Economy & Market

Shaping a Low-Carbon Cement Future

Published

6 months ago

November 17, 2025

admin

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

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

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

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

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

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

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

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

Carbon Emissions in Ready-Mix Concrete

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

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

Reducing CO2 in Cement Production

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

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

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Concrete

Filtration Technology is Critical for Efficient Logistics

Published

4 days ago

May 15, 2026

admin

Niranjan Kirloskar, MD, Fleetguard Filters, makes the case that filtration technology, which has been long treated as a routine consumable, is in fact a strategic performance enabler across every stage of cement production and logistics.

India’s cement industry forms the core for infrastructure growth of the country. With an expected compound annual growth rate of six to eight per cent, India has secured its position as the second-largest cement producer globally. This growth is a result of the increasing demand across, resulting in capacity expansion. Consequently, cement manufacturers are now also focusing on running the factories as efficiently as possible to stay competitive and profitable.
While a large portion of focus still remains on production technologies and capacity utilisation, the hidden factor in profitability is the efficiency of cement logistics. The logistics alone account for nearly 30 per cent to 40 per cent of the total cost of cement, making efficiency in this segment a key lever for profitability and reliability.
In the midst of this complex and high-intensity ecosystem, filtration often remains one of the most underappreciated yet essential enablers of performance.

A demanding operational landscape
Cement production and logistics inherently operate in some of the harshest industrial environments. With processes such as quarrying, crushing, grinding, clinker production, and bulk material handling expose the machinery to constant high temperatures, heavy loads, and dust, often the silent destructive force for engines.
The ecosystem is abrasive, and often one with a high contamination index. These challenging conditions demand equipment such as the excavators, crushers, compressors, and transport vehicles to perform and perform efficiently. The continuous exposure to contamination across every aspect like air, fuel, lubrication, and even hydraulic systems causes long-term damage. Studies have also shown that 70 to 80 per cent of hydraulic system failures are directly linked to contamination, while primary cause of engine wear is inadequate air filtration.
For engines as heavy as these, even a minor contaminant has a cascading effect; reducing efficiency, performance and culminating to unplanned downtime. Particles as small as 5 to 10 microns, far smaller than a human hair (~70 microns), can cause significant damage to critical engine components. In an industry where margins are closely linked to operational efficiency, such disruptions can significantly affect both cost structures and delivery timelines.

Dust management: A persistent challenge
Dust is a natural by-product in cement operations. From drilling and blasting in the quarries to packing in plants, this fine particulate matter does occupy a large space in operations. Dust concentration levels in quarry and crushing zones often create extremely high particulate exposure for equipment. These fine particles, when enter the engines and critical systems, accelerates the wear and tear of the component, affecting directly the operational efficiency. Over time every block fall; engine performance declines, fuel consumption rises, and maintenance cycles shorten. In this case, effective air filtration is the natural first line of defence. Advanced filtration systems are designed to capture high volumes of particulate matter while maintaining consistent airflow, ensuring that engines and equipment operate under optimal conditions.
In high-dust applications, as in cement production, even the filtration systems are expected to sustain performance over extended periods without the need of frequent replacement. This becomes crucial in remote quarry locations where access to frequent maintenance may be limited.

Fluid cleanliness and system integrity
Beyond air filtration, fluid systems also play a crucial role for equipment reliability in cement operations. Fuel systems are required to remain free from contaminants for efficient working of combustion and injection protection. Additionally, lubrication systems also need to maintain the oil purity to reduce friction and prevent any premature wear of moving parts. The hydraulic systems, which are key to several heavy equipment operations, are especially sensitive to contamination.
If fine particles or water enters these systems, it can lead to reduced efficiency, erratic performance, and eventual failure of the system. Modern filtration systems are designed with high-efficiency media capable of removing extremely fine contaminants, with advanced fuel and oil filtration solutions filtering particles as small as two to five microns. Multi-stage filtration systems further ensure that fluid performance is maintained even under challenging operating conditions.
Another critical aspect of fuel systems is water separation. Removing moisture helps prevent corrosion, improves combustion efficiency and enhances overall engine reliability. Modern water separation technologies can achieve over 95 per cent efficiency in removing water from fuel systems.

Ensuring reliability across the value chain
Filtration plays a critical role across every stage of cement logistics:
• Quarry operations: Equipment operates in highly abrasive environments, requiring strong protection against dust ingress and hydraulic contamination.
• Processing units: Crushers, kilns, and grinding mills depend on clean lubrication and cooling systems to sustain continuous operations.
• Material handling systems: Pneumatic and mechanical systems rely on clean air and fluid systems for efficiency and reliability.
• Transportation networks: Bulk carriers and trucks must maintain engine health and fuel efficiency to ensure timely deliveries.
Across these operations, filtration plays a vital role; as it supports consistent equipment performance while reducing the risk of unexpected failures.
Effective filtration solutions can reduce unscheduled equipment failures by 30 to 50 per cent across heavy-duty operations.

