Holistic solutions: Cement manufacturers tackle challenges from production to green utilisation
Cement, a cornerstone of modern construction, has faced increasing scrutiny due to its contribution to global greenhouse gas emissions. In India, the second-largest cement producer and consumer globally, the environmental challenges have never been more pronounced. As the nation surges towards a $5 trillion GDP and aims to become the world’s third-largest economy by the end of the decade, the ecological impact looms large.
Cement production capacity in India is projected to rise from 570 million tonnes (MT) to over 700 MT in the next five years, with consumption expected to reach 450 MT by 2027. Recognising the urgency, major cement manufacturers in India have committed to becoming carbon neutral by mid-century, aligning with India’s Net Zero goal for 2070.
Green Initiatives Across the Value Chain
Cement manufacturers are proactively addressing these challenges through a holistic approach that covers every aspect of cement manufacturing, from production to increased utilisation of green cement. Energy-intensive cement plants are embracing cleaner sources, including solar and wind power for a captive generation. Sustainability extends to logistics, with the adoption of electric trunks and biofuel-powered shipping to reduce the carbon footprint. Waste Heat Recovery Systems are making substantial contributions by reducing coal consumption and enhancing cost-efficiency.
Cement production also involves the energy-intensive process of clinker production. To mitigate this, manufacturers are replacing clinker with industrial by-products without compromising cement quality. Municipal waste is being transformed into Refuse Derived Fuel (RDF) through pre and co-processing, serving as an alternative energy source for cement kilns. This not only saves conventional energy resources but also facilitates safe municipal waste disposal. Other industries, such as pharmaceuticals and automobiles, are tapped for their waste, which is recycled and utilised in cement manufacturing processes.
Water Management
Efficient water management has become another key facet of sustainable cement manufacturing. Operations are moving towards water-positivity, where more water is returned to the environment than consumed. In a broader sense, cement manufacturers actively participate in water conservation projects, collaborating with local communities, including farmers.
Environmental Laws and Consumer-Centricity
India has robust environmental legislation in place to ensure industrial sectors like cement adhere to the environmental standards. However, cement manufacturers are setting higher benchmarks voluntarily to ensure that consumers do not bear any hidden environmental costs. Cement has evolved from being a mere commodity to a branded consumer product, with sustainability embedded in its brand value. Informed consumers today expect manufacturers to adopt responsible and sustainable manufacturing practices. The transformation of the Indian cement sector has only just begun.
Balancing Economic Growth and Environmental Sustainability
India’s ambitious development goals, including becoming a ‘Developed Nation by 2047’ and achieving net-zero emissions (NZE) by 2070, necessitate a delicate balance between economic growth and environmental preservation. Achieving this equilibrium relies heavily on transforming the cement industry, a linchpin for infrastructure development and a key player in climate change mitigation.
Traditional cement manufacturing accounts for approx. 8% of global greenhouse gas emissions. The process involves heating raw materials like limestone to high temperatures, releasing substantial carbon dioxide into the atmosphere. Cement manufacturers now prioritise sustainability to drive India toward a more balanced and environmentally conscious path to development, vital for realising its ambitious long-term goals.
Major cement manufacturers like ACC and Ambuja Cement have taken pioneering steps to establish a green cement sector, reducing the industry’s adverse environmental impact and propelling India towards a sustainable future. Their measures encompass innovative technologies, alternative materials, and energy-efficient processes.
Alternatives for Carbon Emission Reduction
The journey towards sustainability in the cement sector is heavily influenced by alternative materials, innovation, and technology. Alternative materials, such as low-carbon fly ash-based Portland Pozzolana Cement (PPC), are environmentally friendly products that can replace a portion of clinker content, reducing carbon emissions. These alternatives often enhance the durability and performance of concrete.
Reducing carbon emissions also involves substituting fossil fuels with alternative sources. Cement manufacturers are increasingly turning to biomass, industrial and household waste, discarded tires, and sewage sludge as efficient and cost-effective fuel alternatives.
Harnessing Efficiency with Technology
Innovation and technology play a pivotal role in enhancing energy efficiency in cement production. Upgrading equipment and adopting energy-efficient technologies help reduce energy consumption and emissions. Waste Heat Recovery Systems capture heat generated during cement production, converting it into usable energy. Carbon capture, utilisation, and storage (CCUS) technologies are gaining traction in the cement industry, making operations more sustainable.
In an era of advanced technology and artificial intelligence, overseeing large-scale construction projects has become more efficient. Innovations like 3D imaging, aerial drone mapping, and digital blueprints provide a comprehensive view of projects before construction commences, saving time and reducing carbon footprints.
A Call for Collaborations
While significant progress has been made in adopting sustainable practices in cement manufacturing, there is still much work to be done. Policies and regulations that set standards and incentivise the industry to reduce its carbon footprint are vital for the sector’s transformation. Substantial investments in research and development (R&D) and changes in production methods and business models will be required.
The cement industry, being a global entity, can address its environmental concerns through collaborative efforts with major players in the industry. These collaborations facilitate knowledge sharing and research to drive innovation in sustainable cement manufacturing.
ACC, for instance, stands as the inaugural Indian Cement Company to sign the Net Zero Pledge with Science Targets, aligning its 2030 carbon emission reduction goals with global initiatives.
A Green Revolution in Cement Manufacturing
Sustainable practices in cement manufacturing are indispensable in addressing the environmental challenges of our time. This shift not only helps protect the planet but also future-proofs businesses. With the global demand for construction materials set to rise, those who provide greener alternatives are likely to lead the cement industry of the future.
