Solutions Energy and Resources, Stantec, says, “Cement plants are built for durability and efficiency, not for future retrofits. Most were not designed with spare land for absorbers, ducting or compression units. Nor with the energy integration needs of capture systems in mind. Retrofitting CCS into these existing layouts presents a series of non-trivial challenges. Reliability also weighs heavily in the discussion. Cement production runs continuously, and any disruption has significant economic consequences. A CCS retrofit typically requires tie-ins to stacks and gas flows that can only be completed during planned shutdowns. Even once operational, the capture system must demonstrate high availability. Otherwise, producers may face the dual cost of capture downtime and exposure to carbon taxes or penalties, depending on jurisdiction.”
India has begun to pilot a variety of capture concepts and small-scale test sites to assess techno economic practicality and downstream utilisation pathways. Recent initiatives include five test sites announced in 2025 designed to capture CO2 from cement production for conversion into synthetic fuels, construction aggregates and other products, and government industry workshops have highlighted pilot projects such as amine based and biological capture trials (including photobioreactor approaches) under development at research facilities and industrial partners. A report by GCCA India and a NITI Aayog linked workshop note that Indian pilots remain modest in capacity but are important for building local data on capture efficiency, impurity handling and integration costs.
Dr Yogendra Kanitkar, VP R&D, Pi Green Innovations, explains, “Carbon Capture, Utilisation, and Storage (CCUS) technologies are emerging as a critical lever for achieving deep emission cuts, particularly since process emissions are chemically unavoidable. Post combustion amine scrubbing using solvents like monoethanolamine (MEA) remains the most mature option, with capture efficiencies between 90 per cent to 99 per cent demonstrated at pilot scale. However, drawbacks include energy penalties that require 15 per cent 30 per cent of plant output for solvent regeneration, as well as costs for retrofitting and long term corrosion management (Heidelberg Materials 2025). Oxyfuel combustion has been tested internationally, producing concentrated CO2 laden flue gas, though the high cost of pure oxygen production impedes deployment in India.”
Global experience — particularly from Europe and Japan — is shaping India’s deployment roadmap by underlining two lessons: first, CCUS for cement is capital intensive and needs coordinated value chain thinking (capture, transport, storage or utilisation), often requiring public support and cross sector infrastructure; second, technology selection is context specific. Large European demonstrations such as the Brevik project in Norway (where a cement plant was retrofitted with capture and linked to offshore storage under the Longship initiative) and Japan’s government backed “Advanced CCS” projects are instructive on financing models, regulatory frameworks and clustering opportunities for shared CO2 transport and storage. These projects show that commercial scale CCUS in cement is achievable but hinges on policy certainty, fiscal support and the emergence of CO2 transport and storage hubs — lessons India is already factoring into its pilot planning.

Green logistics
Efficient logistics is becoming a critical lever for decarbonisation in the cement sector. In India, road transport still dominates finished cement distribution, with approximately 71 per cent to 72 per cent of cement moved by road and only around 25 per cent by rail (with waterways making up about 3 per cent to 4 per cent). Emissions associated with distribution have grown — one study found that in 2018-19, road transport accounted for 87 per cent of distribution related CO2 emissions for cement despite carrying about 62 per cent of the load. By contrast, rail borne cement accounted for 35 per cent of tonnage but only 13 per cent of emissions. Shifting more freight to rail and bulk logistics (for example by using specialised wagons and terminals) therefore presents a clear pathway to lowering the carbon footprint beyond the plant gate.
Ashwini Khunte, Regional Head – Sales and Marketing, Martin Engineering, elaborates, “Even though the entire cement operation depends on conveyor performance, the importance of clean belts to overall productivity is rarely understood or prioritised by busy plant maintenance teams. Fortunately help is at hand, with specialists from Martin Engineering in available to help Indian cement producers to identify the root causes of their pain points and recommend innovative solutions that are proven to work.”
Beyond mode shift, the industry is also embracing bulk handling and efficient packaging systems to optimise supply chain carbon performance. Bulk cement movements (rather than bagged) reduce multiple handling, mitigate dust losses, and permit more efficient transport and storage. A trade body note highlights that bulk movement of cement in India grew at a compound annual rate of 15 per cent to 20 per cent between 2014-15 and 2019-20. By building more rail silo to plant configurations, deploying dedicated bulk terminals and investing in larger capacity rail tankers, the industry is better positioned to reduce per tonne logistics emissions.

