The Role of Indian Cement Industry in Achieving India's Climate Goals

In an exclusive interview with Industry Outlook, Vinita Singhania shared her thoughts on achieving sustainability by reducing carbon emissions and oriented strategies for driving the cement industry towards a sustainable path. She is a seasoned businesswoman and industrialist and boasts nearly three decades of diverse experience. Throughout her journey, she has led the company to unparalleled growth, elevating its brand value and spearheading innovative initiatives. Recognized with numerous awards, her visionary leadership extends to impactful CSR endeavors and significant industry roles.

Concrete is the most ubiquitous material on this earth which makes it indispensable for modern society. Cement, being an important component of it, is consumed globally, and India is the second largest producer of it in the world. It is integral to our civilization and an essential material for the infrastructural development of the nation’s economy. The whole construction industry plays a paramount role in paving a sustainable future for all of us and meeting the climate goals. As India commits to achieving net-zero carbon emissions by 2070, the cement industry must embrace green technologies and sustainable practices to reduce its carbon footprint.

Progress in Reducing Carbon Emissions

Cement manufacturing is an emission-intensive process. The production processes are energy-intensive and significantly impact the environment.  However, India’s cement industry has already made commendable strides in reducing its carbon footprint as compared to global standards.  This progress is because of the industry's proactive adoption of energy-efficient technologies, waste heat recovery systems, and an increasing use of alternative fuels. Nevertheless, to align with India's ambitious climate goals, continuous innovation and technological advancements are imperative.

One significant advancement has been the increased use of blended cements which include supplementary cementitious materials such as fly ash, slag, and limestone. Raw materials from one stage of the economic chain, like fly ash from thermal power plants are used to make cement. The cement industry presently uses up to 25 percent of all fly ash produced in the nation. In a similar vein, cement manufacture fully utilizes steel industry slag.

By doing so, the demand for clinkers, which is the most carbon-intensive component of cement, is reduced. Among these, Limestone Calcined Clay Cement (LC3) stands out because of its lower carbon emissions. LC3 cement can reduce CO2 emissions by up to 40% as compared to the traditional Portland cement. The use of SCMs not only lowers CO2 emissions but also enhances the durability and performance of the final product. This makes it a promising solution for sustainable construction. Its adoption can significantly mitigate the environmental impact of cement production, aligning with India's climate objectives.

Strategies for Future Sustainability

Transitioning to Alternative Fuels and Raw materials

The use of alternative fuels and raw materials is a pivotal strategy for decarbonizing the cement industry. This approach involves substituting conventional fossil fuels with renewable sources of energy and alternative fuels such as biomass and municipal solid waste. A study by the Council on Energy, Environment and Water (CEEW) found that adopting energy efficiency measures can reduce emissions by 9% while using renewable energy and alternative fuels can reduce emissions by 13%.

Energy Efficiency and Comprehensive Carbon Management

An essential component of sustainable cement production is energy efficiency. The industry has been making significant investments in energy-efficient technologies in an effort to reduce energy usage and optimize processes. Energy efficiency and clinker substitution material can reduce the average emissions intensity of cement by 32% without any cost increase. Preheaters, waste heat recovery systems, and advanced kiln systems are being used to absorb and use excess heat, which lowers the requirement for further energy inputs. Significant energy savings have also been achieved through the precise control and optimization of energy usage made possible by the integration of artificial intelligence and machine learning algorithms. A lot of efforts have been made to shift from coal power to solar/wind power, thereby reducing the effect of CO2 emissions.

Additionally, comprehensive carbon management strategies are essential for mitigating emissions in the cement industry. These strategies include carbon capture, storage, and utilization (CCSU), which collect CO2 emissions from industrial processes. These technologies either store them underground or repurpose them into various industrial applications. While there are significant challenges to overcome, the potential environmental and economic benefits make it a vital component of a comprehensive climate strategy. With continued innovation, policy support, and investment, CCSU can play a crucial role in achieving a sustainable and low-carbon future.

The PAT Scheme

The successful implementation of the Perform, Achieve, and Trade (PAT) scheme has been instrumental in driving energy efficiency within the cement industry. This market-based mechanism incentivizes energy-saving measures, encouraging the adoption of cutting-edge technologies and best practices.

Towards Net-Zero Emissions

By aiming for a circular economy and adapting to sustainable practices, the industry aligns itself with India's broader goal of transitioning to a net-zero economy. This will not only enhance the cement sector’s waste management challenges but will also enhance their resource efficiency. Simultaneously, collaborative efforts are paramount in this journey. Constructive partnerships among policymakers, regulators, industry stakeholders, and academic institutions are critical in driving innovation and developing effective policies. The Indian government has also launched initiatives like the National Infrastructure Pipeline and the SMART Cities mission, which are expected to drive demand for cement. However, these projects must be designed with sustainability in mind to ensure that they do not compromise India's climate commitments.

As India continues to urbanize and expand its infrastructure, adopting the circular economy approach across various industries will be crucial for reducing environmental impact and promoting sustainable development. The path to net-zero emissions by 2070 is challenging, but the Indian cement industry's efforts in using alternative fuels and CCSU and other promising new technologies demonstrate its commitment to this goal. By setting a benchmark in sustainability and efficiency, the cement industry is not only reducing its carbon footprint but also serving as a model for other sectors to emulate.