Uptime as a strategic imperative
In cement manufacturing, uptime is currency. Downtime not only delays the production, but it also greatly impacts the supply commitments and logistics planning. With the right filtration systems, contaminants are kept at bay from entering the
critical systems, and they also significantly extend the service intervals.
Optimised filtration can extend service intervals by 20 to 40 per cent, reducing maintenance frequency while maintaining consistent performance across demanding operating conditions. Filtration systems designed for heavy-duty applications sustain efficiency throughout their lifecycle, ensuring reliable protection with minimal interruptions. This leads to improved equipment availability, lower maintenance costs, and more predictable operations, with well-maintained systems capable of achieving uptime levels of over 90 to 95 per cent in challenging cement environments.

Supporting emission and sustainability goals
With the rising environmental awareness, the cement industry too is aligning with the stricter norms and sustainability targets. In this scenario, the operational efficiency is directly linked to emission control.

Air and fuel systems that are clean enable
much more efficient combustion. They also reduce emissions from both the stationary equipment and transport fleets. Similarly, with a well-maintained fluid cleanliness, emission systems function better. Poor combustion due to contamination can increase emissions by 5 to 10 per cent, making clean systems critical for compliance.
Additionally, efficient and longer lasting filtration systems significantly reduce any waste generation and contribute to increased sustainable maintenance practices. Extended-life filtration solutions can reduce filter disposal and maintenance waste by 15 to 20 per cent. Smart and efficient filtration in this case plays an important role in meeting the both regulatory and environmental objectives within the industry.

Advancements in filtration technology
Over the years, there has been a significant evolution in the filtration technology to meet the modern industrial applications.
Key developments include:
• High-efficiency filtration media capable of capturing very fine particles without restricting flow
• Compact and integrated designs that combine multiple filtration functions
• Extended service life solutions that reduce replacement frequency and maintenance downtime
• Application-specific engineering tailored to different stages of cement operations
Modern multi-layer filtration media can improve dust-holding capacity by up to two to three times compared to conventional systems, while maintaining consistent performance. These advancements have transformed filtration from a basic maintenance component into a critical performance system.

Adapting to diverse operating conditions
The cement industry of India operates across diverse geographies. Spanning across regions with arid regions with higher dust levels, to the coastal areas with higher humidity, challenges of each region pose different threats to the engines. Modern filtration systems are thus tailored to address these unique challenges of each region.
Indian operating environments often range from 0°C to over 50°C, with some of the highest dust loads globally in mining zones.
Additionally, filtration technology can also be customised to variations which then align the system design with factors like dust load, temperature, and equipment usage patterns. Equipment utilisation levels in India are typically higher than global averages, making robust filtration even more critical. This approach ensures optimal performance and durability across different operational contexts.

Impact on total cost of ownership
Filtration has a direct and measurable impact on the total cost of ownership of equipment.
Effective filtration leads to:
• Lower wear and tear on critical components
• Reduced maintenance and repair costs
• Improved fuel efficiency
• Extended equipment life
• Higher operational uptime
Effective filtration can extend engine life by 20 to 30 per cent and reduce overall maintenance costs by 15 to 25 per cent over the equipment lifecycle. These benefits collectively enhance productivity and reduce lifecycle costs. Conversely, inadequate filtration can result in frequent breakdowns, increased maintenance expenditure, and reduced asset utilisation.

Building a more efficient cement ecosystem
With the rising demand across various sectors, the cement industry is expected to expand at an unprecedented rate. This growth is forcing the production to move towards a more efficient and resilient system of operations. This requires attention not only to production technologies but also to the supporting systems that enable consistent performance. Filtration must be viewed as a strategic investment rather than a routine consumable. By ensuring the cleanliness of air and fluids across systems, it supports reliability, efficiency, and sustainability.

The road ahead
The future of cement logistics will be shaped by increasing mechanisation, digital monitoring, and stricter environmental standards. The industry is also witnessing a shift towards predictive maintenance and condition monitoring, where filtration performance is increasingly integrated with real-time equipment diagnostics.
In this evolving landscape, the role of filtration will become even more critical. As equipment becomes more advanced and operating conditions more demanding, the need for precise contamination control will continue to grow. From quarry to construction site, filtration technology underpins the performance of every critical system. It enables equipment to operate efficiently, reduces operational risks, and supports the industry’s broader goals of growth and sustainability. In many ways, it is the unseen force that keeps the cement ecosystem moving, quietly ensuring that every link in the value chain performs as expected.