Industry collaboration and circular economy
Collaboration between cement manufacturers, municipal authorities and waste management firms is rapidly becoming a cornerstone of circular economy practices in India. For example, the Confederation of Indian Industry (CII) has launched a Waste Material Exchange platform which enables cement plants to access industrial and urban waste streams as alternative raw materials and fuels.
Jignesh Kundaria, CEO and Director, Fornnax, says, “Based on extensive R&D and on-site analysis at numerous cement plants, we have identified and addressed the key bottlenecks hindering AFR adoption in India. These challenges include the absence of a standardised process layout, the difficulty of handling high moisture or contaminated waste and a heavy reliance on imported equipment that lacks customisation for Indian conditions. Other issues include long lead times for spares, high maintenance costs for imported secondary shredders and inconsistent output from equipment that performs only primary or secondary shredding.”
India’s cement sector is increasingly ‘diverting waste materials from landfill via partnerships and collaborations’ and thereby reducing both disposal costs and input material emissions. One study estimates that the Indian cement industry could reduce its dependence on virgin raw materials by up to 20 per cent to 30 per cent through systematic utilisation of waste derived feedstocks and byproducts under circular economy models. Such collaborative efforts not only cut resource extraction and emissions but also build a symbiotic industrial ecosystem where the waste output of one sector becomes the input for another.
Olli Hänninen, Owner and Co-Founder, Moviator Oy, states, “Decarbonising cement will not happen overnight. It will take imagination, cross sector collaboration and new standards that reward permanent carbon binding. But the tools are already here — from smarter slag processing to direct CO2 mineralisation. Moviator’s work in refining steel skulls and utilising slag demonstrates that circular, low carbon materials are not science fiction. They are emerging now, one pilot and partnership at a time.”
Despite the promise, the road to full circularity is paved with challenges that require coordination across multiple stakeholders. Material recovery infrastructure, consistent waste feedstock quality, and transparent liability frameworks need to be developed in tandem with policy incentives and industry buy in. A systematic review in 2025 emphasises that while interest in circular economy practices in the cement sector is ‘substantially increasing’ (with an annual publication growth of 23.4 per cent) it also warns that ‘scaling remains constrained by regulatory, socio-economic and logistical barriers. In response, a number of Indian cement companies have signed MoUs with local municipal bodies and waste management firms to secure streams of municipal solid waste, construction and demolition debris and industrial byproducts — signalling a shift from isolated pilots to ecosystem level collaboration.

Towards Net Zero cement
As the Indian cement industry charts its trajectory toward net zero emissions, the horizon offers both urgency and opportunity. By 2030, the global roadmap for cement envisages a reduction in CO2 intensity to roughly 0.45 tonnes per tonne of cement — a level that Indian producers, if aligned with the 3 Cs of decarbonisation (Cut emissions, Cement innovations, Carbon capture and utilisation), could realistically aim for. By 2050, the ambition in many roadmaps is to hit near zero operational emissions, with residual emissions offset or captured — a target that places technological adoption, scale up and financing at the heart of the transition.
Achieving these milestones will demand more than incremental change. Policy frameworks must strengthen carbon pricing or trading mechanisms that include cement, fiscal support for CCUS and alternative binder investments, regulatory push for low carbon procurement, and infrastructure for CO2 transport and storage are essential enablers. Simultaneously, private investment from both domestic firms and global players must flow into retrofits of vintage plants, digital and automation upgrades, large scale alternative fuel/coprocessing systems
and full-scale carbon capture installations. The confluence of innovation, structured finance and regulatory certainty will determine how smoothly the industry migrates from pilot phase ambition to full scale deployment.
Ultimately, intent and action must remain in sync. Indian producers possess competitive strength in large scale, strong domestic market growth, and a rich resource base. With the accelerating uptake of low clinker cements, automation across operations and strategic collaborations for waste to resource value chains, the critical ingredients are already in play. What remains is execution at pace and scale — delivering the decarbonised cement that India’s infrastructure vision demands, while ensuring that the industry contributes positively to the nation’s climate and sustainability goals.

