Economy & Market

The 3Cs of Decarbonisation

Published

11 months ago

November 20, 2025

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Dr Avijit Mondal, Scientist, NTPC Energy Technology Research Alliance (NETRA), explores the holistic pathway to decarbonise the cement industry and build a resilient, low-carbon future for India.

The global climate discourse has placed the spotlight firmly on hard-to-abate sectors, and the cement industry is one of the most critical among them. Cement is the backbone of modern infrastructure, but it also accounts for nearly 7-8 per cent of global CO2 emissions. As economies continue to grow, the demand for cement will persist-making decarbonisation strategies not just desirable but indispensable.

In this context, the 3Cs of decarbonisation – Cut emissions, Cement innovations, and Carbon capture and utilisation (CCU) – offer a comprehensive framework for reshaping the industry’s future.

1. Cut emissions: Driving efficiency and clean energy integration
The first step is to cut emissions at the source. Cement production is energy-intensive, and approximately 40 per cent of emissions come from fuel combustion in kilns. The rest originates from the calcination of limestone during clinker production. Cutting emissions, therefore, requires both process optimisation and energy transition.

Energy efficiency: Adoption of waste heat recovery systems, improved kiln design, and digitalisation-driven process control can reduce the thermal and electrical energy footprint.
Alternative fuels: Replacing coal and petcoke with biomass, agricultural residues, and refuse-derived fuels can significantly lower carbon intensity.
Green power integration: Utilisation of solar, wind, and hybrid renewable solutions in auxiliary operations (grinding, material handling, etc.) ensures indirect emissions are reduced.

Case studies

Ambuja Cements (India) has installed waste heat recovery systems across multiple plants, reducing dependency on fossil fuels and cutting CO2 emissions.
CEMEX (Mexico) has adopted alternative fuels at a massive scale, with some plants operating on more than 80 per cent non-fossil fuel share.

For countries like India, where cement demand is still growing, integrating efficiency measures with renewable energy can yield rapid decarbonisation gains.

2. Cement innovations: Rethinking the product itself
The second ‘C’ focuses on redefining what cement is and how it is made. Since clinker production is the largest source of process emissions, lowering clinker factor is central to innovation.

Blended cements: Increased utilisation of supplementary cementitious materials (SCMs) such as fly ash, slag, silica fume and calcined clays can replace a portion of clinker while maintaining strength and durability.
Novel binders: Research is advancing in alternative binders like geopolymers and limestone calcined clay cement (LC3), which can reduce emissions by up to 40 per cent compared to ordinary
Portland cement.
Circular economy integration: Industrial by-products (steel slag, red mud and other
mineral wastes) can be valorised into cementitious materials, reducing both environmental burden and resource dependency.
Digital innovations: AI-driven mix design optimisation can ensure maximum performance with lower carbon content.

Case studies

NTPC Ltd (India) has been a pioneer in fly ash utilisation, supplying millions of tonnes annually to cement manufacturers, turning a waste product into a valuable resource.
Dalmia Cement (India) has adopted a carbon-negative vision by pushing for low-clinker cement and exploring alternative binders.
LC3 Project (Switzerland, India, and Cuba) demonstrated at pilot scale that calcined clay + limestone blends can reduce emissions by 30-40 per cent, offering a scalable solution for emerging economies.

In India, the synergy between power plants and cement units highlights how industrial symbiosis can accelerate innovation.

3. Carbon capture and utilisation: Closing the loop
Even with aggressive efficiency measures and material innovations, residual emissions from calcination will remain a challenge. This is where CCU technologies come in.

Carbon capture: Advanced post-combustion capture systems (amine scrubbing, oxy-fuel combustion and emerging solid sorbents) are being piloted globally in cement kilns.
Carbon utilisation: Captured CO2 can be converted into value-added products-carbonated aggregates, synthetic fuels, or even used in curing processes for concrete. Such solutions not only mitigate emissions but also create new revenue streams.
Carbon storage: Where utilisation is not feasible, geological storage offers a long-term abatement pathway.