About the author
Niranjan Kirloskar, Managing Director, Fleetguard Filters, is focused on driving innovation, operational excellence, and long-term business growth through strategic and people-centric leadership. With a strong foundation in ethics and forward-thinking decision-making, he champions a culture of collaboration, accountability, and technological advancement.

Concrete

Cement’s Next Fuel Shift

Published

4 days ago

May 15, 2026

admin

Jignesh Kindaria highlights how Thermal Substitution Rate (TSR) is emerging as a critical lever for cost savings, decarbonisation and competitive advantage in the cement industry.

India is simultaneously grappling with two crises: a mounting waste emergency and an urgent need to decarbonise its most carbon-intensive industries. The cement sector, the second-largest in the world and the backbone of the nation’s infrastructure ambitions, sits at the centre of both. It consumes enormous quantities of fossil fuel, and it has the technical capacity to consume something else entirely: the waste our cities cannot get rid of.
According to CPCB and NITI Aayog projections, India generates approximately 62.4 million tonnes of municipal solid waste annually, with that figure expected to reach 165 million tonnes by 2030. Much of this waste is energy-rich and non-recyclable. At the same time, cement kilns operate at material temperatures of approximately 1,450 degrees Celsius, with gas temperatures reaching 2,000 degrees. This high-temperature environment is ideal for co-processing, ensuring the complete thermal destruction of organic compounds without generating toxic residues. The physics are in our favour. The infrastructure is not.
Pre-processing is not the support act for co-processing. It is the main event. Get the particle size wrong, get the moisture wrong, get the calorific value wrong and your kiln thermal stability will suffer the consequences.

The regulatory push is real
The Solid Waste Management (SWM) Rules 2026 mandate that cement plants progressively replace solid fossil fuels with Refuse-Derived Fuel (RDF), starting at a 5 per cent baseline and scaling to 15 per cent within six years. NITI Aayog’s 2026 Roadmap for Cement Sector Decarbonisation targets 20 to 25 per cent Thermal Substitution Rate (TSR) by 2030. Beyond compliance, every tonne of coal replaced by RDF generates measurable carbon reductions which is monetisable under India’s emerging Carbon Credit Trading Scheme (CCTS). TSR is no longer a sustainability metric. It is a financial lever.
Yet our own field assessments across multiple Indian cement plants reveal a sobering reality: the primary barrier to scaling AFR adoption is not waste availability. It is the fragmented and under-engineered pre-processing ecosystem that sits between the waste and the kiln.

Why Indian waste is a different engineering problem
Indian municipal solid waste is not the material that imported shredding equipment was designed for. Our waste streams frequently exceed 40 per cent to 50 per cent moisture content, particularly during monsoon cycles, saturated with abrasive inerts including sand, glass, and stone. Plants relying on imported OEM equipment face months of downtime awaiting proprietary spare parts. Machines built for segregated, low-moisture waste fail quickly and disrupt the entire pre-processing operation in Indian conditions.
The two most common failures we observe are what I call the biting teeth problem and the chewing teeth problem. Plants relying solely on a primary shredder reduce bulk waste to large fractions, but the output remains too coarse for stable kiln combustion. Others attempt to use a secondary shredder as a standalone unit without a primary stage to pre-size the feed, leading to catastrophic mechanical failure. When both stages are present but mismatched in throughput capacity, the system becomes a bottleneck. Achieving the 40 to 70 tonnes per hour required for meaningful coal displacement demands a precisely coordinated two-stage process.

Engineering a made-in-India answer
At Fornnax, our response to these challenges is grounded in one principle: Indian waste demands Indian engineering. Our systems are built around feedstock homogeneity, the holy grail of kiln stability. Consistent particle size and predictable calorific value are the foundation of stable kiln combustion. Without them, no TSR target is achievable at scale.
Our SR-MAX2500 Dual Shaft Primary Shredder (Hydraulic Drive) processes raw, baled, or loosely mixed MSW, C&I waste, bulky waste, and plastics, reducing them to approximately 150 mm fractions at throughputs of up to 40 tonnes per hour. The R-MAX 3300 Single Shaft Secondary Shredder (Hydraulic Drive), introduced in 2025, takes that primary output and produces RDF fractions in the 30 to 80 mm range at up to 30 tonnes per hour, specifically optimised for consistent kiln feeding. We have also introduced electric drive configurations under the SR-100 HD series, with capacities between 5 and 40 tonnes per hour, already operational at a leading Indian waste-processing facility.
Looking ahead, Fornnax is expanding its portfolio with the upcoming SR-MAX3600 Hydraulic Drive primary shredder at up to 70 tonnes per hour and the R-MAX2100 Hydraulic drive secondary shredder at up to 20 tonnes per hour, designed specifically for the large-scale throughput that higher TSR ambitions require.

