CCUS at the Core of Decarbonizing India’s Cement Industry

Author: Mr. Keshav Goela      Posted on: 07-04-2025
CCUS technology applied to cement plant chimneys

Introduction

India’s cement sector currently stands at the crossroads of an exciting yet challenging decarbonization journey. Second only to China in production volume, India’s cement capacity is estimated at around 600 million tonnes (Mt). As our infrastructure and housing needs continue to expand—buoyed by rapid urbanization and government initiatives such as the National Infrastructure Pipeline (NIP) and Smart Cities Mission—the cement industry’s growth trajectory will stay robust for decades to come. However, the urgency to reduce carbon emissions is more pressing than ever, in light of India’s net-zero commitment by 2070.

Recent findings from a comprehensive decarbonization roadmap, jointly developed by the Global Cement and Concrete Association (GCCA) and The Energy and Resources Institute (TERI), underscore Carbon Capture, Utilization, and Storage (CCUS) as an indispensable pillar in achieving net-zero emissions in the cement sector. Despite the industry’s adoption of innovative energy-saving measures and the widespread use of blended cements, process emissions—those released directly from the calcination of limestone—remain a steep hurdle. Traditional levers like energy efficiency, low-carbon fuels, and waste heat recovery systems, while vital, can only address some of the problem. Tackling the process emissions locked in the very chemistry of cement production demands CCUS.

At GAS LAB, we bring over six decades (60+ years) of engineering expertise and global field experience in CO2 capture, spanning upwards of 25 countries across diverse industrial sectors. Unlike many new players in carbon capture, we are not a fledgling startup; our solutions have been refined, tested, and proven over the years. We also pride ourselves on our strategic partnership with Carbonetics Carbon Capture, whose AI-driven solutions optimize the entire carbon capture lifecycle. From pilot-scale testing with our IGNI1 mobile unit—offered on a zero-capex rental model—to large-scale implementations, we’re committed to providing low-cost, home-grown, and rapidly deployable capture solutions tailored for India’s cement industry.

In this extended blog post, we’ll dive deeper into:

  • The imperatives of CCUS in decarbonizing India’s cement sector, with data drawn from the latest GCCA-TERI roadmap.
  • The salient features of GAS LAB’s IGNI1 mobile testing unit and how it de-risks CCUS adoption at cement facilities.
  • The long-term value of local service, maintenance, and AI-based process optimizations that lower lifecycle costs.
  • Steps to scale from pilot to commercial CCUS projects, along with the policy, technology, and financing enablers required.

Why CCUS Is Vital for India’s Cement Sector

  • Process Emissions Require Specialized Solutions
    Cement manufacturing releases CO2 partly from burning fuels in the kiln, but predominantly from calcination of limestone—a chemical reaction that inherently emits CO2. According to the GCCA-TERI roadmap, almost 60% of cement sector emissions stem from process-related decomposition of calcium carbonate (limestone), leaving about 40% from fuel combustion and electricity use. While you can electrify or switch to biofuels to cut down on fossil-based CO2, process emissions remain largely unchanged without capture-based technologies.
  • Growing Demand, Growing Emissions
    Estimates suggest that India’s cement production is likely to increase from 334 Mt in 2020 to well over 1,500 Mt by 2070. The government’s push for affordable housing, big-ticket infrastructure projects like Bharatmala and Sagarmala, and increasing urbanization will ensure high cement demand for decades. Even if the clinker factor drops from about 0.75 to around 0.56 by 2070—through wider use of blended cements such as Portland Pozzolana Cement (PPC), Portland Slag Cement (PSC), Limestone Calcined Clay Cement (LC3), and other emerging blends—CCUS remains crucial to mitigate the inevitable process CO2.
  • Alignment with India’s Net-Zero 2070 Vision
    India’s commitment to net-zero by 2070 mandates deep decarbonization in hard-to-abate sectors. This includes not just adopting existing best practices like energy efficiency, alternative fuels, or supplementary cementitious materials (SCMs) but going further to install and mainstream carbon capture infrastructure.
  • Scaling Up Low-Carbon Technologies
    While many plants now use Waste Heat Recovery (WHR) systems, biomass, and refuse-derived fuels (RDF), the net-zero roadmap calls for greater than 25% emissions cuts to be realized through CCUS by 2070. This is backed by broad industry consensus that carbon capture technology, whether storage or utilization-focused, must be at the center of the cement decarbonization strategy.

