Economy & Market

Leading the Green Revolution

Published

3 years ago

January 12, 2024

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Ajay Kapur, CEO – Cement Business, Adani Group, explores India’s proactive measures, from embracing renewable energy and waste heat recovery to reducing clinker usage and innovatively repurposing industrial by-products, signaling a promising shift towards sustainable cement manufacturing.

Imagine a world without cement – it’s almost like picturing a skyline without its defining structures. As one of the most commonly used building materials, the manufacturing of cement faces significant challenges in decarbonising. Tackling this challenge goes beyond the ordinary, considering that the cement sector is a major player, contributing up to 7-8 per cent of global greenhouse gas emissions. The significance of this issue is particularly pronounced for India, as we currently hold the dual status of the world’s second-largest producer and consumer of cement. The production capacity of the Indian cement sector is poised to grow to more than 700 million tonnes (MT) over the next five years from around 570 MT now. Consumption on the other hand is also set to grow to 450 MT by 2027.
As the Indian economy expands and continues on this growth path to reach $5 trillion in GDP in the near term and emerge as the world’s third largest economy before the end of the current decade, the environmental challenges will also become more formidable.
Most large cement manufacturers in India have already committed to becoming carbon neutral sometime around the middle of this century and this is also going to contribute to India’s Net Zero ambition set for 2070. The road ahead for Indian cement manufacturers is very similar to what the energy sector faces. India’s economic turnaround that started in 1991 also brought home conversations around the rising and unprecedented levels of consumption of energy to fire up the economy, putting the country under the environmental spotlight, too. Cement production is not only energy intensive but also depends on natural mineral resources. The widespread adoption of well-understood and sustainable cement production practices has been a gradual process, gaining momentum over time. Today, the Indian cement sector is ready to meet sustainability challenges head-on through a whole range of measures that covers the entire value chain in cement manufacturing, leading all the way to increasing the share of green cement on the demand side.

Alternative fuel and raw materials
Being an energy-intensive sector, cement manufacturers have started investing in cleaner sources of energy like solar and wind as captive generation units to run their plants. This shift in no small measure is supported by the falling cost of renewable energy India. Between 2010 and now, the cost of solar modules in India have dropped by more than 80 per cent, making it one of the most sought after sources of clean energy for large industrial units including cement. Similar efforts are also on to move finished cement, packed and bulk on more sustainable or green logistics like soya extract-based biofuel powered shipping. Bulk terminals and grinding units along India’s long coastline can enable the movement of clinker and cement through the sea route at the lowest possible cost.
The share of green energy is further enhanced through investments in Waste Heat Recovery Systems (WHRS). These systems not only adhere to the principles of the circular economy but also result in fossil fuels savings. This not only nurtures a more cost-efficient process but also directly impacts the bottom line.
According to the Ministry of New and Renewable Energy (MNRE), the Indian cement Industry has the highest potential to adopt WHRS as an alternative to conventional sources of energy. WHRS installations will continue to grow along with the increase in capacity to manufacture cement, bringing it close to 1.3 GW at current production capacity levels. It is estimated that WHRS would help replace the energy requirement equivalent to 8.6 million tonnes of coal, resulting in emissions savings of 12.8 million tonnes of CO2 by the Indian cement manufacturers.
Cement manufacturers are also cutting down on the ‘clinker factor’ by replacing them with industrial by-products without compromising the quality (strength) of the cement. Cutting down the clinker factor offers two immediate benefits. One, it reduces energy consumption because clinker is produced at ~1400°C (from limestone etc.,) and two, it also softens the environmental impact of by-products like flyash, slag and silica fumes. Manufacturing a tonne of Ordinary Portland cement also releases around 800 kg of CO2. Investments are also made in recycling massive quantities of municipal waste into Refuse Derived Fuel or RDF through its pre- and co-processing facilities, which is then used as energy to run cement kilns. The impact of producing and using RDF not only saves on energy from conventional sources but also helps large cities manage municipal waste in a safe manner. Mega cities like Mumbai are now working with cement companies to manage municipal waste through a symbiotic relationship that benefits manufacturers and city administrators.
Red mud, a waste derived from aluminium production, is also now used in the cement manufacturing process as an alternative raw material. Again, this helps build a circular economy through utilisation of aluminium industry’s by-products in an environmentally sound manner. Other large industrial sectors like pharmaceuticals also tapped for zero residue of their process waste and ETP sludge. Similarly cement manufacturers are also able to process hazardous wastes released by the automobile and automobile ancillary sector such as chromium, zinc and paint sludge, oil residue and cotton waste.
Water management is yet another area that is making cement manufacturing in India more sustainable. Apart from becoming water positive (returning more water than what is consumed) from an operations point of view, a lot is also being done under the larger banner of CSR where cement manufacturers are now active participants in water conservation projects, working along with local rural communities including farmers. Large cement manufacturers in India are also working on conserving biodiversity in their areas of operations including large afforestation projects, which helps in strengthening the water table.

Conclusion
India today has a very robust legislative mechanism to ensure that industrial sectors like cement abide by environmental laws. But cement manufacturers, recognising the growing environmental consciousness among consumers, are actively pursuing higher benchmarks to minimise burden on environmental damage. With the growing consumer centricity that has moved cement from being a commodity to a branded consumer product, manufacturers are now able to offer sustainability as part of the brand value and appeal. Green cement as a product in India is still in its nascent stage with a miniscule share in the overall market. It is expected to grow in coming years as sustainability is an important factor for today’s buyers.
Today’s well-informed consumers also expect manufacturers to play a more responsible role in protecting the environment through sustainable manufacturing practices. The transformation of the Indian cement sector has only begun.

ABOUT THE AUTHOR:
Ajay Kapur, CEO – Cement Business, Adani Group has over 30 years of expertise in the cement, construction, power and heavy metals sector. He has been extensively involved in several business forums, such as CII, FICCI, and ASSOCHAM.

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Wonder Cement appoints Mahesh Singh as VP Corporate Brand Communication

Published

3 days ago

October 9, 2026

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

New Delhi

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

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

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

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

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

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

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

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JSW Cement commissions additional 1 MTPA grinding unit at Nagaur

Published

4 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

5 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.