– Kanika Mathur

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Economy & Market

SEW-EURODRIVE India Opens Drive Technology Centre in Chennai

Published

2 weeks ago

March 25, 2026

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The new facility strengthens SEW-EURODRIVE India’s manufacturing, assembly and service capabilities

SEW-EURODRIVE India has inaugurated a new Drive Technology Centre (DTC) in Chennai, marking a significant expansion of its manufacturing and service infrastructure in South India. The facility is positioned to enhance the company’s responsiveness and long-term support capabilities for customers across southern and eastern regions of the country.

Built across 12.27 acres, the facility includes a 21,350-square-metre assembly and service setup designed to support future industrial growth, evolving application requirements and capacity expansion. The centre reflects the company’s long-term strategy in India, combining global engineering practices with local manufacturing and service capabilities.

The new facility has been developed in line with green building standards and incorporates sustainable features such as natural daylight utilisation, solar power generation and rainwater harvesting systems. The company has also implemented energy-efficient construction and advanced climate control systems that help reduce shopfloor temperatures by up to 3°C, improving production stability, product quality and working conditions.

A key highlight of the centre is the 15,000-square-metre assembly shop, which features digitisation-ready assembly cells based on a single-piece flow manufacturing concept. The facility also houses SEW-EURODRIVE India’s first semi-automated painting booth, aimed at ensuring uniform surface finish and improving production throughput.

With the commissioning of the Chennai Drive Technology Centre, SEW-EURODRIVE India continues to strengthen its manufacturing footprint and reinforces its long-term commitment to supporting industrial growth and automation development in India.

Concrete

Material Flow Efficiency

Published

3 weeks ago

March 18, 2026

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We explore how material handling systems are becoming strategic assets in cement plants, enabling efficient movement of raw materials, clinker and finished cement. Advanced conveying, automation and digital technologies are improving plant productivity while supporting energy efficiency and sustainability goals.

Material handling systems form the operational backbone of cement plants, enabling the efficient movement of raw materials, clinker and finished cement across complex production networks. With India’s cement industry producing over 391 million tonnes of cement in FY2024 and possessing an installed capacity of around 668 mtpa, according to the CRISIL Research Industry Report, 2025, efficient material logistics have become critical to maintaining plant productivity and cost competitiveness. At the same time, cement production is highly energy intensive and contributes around 7 per cent to
8 per cent of global CO2 emissions, making efficient material flow and logistics optimisation essential for reducing operational inefficiencies and emissions states the International Energy Agency Cement Technology Roadmap, 2023. As plants scale capacity and integrate digital technologies, modern material handling systems, ranging from automated conveyors to intelligent stockyards, are increasingly recognised as strategic assets that influence plant stability, energy efficiency and environmental performance.

Strategic role of material handling
Material handling is no longer viewed as a secondary utility within cement plants; it is now recognised as a strategic system that directly influences production efficiency and process stability.
Cement manufacturing involves the continuous movement of large volumes of limestone, clay, additives, clinker and finished cement across multiple production stages. Even minor disruptions in conveying systems or storage infrastructure can lead to kiln feed fluctuations, production delays and significant financial losses. According to Indian Cement Industry Operational Benchmarking Study, 2024, unplanned downtime in large integrated cement plants can cost between Rs.15–20 lakh per hour, highlighting the economic importance of reliable material handling systems.
Modern cement plants are therefore investing in advanced mechanical handling systems designed for high throughput and operational reliability. Large integrated plants can process over 10,000 tonnes per day of clinker, requiring highly efficient conveying systems and automated stockyards to maintain continuous material flow, suggests the International Cement Review Industry Analysis, 2024. Efficient material handling also reduces spillage, minimises dust emissions and improves workplace safety. As cement plants become larger and more technologically advanced, the role of material handling is evolving from simple transport infrastructure to a critical operational system that supports both productivity and sustainability.

