Economy & Market

From Clinker to Circularity

Published

11 months ago

November 17, 2025

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Dr SB Hegde, Former President – Manufacturing (Cement Industry); Professor, Department of Civil Engineering, Jain College of Engineering and Technology, Hubballi, India, and Visiting Professor, Pennsylvania State University, USA, discusses breakthroughs in materials, energy and digital systems.

Cement—second only to water in global consumption—supports every major infrastructure programme but contributes 7 per cent to 8 per cent of global CO2. India, the world’s second-largest producer, is projected to reach 441.9 Mt by 2025, while global production stabilises near 4.1 Bt. The industry must now combine growth with carbon discipline. Breakthroughs in materials, energy systems, digital intelligence, and carbon management are redefining competitiveness from ‘volume and cost’ to ‘efficiency and sustainability.’

Industry statuses
Global cement output has stabilised at ~4.1 billion tonnes, while India’s production continues to rise, driven by housing and infrastructure growth. This shift positions India as a key driver of global demand but also heightens pressure to improve energy efficiency and cut emissions. The gap between average and best-practice performance (Table 1a) highlights major scope for cost-effective decarbonisation.
Efficient plants already prove that emission control and profitability align.

Sustainable Innovations in Production
1. Low-Carbon Cement Technologies
Replacing clinker with SCMs—fly ash, slag, calcined clay, limestone— can cut emissions 30 per cent to 70 per cent. LC3 formulations show strong strength and durability when kaolinite content and calcination are well controlled.
2. Clinker Substitution and Electrochemical Processes
• Clinker substitution remains the fastest reduction route.
• Electrochemical cement eliminates kiln CO2 by using low-temperature electrolysis.
Figure 2: Bar chart of CO2 reduction potential (SCMs, AFR, WHR, CCUS, Digital)
3. Carbon Capture, Utilisation and Storage (CCUS)
CCUS targets calcination CO2 (~60 per cent of total). Plant 1 has characterised flue gas; Plant 2 reserved space for modular capture; Plant 3 studies CO2 utilisation. Full deployment could cut emissions ˜ 50 per cent.
4, Alternative Fuels & Waste Heat Recovery (WHR)
Each 10 per cent AFR substitution saves ˜ 25 kg CO2/t clinker. WHR can meet 30 per cent to 35 per cent of power needs if maintained efficiently.
5, Materials-Science Frontiers
Recent advances in clinker chemistry are enabling deeper CO2 reduction. Belite–Ye’elimite–Ferrite (BYF) clinkers operate at firing temperatures nearly 150°C lower than ordinary Portland clinker, reducing process emissions by about 30 per cent.
Calcium Sulphoaluminate (CSA) cements provide rapid early strength with lower energy input. Nano- and graphene-enhanced binders improve strength-to-carbon ratios, while alkali-activated materials (AAMs) and geopolymers utilise fly ash and slag, cutting both emissions and waste. These advances mark a decisive shift toward low-clinker, high-performance systems.

Digital innovations and industry 4.0
The cement industry is rapidly embracing Industry 4.0 technologies to achieve precision, stability, and predictive control in operations. Artificial intelligence (AI), the Industrial Internet of Things (IIoT), and digital twins are transforming kiln, mill, and logistics management by reducing process variability and energy consumption. These tools enable real-time monitoring, data-driven decision-making and improved plant reliability. The following tables highlight the current level of digital adoption and its quantifiable impact across modern cement plants. AI, IoT and digital twins are reducing energy waste and variance across plants.

Circular economies and resource looping
The cement industry is increasingly adopting circular economy principles to close material and carbon loops. Co-processing of municipal and industrial wastes as alternative fuels and raw materials reduces both emissions and landfill burdens. Recycling construction and demolition waste (CDW)as a partial raw feed, and promoting recarbonation of concrete at end of life, further enhance carbon recovery. These initiatives make cement plants integral to sustainable waste management and resource efficiency.

Cement plants are evolving into resource recovery centres:
• Co-processing municipal and industrial wastes as fuel or raw feed.
• Recycling CDW as raw meal additive or aggregate.
• Recarbonation of concrete absorbs ˜ 150 kg CO2/t over life.

Decarbonisation pathways and innovation roadmap
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.

Learning from practice
• Plant 1 implemented multi-source SCMs and advanced QC, cutting emissions by >70 kg/t.
• Plant 2 achieved stable kiln operation with 25 per cent AFR.
• Plant 3 combined WHR and AI controls to self-generate 30 per cent power.
• Plant 4 pre-engineered for future CCUS and CO2 offtake agreements.

Lesson: Innovation succeeds when technology is paired with discipline, cross-functional coordination, and long-term planning.

Innovation enablers: market, finance and policy
Market Signals. Public and private projects are specifying low-carbon materials, pushing plants to expand SCM and AFR capacity. Financing Models. AFR, WHR and digital projects suit traditional project finance. Emerging tech like CCUS needs blended finance (carbon credits + green bonds + grants). ESG-linked loans reward verified CO2 reduction with lower interest rates. Regulatory Ecosystem. Updated standards for high SCM blends, fast-track permits for AFR/WHR, and EPD-based procurement create a virtuous cycle between policy and market.

