Concrete

Low-Carbon Future: Reimagining Cement

Published

7 months ago

November 20, 2025

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Milind Khangan, Manager – Marketing, Vertex Market Research, discusses how cement, India’s hard-to-abate sector, is paving the path to Net Zero.

The Indian cement industry, the world’s second-largest, holds an installed capacity of around 700 million tonnes per annum (MTPA) and is fundamental to India’s infrastructure growth and urbanisation. However, it remains one of the country’s most challenging ‘hard-to-abate’ sectors, contributing nearly 7–8 per cent of national industrial CO2 emissions.
With India’s commitment to achieving Net-Zero by 2070, decarbonising cement production has become a national strategic priority. The sector’s transformation can be understood through the 3Cs of Decarbonisation — Cut emissions, Cement innovation, and Carbon capture and utilisation. Together, these pillars, underpinned by digital optimisation, automation and enabling policy frameworks, represent a structured pathway towards deep emission reduction while maintaining industrial competitiveness. Government-backed pilot projects and public-private testbeds are helping transition the sector from demonstration to early commercial adoption, creating a foundation for large-scale transformation.

Cut: Cutting operational emissions (near-term, high ROI)
The first pillar ‘Cut’ focuses on immediate, high-impact interventions targeting emissions from fuel combustion and electricity use, which collectively account for around 30 per cent of the industry’s total emissions.

Fuel switching and AFR
Co-processing Refuse-Derived Fuel (RDF), industrial waste, and biomass is steadily replacing coal and other high-carbon fossil fuels. This approach not only lowers Scope 1 emissions but also contributes to waste management in urban and industrial clusters.

Ambuja Cements increased its AFR consumption in kilns to 9.4 per cent in H1 FY25 from 7 per cent in H1 FY24, indicating an improved Thermal Substitution Rate (TSR).
Securing consistent, reliable and high-quality RDF feedstock through municipal partnerships has become a strategic priority.

Waste Heat Recovery (WHR)
WHR systems convert residual heat from the pyroprocess into captive electricity, reducing Scope 2 emissions and enhancing thermal efficiency. Increasingly, WHR is being integrated with renewable energy (RE) sources to stabilise green power supply.

As of March 2025, UltraTech Cement held 342 MW of WHR capacity, contributing to a total green energy portfolio of 1.36 GW, including solar and wind.
Dalmia Bharat increased its renewable energy share to 39 per cent in Q2 FY25, targeting 45 per cent by the end of the fiscal year.
In August 2025, UltraTech commissioned a 7.5 MW Hybrid Round-the-Clock (RTC) project (solar + wind + battery) in Gujarat in August 2025 to stabilise renewable energy supply.

Energy efficiency and process optimisation
Advanced digitised process controls, AI-driven kiln optimisation, and predictive maintenance
systems reduce clinker overburn, stabilise AFR use, and optimise thermal efficiency. Closed-loop kiln control using AI/ML is increasingly identified as a strategic differentiator.

AI and machine learning-based closed-loop kiln control delivers thermal energy savings of 5-10 per cent and reduces downtime.
Imubit reported clinker production efficiency improvements of 5-10 per cent and fuel consumption reductions of 3-5 per cent by deployment of Closed-Loop AI Optimisation (AIO).

Renewable power procurement
Vertex Market Research expects the expansion of on-site solar, wind, and open-access corporate PPAs is reducing reliance on grid electricity and mitigating Scope 2 emissions. The trend is shifting towards hybrid and RTC renewable solutions integrating solar, wind, and battery systems.

UltraTech added 269 MW of renewable capacity in Q4 FY25, meeting approximately 46 per cent of its power requirements. The total capacity consists of 1,021 MW of solar, wind, and hybrid energy sources and 342 MW of WHRS.
In its FY25 annual report, Dalmia Bharat announced that its total operational renewable energy (RE) capacity target is set to increase from 267 MW to 595 MW by the end of fiscal year 2026.

Green hydrogen integration
Supported by the National Green Hydrogen Mission, pilot projects are underway to explore green hydrogen as a substitute fuel in kilns and grinding units. While widespread commercial deployment is anticipated post-2030, early trials in calciners and low-temperature operations are creating a technological base for future zero-carbon heat applications.

Decarbonisation targets and commitments
Indian majors are aligning their climate goals with the Science Based Targets initiative (SBTi).

Ambuja and ACC are committed to Net Zero by 2050 and are the only 2 cement companies in India undergoing Net Zero target validation from the Science Based Targets initiative (SBTi).
UltraTech and Ambuja Cement aim for a 27 per cent reduction in Scope 1 CO2 emissions by 2032 and have already achieved a 12 per cent reduction.

Cement: Product and process innovations (medium-term structural change)
The second pillar ‘Cement’ centres on re-engineering materials, clinker ratios, and manufacturing processes to achieve structural emission reduction. It aims to reduce clinker intensity and embodied carbon, thereby addressing the intrinsic process emissions (around 60 per cent of total CO2 output).

Clinker substitution and SCMs
While fly ash and slag remain key SCMs, their long-term availability could decline as the power and steel sectors decarbonise. Consequently, the industry is diversifying into calcined clays, silica fume, and limestone fillers to sustain clinker replacement rates. Multi-component (ternary and quaternary) blends are being tested to maximise emission reduction potential.