From quarry to plant
The transport of raw materials from quarry to processing plant represents one of the most energy-intensive stages of cement production. Traditionally, limestone and other raw materials were transported using diesel-powered trucks, which resulted in high fuel consumption, dust generation and increased operational costs. However, modern plants are increasingly adopting long-distance belt conveyors and pipe conveyors as a more efficient alternative. These systems allow continuous material transport over distances of 10–15 kilometres, significantly reducing fuel consumption and operating costs while improving environmental performance, states the FLSmidth Cement Industry Technology Report, 2024.
Milind Khangan, Marketing Manager, Vertex Market Research & Consulting, says, “Efficient and enclosed handling of fine materials such as cement, fly ash and slag requires modern pneumatic conveying systems. By optimising the air-to-material ratio, these systems can reduce energy consumption by 10 per cent to 15 per cent while ensuring smooth material flow. Closed-loop conveying further minimises dust loading and improves the performance of bag filters, supporting cleaner plant operations. In addition, flow-regulated conveying lines help prevent clogging and maintain reliable dispatch performance. Overall, automation in pneumatic conveying delivers immediate operational benefits, including improved equipment uptime, lower energy use, reduced material spillage and more stable kiln and mill performance.”
Pipe conveyor systems are particularly gaining traction because they provide a completely enclosed transport system that prevents material spillage and dust emissions. According to global cement engineering studies, conveyor-based transport can reduce energy consumption by up to 30 per cent compared to truck haulage, while also improving operational reliability. Several cement plants in India have already implemented such systems to stabilise quarry-to-plant logistics while reducing carbon emissions associated with diesel transport.

Stockyard management and homogenisation
Stockyards play a critical role in maintaining raw material consistency and stabilising kiln feed quality. Modern cement plants use advanced stacker and reclaimer systems to ensure efficient storage and blending of raw materials before they enter the grinding and pyroprocessing stages. Automated stacking methods such as chevron or windrow stacking enable uniform distribution of materials, while bridge-type or portal reclaimers ensure consistent extraction during kiln feed preparation. These systems are essential for maintaining stable chemical composition of raw meal, which directly influences kiln efficiency and clinker quality. The Cement Plant Operations Handbook, 2024 indicates that advanced homogenisation systems can reduce raw mix variability by up to 50 per cent, significantly improving kiln stability and energy efficiency. Integrated stockyard management systems also incorporate sensors for monitoring bulk density, moisture levels and stockpile volumes, enabling real-time control over material blending processes.

Clinker and cement conveying technologies
Once clinker is produced in the kiln, it must be efficiently transported to storage silos and subsequently to grinding and packing units. Modern cement plants rely on high-capacity belt conveyors, bucket elevators and pneumatic conveying systems to manage this stage of material flow. Steel-cord belt bucket elevators are now capable of lifting materials to heights exceeding 120 metres with capacities reaching 1,500 tonnes per hour, making them suitable for large-scale clinker production lines, states the European Cement Engineering Association Technical Paper, 2023.
For fine materials such as cement, fly ash and slag, pneumatic conveying systems provide a reliable and dust-free solution. These systems transport powdered materials using controlled airflow, ensuring enclosed and contamination-free movement between grinding units, silos and packing stations. Optimised pneumatic systems can reduce energy consumption by 10 per cent to 15 per cent compared to older conveying technologies, while also improving plant cleanliness and environmental compliance, according to the Global Cement Technology Review, 2024.

