Cement Energy & Environment

46 8. ENERGY AND CO 2 REDUCTION ROADMAP 2025–2035 India’scement industryaims toreduceCO 2 intensity by 40% by 2035 through combined thermal and digital measures. Figure 5 projects the energy and emission trajectory based on CMA’s 2025–2035 roadmap. Specific heat is expected to fall from 740 to 670 kcal/kg clinker, while CO 2 intensity drops from 820 to about 700 kg/t clinker. Figure 5 - Energy and CO 2 Reduction Roadmap 2025-2035 Primary Energy CO 2 Emissions 0 20 40 60 100 0% -5% -10% -15% -20% -25% Figure 5 – Energy and CO 2 Reduction Roadmap 2025–2035 (Projected decline in energy use and CO 2 intensity with AF, AI, and WHR adoption.) The key contributors to this reduction are: • 20% from alternative fuels and biomass, • 15% from WHR and electrification, • 10% from process digitalization, and • 5% from carbon capture and utilization. These targets are aligned with global decarbonization pathways but adjusted to India’s raw materials and climatic conditions. The integration of low-carbon energy sources, AI- driven efficiency, and data transparency will be crucial in achieving these milestones. 9. IMPLEMENTATIONANDPOLICYOUTLOOK The Perform, Achieve, and Trade (PAT) program under the Bureau of Energy Efficiency (BEE) has been a cornerstone for driving process efficiency. Plants exceeding their energy-saving targets earn tradable certificates, which has motivated wide- scale modernization. The Cement Manufacturers’ Association (CMA) has also issued a Sustainability Roadmap for 2030 emphasizing AF co-processing, WHR installation, and digital transformation. NCCBM is leading R&D efforts in kiln diagnostics, process simulation, and clinker mineralogy optimization. Financial mechanisms such as carbon credits, green loans, and concessional funding from multilateral banks are enabling the next generation of investments. However, policy stability, technology standardizationand workforce training remain critical for sustained implementation. 10. CONCLUSION Indian cement plants are proving that sustainability and operational excellence can progress hand in hand. Through digital control, optimized heat management, alternative fuels, waste-heat recoveryand emerging carbon- capture technologies, they can achieve 10–15% CO 2 reduction and around 10% energy savings without compromising clinker quality. The transition frommanual, fuel-intensive systems to intelligent, data-driven operations represents a new era for the cement industry. By 2035, Indian plants will be among the most energy-efficient globally, showcasing how digital and thermal innovations together can transform an industry once defined by high emissions into one defined by intelligent sustainability. REFERENCES 1. 1National Council for Cement and Building Materials (NCCBM) (2024). Indian Cement Industry Performance Review 2023–24. New Delhi. 2. Cement Manufacturers’ Association (CMA) (2024). Sustainability Roadmap for the Indian Cement Sector. New Delhi. 3. Bureau of Energy Efficiency (BEE) (2023). PAT Cycle VI – Cement Sector Performance. Government of India. 4. Shakti Foundation (2023). Alternative Fuels and Raw Materials in Cement Industry. New Delhi. 5. International Energy Agency (IEA) (2025). Cement Tracking Report 2025. Paris. 6. Internal Operational Reports, Plants 1–7 (2024– 2025).