Decarbonization Insights from the GCCA-TERI Roadmap

  • Energy and Emissions Intensity: The Indian cement sector has already achieved considerable gains, with an average thermal energy intensity near 731 kcal per kg clinker, and electrical intensity of around 73 kWh per tonne cement. Emissions intensity sits near 0.68 tonne of CO2 per tonne of cement (baseline 2020). The roadmap envisions pushing this down to about 0.51 by 2047 and net zero by 2070, requiring CCUS, low-carbon fuels, and more.
  • Shift to Low-Carbon Fuels: Alternative fuels like municipal solid waste, used tyres, and agricultural residues are expected to replace fossil fuels. By 2070, the GCCA-TERI study indicates that 100% of heat could come from a combination of green hydrogen, biomass, electrified kilns, and other low-carbon energy sources. Yet, all these measures combined do not fully eliminate process emissions.
  • Cement Use Efficiency: Alongside CCUS, the report urges cement-use efficiency in construction, projecting a possible 30% reduction in overall societal cement demand by 2070 through bulk handling, optimized mix design, ready-mix, precast elements, and more. This helps reduce total emissions but doesn’t negate the need for CCUS.

Overall, the GCCA-TERI document identifies CCUS as mandatory for net-zero attainment, describing how collaborative pilots, robust policy frameworks, and advanced R&D can nurture the technology at scale.

GAS LAB’s Low-Cost Home-Grown Solutions: Why They Stand Out

  • A Track Record of Over 60 Years
    GAS LAB is no newcomer. We have developed, deployed, and serviced a range of CO2 capture and gas separation units for refineries, fertilizer plants, steel mills, beverage carbonation, and more. This extensive field experience has honed designs that are reliable and cost-effective over the entire operating cycle.
  • Made-in-India Technology
    Because our solutions are indigenous, the initial procurement and subsequent upkeep costs are significantly lower than imported technologies. Local manufacturing ensures faster turnaround for spare parts and robust after-sales support. Indian-made solutions also align with the government’s “Aatmanirbhar Bharat” vision, reinforcing local capacity building.
  • Global Footprint, Local Support
    Despite being a home-grown entity, we have deployed systems in more than 25 countries worldwide. This global presence allows us to track international best practices, emerging technologies, and market trends—providing synergy between local cost advantages and world-class engineering.
  • Innovation with AI
    Through our collaboration with Carbonetics Carbon Capture, we incorporate advanced AI software for process optimization. CCUS operations can be monitored and fine-tuned in real time, significantly reducing energy consumption and operational expense. The result: a drastically improved lifecycle cost profile.

Introducing IGNI1: The Mobile Pilot Test Unit for Cement Plants

IGNI1 is our flagship offering to help cement producers “try before they buy.” Supplied on a rental basis at zero capex, it allows any cement facility to determine site-specific capture rates, energy consumption, and integration logistics.

Key Features

  • Modular Design: The compact skid-mounted system easily integrates into existing process lines with minimal modifications.
  • Real-World Data Generation: Collects real-time data on process conditions, flue gas composition, and capture rates so you can quantify performance under actual operational loads.
  • AI-Driven Analytics: Equipped with Carbonetics’ AI algorithms, IGNI1 tracks performance metrics around the clock. It automatically adjusts solvents, temperatures, and flow rates to maintain peak capture efficiency.
  • Seamless Scalability: Positive pilot results enable a straightforward transition to commercial-scale capture systems, informed by real data on CAPEX, OPEX, and performance reliability.

The Zero-Capex Rental Approach

Typically, one of the biggest roadblocks to adopting CCUS is high upfront capital. By renting IGNI1, plant operators gain firsthand exposure to the technology without worrying about large sunk investments. If IGNI1’s data corroborates feasibility, scaling up becomes a more confident exercise.

Technical & Maintenance Support

At GAS LAB, we’re committed to a full-service experience. Our engineering experts and local service teams help with unit installation, provide operator training, and offer on-call maintenance. This ensures the pilot runs smoothly, delivering accurate insights.

Pathway from Pilot to Commercial Scale

A typical CCUS deployment in a cement plant can be envisioned as follows:

  • Initial Consultation: Evaluate flue-gas volumes, kiln operating temperatures, and project goals.
  • Pilot Deployment with IGNI1: Depending on plant size, pilot runs last anywhere from a few weeks to several months, offering enough data to confirm ROI and performance thresholds.
  • Detailed Feasibility & Design: Once validated, we finalize engineering designs for a large-scale capture unit, complete with ancillary systems.
  • Financing & Partnerships: We help clients explore carbon credits, green bonds, and co-funding opportunities, aligning with government incentives.
  • Deployment & Integration: Site readiness ensures minimal production disruption while the CCUS system is installed.
  • Operation & Continuous Improvement: Our AI-driven solutions keep refining the capture process, reducing energy consumption over the plant’s lifetime.