Automation and digitalisation
Digitalisation is transforming material handling systems by introducing real-time monitoring, predictive maintenance and automated control. Advanced sensors and Industrial Internet of Things (IIoT) platforms enable plant operators to track conveyor health, stockpile levels and equipment performance in real time. Predictive maintenance systems analyse vibration patterns, temperature fluctuations and equipment load data to detect potential failures before they occur. According to McKinsey’s Industry 4.0 Manufacturing Report, 2023, for heavy industries, digital monitoring and predictive maintenance technologies can reduce equipment downtime by up to 30 per cent and increase productivity by 10 per cent to 15 per cent. Digital control centres also integrate data from conveyors, stacker reclaimers and dispatch systems, enabling centralised management of material flows from quarry to dispatch.

Handling of AFR
The growing adoption of Alternative Fuels and Raw Materials (AFR) has introduced new challenges and opportunities for material handling systems in cement plants. AFR materials such as refuse-derived fuel (RDF), biomass and industrial waste often have irregular particle sizes, variable moisture content and lower bulk density compared to conventional fuels. As a result, specialised storage, dosing and feeding systems are required to ensure consistent kiln combustion. According to the Cement Sector Decarbonisation Roadmap published by NITI Aayog in 2026, increasing the use of AFR could enable India’s cement sector to achieve thermal substitution rates of around 20 per cent in the coming decades. To support this transition, plants are investing in automated receiving stations, shredding units, drying systems and precision dosing equipment to stabilise AFR supply and combustion performance.

Energy efficiency and dust control
Material handling systems also play a crucial role in improving plant energy efficiency and environmental performance. Modern conveyor systems equipped with variable speed drives and energy-efficient motors can significantly reduce electricity consumption. Permanent magnet motors used in conveyor drives can deliver 8 per cent to 12 per cent energy savings compared to conventional induction motors, improving overall plant energy efficiency according to the IEA Industrial Energy Efficiency Study, 2023. Dust control is another major concern in cement plants, particularly during material transfer and storage operations. Enclosed conveyors, dust extraction systems and advanced bag filters are widely used to minimise particulate emissions and improve workplace safety.

Future trends in material handling
The future of material handling in cement plants will be shaped by automation, digitalisation and sustainability considerations. Emerging technologies such as AI-driven logistics optimisation, autonomous mobile equipment and digital twins are expected to further improve plant efficiency and operational visibility. Digital twin models allow engineers to simulate material flow patterns, optimise stockyard operations and predict equipment performance under different operating conditions. According to the International Energy Agency Digitalisation and Energy Report, 2024, the adoption of advanced digital technologies could improve industrial energy efficiency by up to 20 per cent in heavy industries such as cement manufacturing. As cement plants expand capacity and adopt low-carbon technologies, intelligent material handling systems will play a critical role in maintaining productivity and reducing environmental impact.

Conclusion
Material handling systems have evolved from basic transport infrastructure into strategic operational systems that directly influence plant efficiency, reliability and sustainability. From quarry transport and automated stockyards to digital dispatch platforms and advanced conveying technologies, modern material handling solutions enable cement plants to manage large production volumes while maintaining process stability.
As India’s cement industry continues to expand to meet infrastructure and urban development demands, investments in advanced material handling technologies will become increasingly important. By integrating automation, digital monitoring and energy-efficient systems, cement manufacturers can improve operational performance while supporting the industry’s long-term sustainability and decarbonisation goals.

Kanika Mathur

Concrete

Modernise to Optimise

Published

3 weeks ago

March 18, 2026

admin

Cement plant modernisation is reshaping the industry through upgrades in
kilns, energy systems, digitalisation, AFR integration and advanced material
handling. We explore these technologies that improve efficiency, reduce
emissions, strengthen competitiveness, while preparing the industry for India’s
next phase of infrastructure growth.

