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AFR supports circular resource use

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Saurabh Palsania, Joint President, Shree Cement, discusses pragmatic pathways to decarbonisation using AFR, and the pressing challenge of India’s fragmented waste ecosystem.

For Shree Cement, alternative fuels and raw materials (AFR) is a strategic lever that sits at the intersection of operational efficiency, regulatory compliance, and long-term cost resilience. In this conversation, Saurabh Palsania, Joint President, Shree Cement, speaks candidly about supply chain challenges of scaling AFR across plants, the role of government policies, and what it will realistically take for the Indian cement industry to push Thermal Substitution Rates (TSR) toward the 30 per cent mark over the next decade.

How does AFR fit into your company’s long-term decarbonisation and cost optimisation strategy?
Alternative fuels and raw materials (AFR) are non-fossil substitutes that replace conventional fuels such as coal and pet coke in cement production. By utilising waste from industries, municipal bodies, and agricultural sources, AFR helps reduce dependence on fossil fuels and supports circular resource use. This approach contributes directly to lowering carbon emissions while also improving long-term cost efficiency by reducing reliance on conventional energy sources. As a result, AFR forms a key pillar of both decarbonisation and sustainable cost optimisation strategies.

What operational or technological challenges have you faced in scaling AFR usage across plants, and how have you addressed them?
One of the biggest challenges in India’s waste management ecosystem is the lack of segregation at source, which affects the quality and consistency of waste streams. Even after procurement, significant pre-processing is often required before the material can be effectively used. Operationally, fluctuations in calorific value and the absence of precise measurement systems for waste quality and quantity can create instability in kiln feeding and impact production efficiency. In addition, high ash and chloride content in certain waste streams limits usability.
These challenges are being addressed through stronger pre-processing practices, better quality control, and optimisation of AFR blends with conventional fuels to maintain consistent kiln performance and product quality.

How do you balance clinker quality, kiln stability, and emission norms while increasing AFR substitution rates?
Clinker quality remains stable when AFR usage is supported by robust monitoring and process control systems. Regular sampling of ash and chloride levels helps optimise AFR consumption while maintaining raw mix balance and kiln stability. Modern cement plants are equipped with Electrostatic Precipitators (ESPs), which enable efficient recirculation of unburnt particles into the production process. With kiln temperatures exceeding 1300°C, most harmful compounds are effectively neutralised, ensuring compliance with emission norms, including the control of dioxins and furans. This allows higher AFR substitution without compromising product quality or environmental compliance.

What role do policy frameworks and regulatory support in India play in accelerating AFR adoption, and where are the gaps?
Government policies, particularly from the Ministry of Environment and Forests, have played an important role in supporting AFR adoption through frameworks such as the ‘polluter pays’ principle and Extended Producer Responsibility (EPR). However, implementation challenges remain, especially around cost structures, enforcement, and consistent access to quality waste streams. The development of centralised digital platforms for tracking EPR credits is a positive step, but stronger policy support for waste segregation at source, both industrial and municipal, is still essential. Improved enforcement and better waste management systems will be critical to accelerating AFR adoption at scale.

How are you building supply chain ecosystems for consistent and quality AFR sourcing in a fragmented waste market?
Ensuring reliable AFR sourcing requires strong partnerships with waste generators, including municipal corporations and industries. Participation in waste auctions, along with direct collaborations, helps secure a steady supply of usable material. At the same time, tie-ups with pre-processors are essential to improve waste quality and prepare materials for efficient co-processing. This combination of direct sourcing and pre-processing partnerships helps build a more reliable, scalable and quality-driven AFR supply chain.

Can digitalisation and process optimisation unlock higher TSR, and what innovations are you investing in?
Digitalisation and process optimisation are critical to improving TSR. Advanced control systems in Central Control Rooms (CCR) help monitor equipment performance, operational parameters, and AFR feed rates in real time, enabling better operational control. Investments are also being made in intelligent systems that improve AFR feeding precision and optimise clinker production. These innovations support faster decision-making, better operator control, and improved process efficiency, all of which are essential for scaling TSR sustainably.

What is your realistic TSR target for the next 5–10 years, and what will it take for the industry to get there?
Currently, TSR levels across the industry range from five to 30 per cent. Over the next five years, this is expected to increase to 15 to 40 per cent, with an average target of around 30 per cent over the next decade. Achieving this will require sustained investments in training, process adaptation, and stronger collaboration between waste generators and co-processors. Improvements in waste segregation, pre-processing technologies, and fuel quality enhancement will also play a major role in enabling higher and more consistent TSR adoption across the industry.

  • Kanika Mathur

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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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.

 

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Building a Greener Future Together

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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.

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JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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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.

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