Policy and regulatory levers for acceleration
India’s leadership in low-carbon cement depends on pragmatic steps:
1. Raise blending limits to 65 per cent to 70 per cent where performance permits.
2. Streamline approvals for AFR and WHR projects.
3. Adopt green procurement with EPD requirements.
4. Provide carbon credits and tax rebates for early CCUS and LC3 plants.
5. Implement national MRV protocols aligned with global benchmarks.
Such policies offer predictability and move innovation from pilot to mainstream.

Sequencing the transition (2025–2050)
• Phase 1 (2025–2030): Deploy SCMs, AFR, WHR and digital optimisation — low-risk, high-impact.
• Phase 2 (2030–2040): Scale CCUS and partial electrification as costs drop.
• Phase 3 (2040–2050): Adopt new clinker chemistries and full carbon capture networks.
This phasing lets plants build skills and capital progressively while meeting net-zero goals.

Conclusion
Cement’s future depends on how fast the sector moves from clinker-intensive processes to circular low-carbon systems. Every path count: lower clinker factor, energy efficiency, AFR, digital control, and CCUS. India possesses the scale, technical talent and market momentum to lead this transformation. With consistent policy support and industry discipline, specific CO2 can fall below 300 kg/t cement by 2050—making the nation a benchmark for sustainable cement production.

References
1. International Energy Agency (IEA). (2023). Cement – Tracking Industry 2023. Paris: IEA.
2. Global Cement and Concrete Association (GCCA). (2024). Cement Industry Net Zero Progress Report 2024/25. London: GCCA.
3. Scrivener, K. L., Martirena, F., Bishnoi, S., & Maity, S. (2018). Calcined clay limestone cements (LC³). Cement and Concrete Research, 114, 49–56.
4. Gartner, E., & Sui, T. (2018). Alternative cement clinkers. Cement and Concrete Research, 114, 27–39.
5. Bosoaga, A., Masek, O., & Oakey, J. E. (2009). CO2 capture technologies for cement industry. Energy Procedia, 1(1), 133–140.
6. Miller, S. A., John, V. M., Pacca, S. A., & Horvath, A. (2018). Carbon dioxide reduction potential in the global cement industry by 2050. Cement and Concrete Research, 114, 115–124.
7. Roussanaly, S., Berstad, D., Husebye, J., & Jakobsen, J. (2021). Towards large-scale CO2 transport and storage networks in Europe: A cost and carbon perspective. International Journal of Greenhouse Gas Control, 105, 103239.
8. Nobre, A. V., Scholes, O., & Butler, I. (2022). Industry 4.0 in cement manufacturing: A review of technologies, applications, and benefits. Journal of Cleaner Production, 359, 132043.
9. Lehne, J., & Preston, F. (2018). Making Concrete Change: Innovation in Low-Carbon Cement and Concrete. London: Chatham House.
10. Reddy, D. V., & Kumar, M. S. (2023). Circular economy pathways for sustainable cement and concrete in India. Resources, Conservation & Recycling Advances, 18, 200164.

About the author:
Dr SB Hegde, Global Industry Expert is a Professor at the Department of Civil Engineering, Jain College of Engineering and Technology, Hubballi, India and Visting Professor, Pennsylvania State University, United States.

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2 days ago

October 9, 2026

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Singh brings 20+ years of brand and marketing experience, and will lead integrated corporate brand communication initiatives at Wonder Cement

New Delhi

Wonder Cement, a leading cement manufacturer, has appointed Mahesh Singh as Vice President – Corporate Brand Communication. In his new role, he will oversee corporate brand strategy and communication, including digital and performance marketing, public relations, trade, events, exhibitions, sports and experiential marketing.

Singh brings over two decades of experience across marketing and communications, with roles spanning the automotive industry, agencies and entrepreneurship. He spent more than a decade with Honda Motorcycle & Scooter India, working across integrated communication, media, digital, retail and consumer engagement. His stint also included helping build the company’s digital marketing capabilities.

He moved to dentsu X India as Vice President – Strategy & Planning, working across categories such as automotive, auto components, electric vehicles, FMCG, consumer electronics, BFSI, apparel and brand consulting. His responsibilities included media and marketing strategy, product launches, content, performance marketing and consumer activations.

Singh subsequently took an entrepreneurial route with Radiant Brands before joining Shriram Ltd (SPR Autotech) as Head – Marketing & Communications. There, his remit included brand and corporate strategy, communications, PR and ORM, retail identity, loyalty programmes and events.

At Wonder Cement, Singh will be responsible for bringing together the company’s corporate brand communication initiatives across digital, performance marketing, PR, trade, sports and experiential platforms. The role will focus on creating an integrated approach to communication across consumers, trade partners and other key stakeholders.

The appointment brings to Wonder Cement a marketer whose career has spanned the brand, agency and entrepreneurial sides of the communications ecosystem.