India’s cement industry, the world’s second-largest, is undergoing a rapid transformation driven by infrastructure demand, decarbonisation targets and technological advancement. The sector’s installed capacity stood at approximately 668 million tonnes per annum (mtpa) in FY2025 and is projected to reach 915–925 mtap by 2030, supported by large-scale capacity expansions and infrastructure investment cycles, suggests CRISIL Intelligence Industry Report, 2025. At the same time, cement production remains highly energy intensive and contributes about 6 per cent to 7 per cent of India’s total greenhouse gas emissions, making efficiency improvements and modernisation critical for long-term sustainability as stated in CareEdge ESG Research, 2025. As a result, cement manufacturers are investing in advanced kiln technologies, digital monitoring systems, waste heat recovery, alternative fuels, and modern material handling infrastructure to enhance productivity while aligning with global decarbonisation pathways.

Need for modernisation
The need for plant modernisation is closely linked to the sector’s rapid capacity expansion and rising operational complexity. India’s installed cement capacity has grown significantly in the last decade and is expected to exceed 900 mtpa by 2030, driven by demand from housing, infrastructure and urban development projects, as per the CRISIL Intelligence Industry Report, 2025. However, increasing scale also places pressure on energy efficiency, logistics, and production stability. The report also suggests that the cement plants must upgrade equipment and processes to operate at higher utilisation rates, which are projected to reach 75 per cent to 77 per cent by the end of the decade, compared to around 72 per cent to 74 per cent in FY2026.
Environmental imperatives are another major driver of modernisation. Cement manufacturing is responsible for a significant share of industrial emissions because clinker production requires high-temperature processes that depend heavily on fossil fuels. According to CareEdge ESG research, the cement sector contributes 6–7 per cent of India’s total greenhouse gas emissions, with approximately 97 per cent of emissions arising from direct fuel combustion and process emissions in kilns. Consequently, plant modernisation initiatives now focus not only on productivity improvements but also on reducing emissions intensity, energy consumption, and reliance on conventional fuels.
“One of the most impactful upgrades implemented at Shree Cement in the last five years has been the adoption of advanced data management platforms that provide real-time visibility across major process areas. This digital advancement has strengthened plant automation by enabling faster and more accurate responses to process variations while improving the reliability of control loops. Real-time dashboards, integrated analytics and automated alerts now support quicker, data-driven decision-making, helping optimise kiln and mill performance, improve energy control and detect deviations early. By consolidating data from multiple systems into a unified digital environment, the company has enhanced operational consistency, reduced downtime and improved both productivity and compliance. This shift towards intelligent automation and real-time data management has become a key driver of operational excellence and future-ready plant management,” says Satish Maheshwari, Chief Manufacturing Officer, Shree Cement.

Kiln and pyroprocessing upgradation
The kiln remains the technological heart of cement manufacturing, and modernisation efforts often begin with upgrades to pyroprocessing systems. Many older plants in India operate with four- or five-stage preheaters, while modern plants increasingly adopt six-stage preheater and pre-calciner systems that significantly improve heat efficiency and clinker output. These systems enhance heat transfer, reduce fuel consumption, and stabilise kiln operations under high throughput conditions.
Professor Procyon Mukherjee suggests, “Cement manufacturing is, at its core, a thermal process. The rotary kiln and calciner together account for energy consumption and emissions. The theoretical thermal requirement for clinker production is around 1700–1800 MJ per tonne, yet real-world plants often operate far above this benchmark due to inefficiencies in combustion, heat recovery and material flow. Modernisation, therefore, must begin with the
kiln system, and not peripheral automation or
isolated upgrades. The shift from wet to dry process kilns, combined with multi-stage preheaters and precalciners, has already delivered step-change improvements, making dry kilns nearly 50 per cent more energy efficient.”
Recent investment programmes across the industry have included kiln cooler upgrades, advanced burners, and improved refractory materials designed to increase operational reliability and reduce specific heat consumption. Such upgrades are essential because cement production remains highly energy intensive, and continuous efficiency improvements are required to meet global decarbonisation targets. According to the International Energy Agency (IEA) Cement Tracking Report, 2023, the cement sector must achieve annual emissions intensity reductions of around 4 per cent through 2030 to align with global net-zero scenarios.