Technology Partnership with Carbonetics Carbon Capture

Our synergy with Carbonetics Carbon Capture is a game-changer for cost efficiency. Their advanced AI engine gathers operational data—like solvent circulation rates, gas composition, heat integration, etc.—and deploys predictive analytics to:

  • Optimize Sorbent Usage: Minimizing consumption of solvents or solid sorbents dramatically reduces OPEX.
  • Lower Energy Penalties: Fine-grained control over temperature and pressure parameters helps push the capture boundary up while pulling operating costs down.
  • Predict Maintenance Needs: Using machine-learning patterns, the system identifies potential hardware or performance glitches in advance, preventing unplanned downtimes.

Over multiple cycles, these incremental optimizations add up, pushing overall project economics in favor of adoption—especially critical for an industry that deals in commodity-level margins.

Service, Maintenance, and Proximity Advantages

  • On-Ground Coverage: With manufacturing facilities and service teams spread across India, we can quickly address any maintenance or replacement needs—crucial for continuous cement kiln operations.
  • Faster Upgrades: AI-based diagnostics highlight performance deficits. Our local teams can implement software updates or even minor hardware upgrades efficiently.
  • Parts & Spares Readily Available: Local supply chains ensure minimal wait times for essential components, keeping downtime close to zero.

Moving the Needle: Policy, Financing, and Collaborative Roadmaps

Although CCUS has solid technological foundations, supportive policy frameworks, collaborative R&D, and innovative financing are critical to scale up. In line with the GCCA-TERI findings and the Government of India’s net-zero pledge, the following measures can accelerate adoption:

  • Green Public Procurement: Encouraging or mandating lower-carbon cements in public-sector projects helps generate demand for CCUS-based production.
  • Tax Incentives & Subsidies: Direct capital grants, carbon credits, or offset policies can significantly reduce the financial risk of installing large-scale CCUS.
  • Carbon Pricing: Over time, a stable carbon pricing regime or carbon credit trading scheme would enhance CCUS viability.
  • Collaborative Hubs: Shared CO2 pipelines, storage, or utilization clusters reduce infrastructure duplication and can lower the overall cost of transporting and storing captured carbon.
  • Dedicated R&D Funds: Funding for advanced solvents, next-generation kiln electrification, and potential breakthroughs in synergy with CCUS can drive down costs further.

Realistic View: Challenges and Limitations

  • High Energy Footprint: Despite AI-driven optimizations, carbon capture can increase a cement plant’s overall energy requirements. Thus, synergy with waste-heat recovery and renewable power purchase agreements is often essential.
  • Infrastructure Barriers: Some regions lack the pipelines or geological storage sites for large-scale CO2. Ocean-based or basalt-based carbon sequestration may prove viable but require more research and robust regulations.
  • Policy & Regulation: India’s regulatory ecosystem for CCUS is evolving. The clarity around liability, leakage monitoring, and incentives needs further strengthening.
  • Financing Hurdles: Large-scale CCUS remains a capital-intensive proposition. Strategies like blended finance—mixing private capital, development bank loans, carbon-credit revenues, and government subsidies—can mitigate risk and catalyze adoption.

Conclusion: The Time to Act is Now

The GCCA-TERI roadmap provides a bold vision for achieving net-zero in India’s cement sector by 2070, with CCUS playing a pivotal role. GAS LAB, with our 60+ years of CO2 removal expertise, home-grown manufacturing base, and AI-driven solutions through Carbonetics, aims to demystify and de-risk the carbon capture journey for all cement players—big or small.

By making our IGNI1 mobile test unit available on a no-capex pilot model, we lower barriers to entry and encourage data-backed decision-making. Indian cement manufacturers can test CCUS viability within their specific operational contexts, proving out ROI and reliability before scaling up. Our local presence and end-to-end service offerings, from pilot to large-scale adoption, make us a trusted partner in your decarbonization quest.

We invite you to join hands and take decisive steps toward climate stewardship. Let’s work together to secure India’s cement sector as a global leader in carbon capture and greenhouse gas mitigation—building a cleaner, more resilient future one tonne of cement at a time.

Ready to Explore On-Site CCUS Trials?

  • Get in Touch: Contact GAS LAB to explore a pilot CCUS deployment with our mobile IGNI1 test unit.
  • Drive the Change: Be part of the transformation. Whether you’re an industry expert, policymaker, or investor, your collaboration can help shape India’s net-zero vision and inspire global replication.
  • Stay Updated: Visit our website or follow us on social media for updates on real-world project outcomes, new technology breakthroughs, and policy developments in carbon capture.

At GAS LAB, we firmly believe that CCUS is not just a theoretical pathway—it’s a practical, near-term solution to one of India’s most pressing industrial challenges. As a nation with ambitious green growth objectives, let’s seize this moment to strengthen our cement sector’s role in meeting the net-zero pledge.