Case studies

Lafarge Holcim’s plant in Brevik (Norway) is building the world’s first full-scale carbon capture facility for cement, capable of capturing 400,000 tonnes of CO2 annually.
Dalmia Cement (India) has announced plans to build a large-scale carbon capture facility at its Tamil Nadu plant, with a target of capturing 500,000 tonnes of CO2 per year.
Solidia Technologies (USA) has developed a process where concrete cures with CO2 instead of water, permanently locking in carbon while reducing cement use.

These pilots demonstrate that CCU is not a distant dream – it is already being tested and scaled.

The road ahead
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.
Ultimately, the 3Cs of decarbonisation represent more than strategies; they embody the industry’s commitment to building not just infrastructure, but a sustainable future.

References:
• L. Marques, M. Vieira, J. Condeo, H. Sousa, C. Henriques, M. M. Mateus, “Review of Power-to-Liquid (PtL) Technology for Renewable Methanol (e-MeOH): Recent Developments, Emerging Trends and Prospects for the Cement Plant Industry,” None, 2024. https://doi.org/10.20944/preprints202409.0956.v1
• V. Mittal, L. Dosan, “System Dynamics Modelling of Cement Industry Decarbonization Pathways: An Analysis of Carbon Reduction Strategies,” Sustainability, 2025. https://doi.org/10.3390/su17157128
• I. Bolbot, O. Slovikovskyi, “Multi-Physics Modelling and Adaptive Control of Gas Burner Systems for Enhanced Energy Efficiency and Emission Reduction in Cement Drying Processes,” None, 2025. https://doi.org/10.33042/2079-424x.2025.64.2.01
• K. Sun, J. Sun, C. Bu, L. Jiang, C. Zhao, “Historical Drivers and Reduction Paths of CO2 Emissions in Jiangsus Cement Industry,” C++ Conference, 2025. https://doi.org/10.3390/c11010020
• T. Nayab, T. Ahmed, “CO2 Mitigation of a Cement Industry in North Macedonia, Balkans Peninsula: A Short Review,” Environmental Contaminants Reviews, 2024. https://doi.org/10.26480/ecr.01.2024.32.36
• F. Branger, P. Quirion, “Reaping the Carbon Rent: Abatement and Overallocation Profits in the European Cement Industry, Insights from an LMDI Decomposition Analysis,” RELX Group (Netherlands), 2014. https://doi.org/10.2139/ssrn.2497474
• J. A. Brefo, A. K. Osei, J. A. Opoku, “Sustainable Low-Carbon Cement Technologies for Reducing U.S. Construction Carbon Emissions,” None, 2025. https://doi.org/10.51594/estj.v6i6.1954
• J. Glvez Martos, R. Chaliulina, A. Elhoweris, J. A. Mwanda, A. Hakki, Y. Alhorr, “Techno-Economic Assessment of Calcium Sulfoaluminate Clinker Production Using Elemental Sulfur as Raw Material,” Elsevier BV, 2021. https://doi.org/10.1016/j.jclepro.2021.126888
• Q. Su et al., “Life Cycle Assessment and Environmental Load Management in the Cement Industry,” Systems, 2025. https://doi.org/10.3390/systems13070611
• K. Kaptan, S. Cunha, J. Aguiar, “A Review: Construction and Demolition Waste as a Novel Source for CO2 Reduction in Portland Cement Production for Concrete,” Sustainability, 2024. https://doi.org/10.3390/su16020585

ABOUT THE AUTHOR:
Dr Avijit Mondal, Scientist, NTPC Energy Technology Research Alliance (NETRA), has an extensive research experience in materials processing, powder metallurgy, and advanced characterisation techniques.

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Wonder Cement appoints Mahesh Singh as VP Corporate Brand Communication

Published

13 hours 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

2 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.”

Concrete

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

Published

2 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.

Mumbai

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.