Wonder Cement, part of the RK Group, is a cement manufacturer with roots in Rajasthan and a focus on quality, trust and transparency. The company has grown to six manufacturing plants, and a cement capacity of 21.5 MTPA. With more than 2,000 employees and a network of over 5,000 dealers, its operations span manufacturing, distribution and customer engagement, with a focus on consistent product quality and efficient execution.

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JSW Cement commissions additional 1 MTPA grinding unit at Nagaur

Published

3 days ago

October 8, 2026

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With this commissioning, JSW Cement’s total cement grinding capacity has increased to 25.10 MTPA,
Mumbai

JSW Cement, one of India’s leading green cement producers and part of the diversified JSW Group, today announced the successful commissioning of an additional 1.00 MTPA cement grinding unit at Nagaur, Rajasthan. The commissioning marks another significant milestone in the Company’s growth strategy.

With this commissioning, JSW Cement’s total cement grinding capacity has increased to 25.10 MTPA, while its total clinker manufacturing capacity, including clinker capacity at its joint venture, JSW Cement FZC, stands at 9.74 MTPA.

JSW Cement had commenced operations in North India in March 2026 with the Nagaur Integrated Plant, comprising a 3.30 MTPA clinkerisation unit and 2.50 MTPA cement grinding unit. With the commissioning of the additional 1.00 MTPA cement grinding unit, the plant’s total cement grinding capacity has increased to 3.50 MTPA, enhancing the company’s ability to cater to the growing cement demand across Rajasthan, Haryana, Punjab and the National Capital Region (NCR). The expansion has been funded through a strategic mix of equity and long-term debt.

During the quarter ended 30th September 2026, JSW Cement has also commissioned the Alternate Fuel Handling System and the Waste Heat Recovery system (WHRS) at the Nagaur Integrated Plant.

Nilesh Narwekar, CEO, JSW Cement, said: “The commissioning of additional 1.00 MTPA grinding capacity at Nagaur is a key strategic priority for us and will accelerate JSW Cement’s expansion into North India. We look forward to servicing the growing needs of the region and contributing to the economic growth of Rajasthan, Haryana, Punjab and the NCR area. I am delighted to share that the company has commissioned this grinding unit within the expected timeline, showcasing our project execution capabilities. Further, the Alternate Fuel Handling System and the Waste Heat Recovery system (WHRS) are expected to substantially reduce our production costs going forward.”

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UltraTech becomes first Indian cement firm to cross 2 GW green energy

Published

4 days ago

October 7, 2026

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UltraTech Cement has crossed 2 GW of captive green energy capacity, with renewables and waste heat recovery meeting 48 per cent of its power needs.

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UltraTech Cement Limited has surpassed 2 GW of installed green energy capacity for captive use, becoming the first cement company in India to achieve the milestone. The Aditya Birla Group company commissioned 116.55 MW of wind capacity at its Inter-State Transmission System-connected wind-solar hybrid project in Barmer, Rajasthan, along with 10 MW of Waste Heat Recovery System capacity at Sarlanagar Cement Works in Karnataka.

With these additions, UltraTech’s cumulative installed green energy capacity has reached 2,024 MW. This includes 1,580 MW of renewable energy capacity and 444 MW of waste heat recovery capacity, together meeting around 48 per cent of the company’s current power requirements.

The company said the milestone reflects the progress of its long-term energy transition strategy. In FY27 so far, nearly one-third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements, while five units have crossed 95 per cent.

K C Jhanwar, Managing Director, UltraTech Cement Limited, said, “Crossing the 2 GW green energy milestone is the result of a strategy we have pursued consistently over the past decade. Cement is an energy-intensive, hard-to-abate sector, and showing that reliability and growth can go hand in hand with a rapid shift to green energy sets a benchmark for the industry. With nearly half of our power needs now met through green energy, we are significantly less exposed to fossil fuel supply constraints and power price volatility. As we scale up renewables, waste heat recovery and battery storage across our operations, we are building an energy foundation for stable, long-term growth.”

UltraTech commissioned 430 MW of green energy capacity in FY26 and continues to expand its renewable energy and waste heat recovery portfolio.

The company is also progressively integrating Battery Energy Storage Systems across its operations to improve renewable energy utilisation and supply reliability.

In 2025, UltraTech operationalised what it described as India’s first on-site hybrid round-the-clock renewable energy project at Sewagram Cement Works in Gujarat. The project combines solar, wind and battery storage.

As part of its decarbonisation strategy, UltraTech said it has not invested in new captive thermal power capacity for either greenfield projects or brownfield expansions at its integrated units for more than a decade.

The company said its expanding green energy portfolio is helping reduce dependence on conventional grid electricity and fossil fuel-based power, while lowering exposure to fluctuations in coal and electricity prices.

UltraTech aims to increase green energy’s share in its total power mix to 85 per cent by 2030. As a member of RE100, it has also committed to meeting 100 per cent of its electricity requirement through renewable sources by 2050.

UltraTech Cement, the cement flagship of the Aditya Birla Group, has a total grey cement capacity of 210.1 MTPA and white cement and putty capacity of 3.5 MTPA. The company is also a signatory to the GCCA Climate Ambition 2050 and has committed to the GCCA Net Zero Concrete roadmap.