Limestone calcined clay cement (LC3)
LC3 technology enables up to 50 per cent clinker replacement using locally available clays and limestone, achieving 30–40 per cent lower CO2 emissions without significant cost escalation.

In July 2025, JK Cement and JK Lakshmi launched India’s first commercial LC3 under BIS IS 18189:2023.
Early implementation of LC3 in infrastructure projects such as the Noida International Airport signals growing market acceptance.

Novel kiln concepts
The calcination process is a major source of process emissions. To address calcination-related emissions, innovations such as electrified calciners and Electric Arc Calciners (EAC) are being piloted.

The collaboration between Dalmia Cement and SaltX Technology is focused on advancing the Electric Arc Calciner (EAC) pilot project in India. These pilots are heavily dependent on low-cost renewable electricity. Although at a pre-commercial stage, such technologies are vital for achieving deep decarbonisation beyond 2035.

Blended products portfolio and cement use efficiency (CUE)
The GCCA India–TERI Decarbonisation Roadmap (March 2025) projects that optimised mix designs and multi-blend cements could reduce India’s cement demand from 1,440 MT to 944 MT by 2047, a 34 per cent reduction. Efficient structural design, increased Ready-Mix Concrete (RMC) use, and multi-component blends will be critical enablers.
Recarbonation and circular concrete
Concrete naturally reabsorbs CO2 during its lifecycle, a process termed recarbonation. GCCA India estimates that recarbonation could offset up to 5.9 per cent of cumulative cement sector emissions by 2070. Recycling concrete aggregates can accelerate this process, closing material loops and promoting circularity.

Carbon: CCUS and carbon management (long-term, residual emissions)
The ‘Carbon’ pillar addresses intrinsic process emissions from clinker calcination, which cannot be fully eliminated through fuel switching, process optimisation or clinker substitution.

Carbon capture and utilisation (CCU) and testbeds
India’s approach prioritises CCU over storage (CCS) to convert captured CO2 into value-added products to offset high CAPEX, improving project economics.
India prioritises CCU over storage, converting captured CO2 into value-added products to offset high CAPEX. DST-supported public-private pilot projects validate indigenous technologies such as oxygen-enhanced calcination and solvent-based capture. Pilot-scale operations (1–2 tpd) target products including lightweight concrete blocks, precipitated calcium carbonate, and formic acid.

In May 2025, the Department of Science and Technology (DST) launched five CCU testbeds for the cement sector under a public–private partnership (PPP) framework.
These pilots (1–2 TPD scale) are testing oxygen-enhanced calcination and solvent-based capture technologies, with utilisation routes for precipitated calcium carbonate, lightweight blocks, and formic acid.

Policy and financial levers
The Carbon Credit Trading Scheme (CCTS), established under the Energy Conservation (Amendment) Act 2022, mandates GHG intensity reduction for large cement plants. This creates
financial incentives for low-carbon investments and CCUS adoption.

The Carbon Credit Trading Scheme (CCTS), established under the Energy Conservation (Amendment) Act, 2022, is now being implemented. The Bureau of Energy Efficiency (BEE) released notifications in mid-2025, setting GHG Emission Intensity (GEI) targets for large entities. Cement is a compliance sector with targets for 2 per cent reduction in GEI for FY 2025-26, increasing in subsequent years.
Cement plants are mandated to meet GHG Emission Intensity reduction targets, creating a financial incentive for CCUS adoption and low-carbon cement production. The establishment of a domestic carbon market provides the critical price signal for high-CAPEX solutions such as CCUS. This creates a direct financial mandate for CCUS and low-carbon investment.

Hub-and-cluster infrastructure
Developing shared CCU infrastructure across cement clusters or hubs can lower capital intensity per plant. High-density cement regions such as Andhra Pradesh, Telangana, Gujarat and Rajasthan are under evaluation for hub-and-cluster carbon management models, in alignment with GCCA India’s recommendations.

Conclusion
Indian cement industry is entering a decisive decade of transformation. Through the 3Cs approach, the sector is not merely mirroring global practices but crafting a contextually tailored, India-specific roadmap to Net-Zero.
Near-term measures under Cut can be rapidly scaled, Cement innovations will drive material efficiency and cost competitiveness, and high-tech Carbon management will mitigate unavoidable and residual emissions. Success hinges on sustained policy continuity, financial incentives, functional carbon credit trading scheme, and close coordination among industry leaders, government agencies, and R&D institutions. The collective goal is to translate pilot projects into scalable business models that preserve competitiveness while achieving verifiable emission reductions and positioning India as a global benchmark in low-carbon cement manufacturing.

ABOUT THE AUTHOR:
Milind Khandan, Manager – Marketing, Vertex Market Research, comes with over five years of experience in market research, lead generation and team management.

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Cement Makers Reaffirm Commitment to Sustainable Growth

Published

5 days ago

June 5, 2026

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

Concrete

Building a Greener Future Together

Published

6 days ago

June 4, 2026

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

1 week ago

June 1, 2026

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.