Industry

Cement

Cement’s footprint is dominated by calcination (process CO₂) and kiln fuel combustion. Key levers include clinker factor reduction via supplementary cementitious materials (SCMs), alternative fuels (AFR), and thermal/electrical efficiency improvements, with growing options in CCUS. Challenges: raw mix variability, SCM availability, and maintaining performance specs.

Cement plant with kiln line illustrating process and fuel emissions

Key drivers & challenges

  • Lower clinker ratio with SCMs (fly ash, slag, calcined clay) while meeting strength classes.
  • Increase AFR (biomass/RDF/tires); monitor NOx/SOx trade‑offs and heat balance.
  • Improve thermal efficiency (preheater/precalciner, heat recovery) and electrical intensity.
  • Track raw mix chemistry (LSF, SR, AR) and its effect on calcination emissions.
  • Align with GCCA/GNR, BRSR, and CSRD disclosures.
Scope 1 — Process & Fuel
  • Calcination CO₂ (CaCO₃ → CaO + CO₂) based on clinker output & CaCO₃ share.
  • Kiln/petcoke/coal/AFR combustion (heat rate, specific fuel use).
  • On‑site quarry & mobile equipment fuels.
Scope 2 — Electricity
  • Grid vs. market‑based factors; raw mill, finish mill, packing loads.
  • WHR power attribution; PPAs/RECs tracking.
  • kWh/t cement and kWh/t clinker KPIs.
Scope 3 — Upstream
  • Raw material mining/transport (limestone, additives, gypsum).
  • AFR collection/pre‑processing.
  • Contractor fuel and capital goods.
Scope 3 — Downstream
  • Dispatch logistics & customer transport.
  • Concrete use‑phase assumptions where material.
  • End‑of‑life and recycling credits.

Compliance & Frameworks

BRSR / SEBI

Automated indicators for energy, water, waste & emissions with audit trails and controls.

CSRD / ESRS E1–E5

Materiality mapping, target tracking (tCO₂e/t cement), and scenario disclosures.

GCCA / GNR / GHG Protocol

Method alignment on calcination, clinker factor, AF substitutions, and electricity choices.

Sample Dashboard — Integrated Cement Plant

Emissions

tCO₂e (YTD)
3.2M
Scope 1
0.46M
Scope 2
0.88M
Scope 3
Progress to 2030 target (‑25%)

Clinker, Fuel & Power

Clinker factor
0.73
▼ 3 pts YoY
Thermal intensity
3.25 GJ/t clk
▼ 4%
AFR share
21%
▲ +6 pts
Electrical intensity
86 kWh/t cem
▼ 5%

Compliance Status

Audit‑ready
  • BRSR Mapping 100%
  • CSRD ESRS E1 90%
  • GCCA/GNR alignment Aligned
Internal control effectiveness

SCM & Product Mix

Slag in mix
14%
Fly ash
9%
Calcined clay
5%
Low‑carbon product share

Kiln Operations — Alerts

  • Excess free lime trend Investigate
  • Heat rate above benchmark Action
  • WHR outage scheduled (6 hrs) Upcoming
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