Economy & Market

Energy optimisation is an ongoing process

Published

2 years ago

February 12, 2025

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Ashok Dembla, President and Managing Director, KhD Humboldt, in conversation with Kanika Mathur about the use of technology in the grinding process.

The cement industry, responsible for nearly seven per cent of global CO2 emissions, faces a pressing challenge: balancing growth with sustainability. As companies strive for net-zero emissions, innovations in alternative fuels, carbon capture, and energy efficiency are reshaping the sector. From blended cement to cutting-edge kiln electrification, the industry is moving toward a future beyond carbon. In this interview, ICR explores the evolving technologies and strategies driving cement’s decarbonisation journey.

Tell us about cement beyond carbon.
The cement industry contributes approximately 7 per cent of global carbon dioxide emissions, making it one of the largest industrial contributors to climate change. This places a great responsibility on the industry to reduce emissions and promote sustainability. It becomes a moral obligation for us to work toward carbon neutrality or even carbon negativity to protect the environment and ensure a sustainable future for humanity.
Many companies in the cement industry have already pledged to achieve net-zero emissions by 2050 or beyond. At KHD, our focus is on technological innovation to achieve the vision of cement beyond carbon. Cement remains an essential material for infrastructure development and economic growth, and the challenge is to meet this demand while minimising its carbon footprint.
Currently, conventional methods like producing blended cement, which uses less clinker and more fly ash or slag, have been instrumental in reducing emissions. Additionally, technologies like Waste Heat Recovery (WHR) systems have seen significant adoption in India. WHR systems allow plants to recover and reuse heat, improving efficiency. Another method is the use of Alternative Fuels and Raw materials (AFR). While the industry was at just 4 per cent usage of AFR previously, we have now reached around 7 per cent, with an ultimate goal of surpassing 35 per cent, which is the global benchmark.
However, these conventional methods alone will not suffice to achieve complete decarbonisation. Advanced technologies are being explored, such as capturing carbon dioxide from exhaust gases, improving system efficiencies, and implementing oxy-fuel combustion or electrification of kilns. While these technologies are still in various stages of development, I believe they will become economically viable after 2030. The industry’s focus is on continuous research and development to integrate these technologies into our processes effectively.

How is your technology adapting to changing fuels and raw materials?
The use of alternative fuels and raw materials (AFR) is continuously evolving within the cement industry. As a machinery supplier, we are adapting to these changes by providing advanced solutions for handling and processing AFR. One of our most significant innovations is the PyroRotor, an equipment designed specifically for feeding up to 85 per cent of alternative fuels into the pyroclone, which is far beyond what conventional methods can achieve. This has greatly enhanced our ability to replace traditional fuels with more sustainable alternatives.
In addition, we have developed solutions to address nitrogen oxide (NOx) emissions, a critical environmental concern. Our NOx reduction equipment significantly minimises NOx generation during the production process, helping plants meet stringent regulatory requirements.
Optimisation is another critical focus area. Through digitisation and advanced process control systems like PRO-MAX, we are able to optimise the entire cement production process. This system includes kiln and mill control modules, allowing plants to operate more efficiently and reduce both thermal and electrical energy consumption.
Globally, the industry is also moving toward more advanced technologies, such as increasing oxygen content in fuel firing and capturing carbon dioxide directly from flue gases. While these technologies are already being implemented in some European plants, they require significant capital investment and governmental support. India is also taking steps in this direction, with plans for model plants to showcase the viability of these advanced solutions.

Do any of your solutions have an impact on energy utilisation in cement plants?
Energy utilisation in cement plants involves two main types: thermal energy and electrical energy. On the thermal energy front, significant progress has been made over the past decade. Previously, plants required around 750 kilocalories per kilogram of clinker. Today, this has been reduced to 685 kilocalories or even lower, thanks to continuous improvements in process efficiency.
For electrical energy, we have optimised systems like the roller press, which enhances the efficiency of raw material grinding and cement grinding. These advancements have significantly reduced energy consumption per ton of clinker produced.
Energy optimisation is an ongoing process. By integrating advanced technologies and optimising plant operations, we aim to achieve even greater reductions in energy consumption, contributing to both cost savings and environmental sustainability.

How do you see the journey toward net zero unfolding, and what is your perspective on this?
The journey toward net zero is both challenging and rewarding. One of the critical areas we have focused on is the increased use of alternative fuels and raw materials (AFR). The technology to utilise AFR is available, but its successful implementation depends on a well-organised system for waste collection and processing.
In India, progress has been made in cities like Indore and Bengaluru, where systems for waste segregation and preparation are more developed. However, there is still a long way to go to make this a common practice across the country. Government support is crucial in this regard, especially in establishing efficient logistics systems to transport waste from its generation point to cement plants for use as fuel.
Collaboration between industries, government bodies, and city administrations is essential to achieve the full potential of AFR utilisation. The ultimate goal is to make the use of AFR economically viable while ensuring that the logistics and supply chain challenges are effectively addressed.
Net zero is not just a technological goal; it is a systemic change that requires the entire ecosystem to work together. While the industry has made significant strides, much work remains to be done to make net zero a reality.

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Wonder Cement appoints Mahesh Singh as VP Corporate Brand Communication

Published

5 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.

Concrete

JSW Cement commissions additional 1 MTPA grinding unit at Nagaur

Published

6 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

1 week 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.