Energy efficiency and WHRS
Energy efficiency remains one of the most important areas of modernisation in cement manufacturing, given the sector’s heavy reliance on thermal and electrical energy. Modern plants deploy advanced process controls, efficient grinding systems, and improved combustion technologies to reduce specific energy consumption. The adoption of energy-efficient technologies is particularly important in India, where energy costs account for a large share of production expenses. As demand grows and plants expand capacity, improving energy performance becomes essential to maintain competitiveness.
Waste Heat Recovery Systems (WHRS) have emerged as a key solution for improving plant energy efficiency. During cement production, large volumes of high-temperature gases are released from kilns and coolers. WHRS technology captures this waste heat and converts it into electricity, thereby reducing reliance on external power sources. According to energy benchmarking studies for the Indian cement industry, installed waste heat recovery capacity in the sector has reached approximately 840 MW, with an additional potential of around 500 MW states the Green Business Centre, Energy Benchmarking Report, 2023. Several leading producers have already implemented large WHRS installations; for example, UltraTech Cement has deployed systems with around 121 MW of waste heat recovery capacity, reducing carbon emissions by nearly 0.5 million tonnes annually according to the Energy Alternatives India Case Study, 2024.

Integration of AFR
The integration of Alternative Fuels and Raw Materials (AFR) is another critical dimension of cement plant modernisation. AFR refers to the use of industrial waste, biomass, refuse-derived fuel (RDF), and other non-fossil materials as substitutes for conventional fuels such as coal and petcoke. Increasing the use of AFR helps reduce fossil fuel consumption while simultaneously addressing waste management challenges. According to the NITI Aayog Decarbonisation Roadmap, 2026, scaling the use of RDF and other alternative fuels could enable the sector to achieve thermal substitution rates of around 20 per cent in the coming decades.
However, integrating AFR requires significant plant modifications and operational adjustments. Waste-derived fuels often have inconsistent calorific values, higher moisture content, and heterogeneous physical properties compared to traditional fuels. As a result, modern plants invest in advanced fuel preparation systems, dedicated feeding equipment, and automated dosing technologies to ensure stable kiln operation. These upgrades allow plants to maintain consistent clinker quality while increasing the share of alternative fuels in their energy mix.

Digitalisation and smart plant operations
Digitalisation is rapidly transforming cement plant operations by enabling data-driven decision-making and predictive maintenance. Industry 4.0 technologies such as IoT sensors, artificial intelligence (AI), and advanced analytics are now used to monitor equipment performance, optimise process parameters, and anticipate maintenance requirements. These digital tools enable plant operators to detect early signs of equipment failure, minimise unplanned downtime, and improve operational efficiency. Predictive maintenance systems, for example, analyse vibration, temperature, and acoustic signals from rotating equipment to identify potential faults
before they escalate into major breakdowns. Digital twins and integrated control systems further allow operators to simulate plant performance under different scenarios and optimise production strategies. Such technologies are becoming increasingly important as cement plants operate at larger scales and higher levels of process complexity.
Maheshwari also adds, “Plant modernisation is also increasingly central to the global competitiveness of Indian cement manufacturers. As cost pressures rise across energy, logistics and regulatory compliance, modern plants offer the structural efficiency required to operate reliably and competitively over the long term. Technologies such as AI-driven Advanced Process Control (APC) integrated with real-time data systems are emerging as essential investments for the future. These platforms use predictive algorithms, machine learning and live process inputs to optimise kiln, mill and utility operations with greater precision than traditional control systems. By continuously analysing variations in feed chemistry, temperature profiles, energy demand and equipment behaviour, APC enables stable operations, lower specific energy consumption, reduced emissions and improved product consistency. As regulatory expectations tighten and plants pursue higher efficiency with lower carbon intensity, AI-enabled APC will play a crucial role in strengthening automation, enhancing decision-making and ensuring long-term operational resilience.”