The investment case is now
The 2070 Net-Zero target is not a distant goal for India’s cement sector. It starts today, with decisions being made on the plant floor.
The SWM Rules 2026 are already in effect, requiring cement plants to replace coal with RDF. Carbon credit markets are opening up, and coal prices are not going to get cheaper. Every tonne of coal a cement plant replaces with waste-derived fuel saves money on one side and generates carbon credit revenue on the other. Pre-processing infrastructure is no longer just a compliance requirement. It is a business investment with a measurable return.
The good news is that nothing is missing. The technology works. The waste is available in every Indian city. The government has provided the policy direction. The only thing standing between where the industry is today and where it needs to be is the commitment to build the right infrastructure.
The cement companies that move now will not just meet the regulations. They will be ahead of every competitor that waits.

About the author
Jignesh Kundaria is the Director and CEO of Fornnax Technology. Over an experience spanning more than two decades in the recycling industry, he has established himself as one of India’s foremost voices on waste-to-fuel technology and alternative fuel infrastructure.

Concrete

Dalmia Bharat Cement launches water repellent cement brand Weather 365 in Eastern India

Published

4 days ago

May 15, 2026

admin

The company has introduced water repellent cement to target rising consumer demand for weather-resilient housing solutions.

New Delhi, May 15, 2026

Dalmia Bharat Cement, one of India’s leading cement manufacturing companies, has launched Weather 365, a new super-premium water repellent cement brand aimed at addressing growing consumer demand for durable, weather-resistant construction materials in Eastern India. The product is positioned as a high-performance offering for consumers seeking long-term protection against seepage, dampness and moisture damage. The launch marks a strategic push by Dalmia Bharat Cement into the fast-growing premium cement segment, where consumer preference is increasingly shifting from price-led purchases to specialised, performance-oriented building materials.

Reinforcing its super-premium positioning, the product will be available in premium-quality water-resistant and tamper-proof BOPP packaging. ‘Weather 365’ will be introduced across its retail markets in West Bengal and Bihar.

In addition to the product rollout, the company will provide on-site technical support through its engineering and technical services teams to guide customers on best construction practices and improve long-term building performance.

Speaking on the launch, company spokesperson from Dalmia Bharat Cement said: “Weather 365 is a testament to Dalmia Bharat Cement’s relentless pursuit of innovation. Eastern India experiences prolonged monsoons, high humidity and challenging weather conditions that significantly impact the life of buildings and homes. Consumers today are actively looking for solutions that offer long-term protection and lower maintenance costs. Weather 365 is our answer to that need – a differentiated premium product that combines structural strength with advanced moisture protection that safeguards homes at every level, every season. We believe this category will see strong growth in the coming years.”

Weather 365 is a specialised cement product developed to meet the rigorous demands of modern construction in regions exposed to high humidity, heavy rainfall and extreme weather cycles. Designed for roofs, columns and foundations, it delivers end-to-end moisture protection across the entire home from the structure’s core to its visible surfaces. Its proprietary uniform water repellent technology helps reduce water penetration, minimize steel corrosion in RCC structures while preventing efflorescence and damp patches, thereby ensuring stronger concrete, improved paint life and long-lasting structural health. Positioned as a super-premium product in Dalmia Bharat Cement’s portfolio, Weather 365 targets discerning homeowners, contractors and builders who seek the best-in-class protection for their construction investments.

With a strong manufacturing and market presence across Eastern India, Dalmia Bharat Cement continues to strengthen its footprint in one of its key strategic markets. As the company advances towards its vision of becoming a pan-India cement leader, it remains focused on delivering innovative, premium construction solutions tailored to evolving consumer needs.

Dalmia Bharat Cement, a subsidiary of Dalmia Bharat Limited, is a leading player in the cement manufacturing segment and has been in existence since 1939. It is the first cement company to commit to RE100, EP100 & EV100 (first triple joiner) – showing real business leadership in the clean energy transition by taking a joined-up approach. With a growing capacity, currently pegged at 49.5 million tonne, Dalmia Bharat Cement is the fourth-largest cement manufacturing group in India by installed capacity. Spread across ten states and fifteen manufacturing units, the company is a category leader in super-specialist cement used for oil well, railway sleepers and airstrips and is the country’s largest producer of Portland Slag Cement (PSC).