Modern material handling and logistics
Material handling systems play a critical role in ensuring smooth plant operations and efficient logistics. Modern cement plants rely on advanced conveying systems, automated stockyards, and digital dispatch platforms to manage the movement of raw materials, clinker, and finished cement. Long-distance belt conveyors and pipe conveyors are increasingly replacing truck-based transport between quarries and plants, reducing fuel consumption, dust emissions, and operational costs. Automated stacker-reclaimers ensure consistent blending of raw materials,
which improves kiln stability and clinker quality. Meanwhile, advanced packing and dispatch systems equipped with high-speed rotary packers and robotic palletisers enhance throughput and reduce manual labour. These technologies allow cement plants to optimise logistics efficiency while supporting higher production capacities.

Emission control and environmental compliance
Environmental compliance has become a central focus of cement plant modernisation as regulators and investors place greater emphasis on sustainability performance. Modern plants deploy advanced emission control technologies such as high-efficiency bag filters, electrostatic precipitators, and selective non-catalytic reduction systems to reduce particulate matter and nitrogen oxide emissions.
Sine Bogh Skaarup, Vice President, Head of Green Innovation and R&D, Fuller Technologies says, “One of our key focus areas is decarbonisation. We help cement producers reduce CO2 and overall carbon emissions. We offer alternative fuel solutions and calcined clay technologies to enable the production of LC3 cement, which play a significant role in decarbonising the cement industry. By combining alternative fuels and calcined clay solutions, CO2 emissions can be reduced by up to 50 per cent, making this a highly impactful approach for sustainable cement production.”
Continuous emission monitoring systems are increasingly used to track environmental performance in real time and ensure compliance with regulatory standards. In addition to air pollution control, cement companies are also investing in water recycling systems, renewable energy integration, and carbon reduction initiatives. These measures are essential for aligning the sector with national climate goals and improving the environmental footprint of
cement manufacturing.

Economic benefits and future outlook
Beyond environmental and operational advantages, cement plant modernisation also delivers significant economic benefits. Energy efficiency improvements, digital process optimisation, and advanced material handling systems reduce operating costs and improve asset utilisation. Waste heat recovery and alternative fuels help lower fuel expenditure and reduce exposure to volatile fossil fuel markets. As the industry expands capacity to meet growing demand, modernised plants are better positioned to achieve higher productivity and maintain profitability. The long-term outlook for the sector remains positive, with India expected to continue large-scale infrastructure investments in roads, housing, railways, and urban development.
Milan R Trivedi, Vice President – Projects, Prod & QC, MR, Shree Digvijay Cement, says, “The main focus in case of modernisation projects drives through the investment decision, which is mainly based on IRR and impact on overall efficiency improvement, cost optimisation and improvement in reliability. However, there are certain modernisation, which has high impact on environmental impact, statutory requirements, etc. has higher priority irrespective of ROI or payback period.”
“The energy efficiency and reliability investment projects generally provide fast return on investment whereas strategic, digitalisation and environmental investment projects provide long term and compounded benefits. Typical modernisation investment projects are decided with IRR of about > 20 per cent, payback period of typically 2-3 years for fast-track projects,” he adds.
In this context, modernisation will remain a key strategic priority for cement manufacturers seeking to maintain competitiveness in an increasingly sustainability-focused market.

Conclusion
The modernisation of cement plants is no longer a purely technical upgrade but a strategic transformation that reshapes how the industry operates. As India’s cement sector expands capacity toward the next growth cycle, improvements in energy efficiency, digitalisation, alternative fuels and advanced logistics will determine the competitiveness of individual plants. Modern technologies allow producers to operate at higher productivity levels while simultaneously reducing energy consumption and emissions intensity.
Looking ahead, the pace of technological adoption will play a decisive role in shaping the future of
the cement industry. Companies that successfully integrate modern equipment, digital systems, and sustainable production practices will be better positioned to meet rising infrastructure demand while aligning with global climate commitments. In this evolving landscape, plant modernisation stands as the cornerstone of both operational excellence and environmental responsibility.