No fuel switch, no efficiency measure, no electrification can eliminate calcination CO₂. Only capture can.
India's cement industry produces approximately 380 MT of cement per year and is growing at 5–7% annually, driven by the National Infrastructure Pipeline's USD 1.4 trillion construction programme, the Pradhan Mantri Awas Yojana housing mission, and urbanisation. India consumes more cement per unit of GDP growth than any comparable economy. This growth is essential for India's development — and it makes cement CCUS an urgent priority rather than a long-term aspiration.
Cement's carbon challenge is uniquely intractable: approximately 60% of its CO₂ emissions come not from burning fuel but from the chemical decomposition of limestone (calcite, CaCO₃) into lime (CaO) and CO₂ during the kilning process. This calcination reaction is thermodynamically required for Portland cement chemistry — there is no substitute reaction, no renewable energy solution, and no efficiency improvement that can eliminate it. The only options are to use supplementary cementitious materials (SCMs) to reduce clinker content (achieving partial reductions) or to capture the CO₂ from the kiln exhaust. For deep decarbonisation, CCUS is the only pathway.
India's cement sector faces increasing pressure from multiple directions: voluntary Net Zero commitments by UltraTech, ACC (Holcim India), Shree Cement, and Ambuja; CBAM exposure for Indian cement exporters (though currently limited in volume); and increasing international investor scrutiny of cement sector Scope 1 emissions in ESG reporting frameworks. NCM has conducted preliminary capture screening for 12 major Indian cement plants across 6 states and is developing the first bankable cement CCUS feasibility study for India.
India's annual cement production — second largest globally, growing 5–7%/year
Share of cement CO₂ from limestone calcination — chemically unavoidable without capture
CO₂ concentration in cement kiln exhaust — higher than coal power flue gas, improving capture economics
India's projected annual cement production by 2030 — CCUS urgency growing with every plant built
Technology choice depends on kiln type, plant size, location, water availability, and electricity cost. NCM evaluates all viable options for each site.
The most mature and widely studied capture route for cement. Applied to kiln exhaust gas — 14–33% CO₂, after pre-treatment for SO₂ and dust. SLB (Schlumberger) ADIP-X, MHI KS-21, and Fluor Econamine are leading licensors with cement reference data. Applicable to all Indian cement kilns with sufficient water and heat.
Combustion in pure oxygen produces a concentrated CO₂ flue stream without chemical separation. Particularly compelling for cement because it captures both fuel combustion CO₂ and calcination CO₂ in a single stream. Heidelberg Materials Brevik (Norway) is the world's first full-scale reference plant.
A novel capture process using limestone as a sorbent — CO₂ is captured by calcined limestone and released in a concentrated stream in a regenerator. Synergistic with cement production because spent sorbent can replace virgin limestone feed. THL and IEA Greenhouse Gas R&D Programme have active CaL cement studies.
Converting only the cement pre-calciner to oxy-fuel — capturing the 60% calcination CO₂ while leaving the main kiln on air-fired operation. Reduces capital cost by 35–45% vs. full kiln oxy-fuel conversion while capturing the majority of unavoidable process CO₂.
Injecting captured CO₂ directly into fresh concrete mix where it reacts with calcium silicate hydrates to form carbonates — permanently storing CO₂ and improving concrete strength. Not a full capture solution but an economical first step applicable to India's large ready-mix concrete sector.
Multiple cement plants sharing CO₂ transport and storage infrastructure — reducing per-tonne CCUS cost. Rajasthan's Beawar-Chittorgarh cement cluster (UltraTech, Shree, JK) is India's highest-priority cement CCUS cluster candidate, with combined annual production exceeding 50 MT.
NCM has completed preliminary capture screening assessments for 12 major Indian cement plants using publicly available production data, kiln technology filings, environmental clearance documents, and satellite imagery. The screening evaluates each plant on five criteria: CO₂ emission volume (plants above 1 MT/year CO₂ are priority candidates), kiln technology (dry process is preferred for PCC retrofit), water availability (critical for PCC and oxy-fuel cooling), proximity to CO₂ storage (geological survey data for saline aquifers and Deccan Traps proximity), and CBAM/ESG exposure (export fraction and investor ownership profile).
The preliminary screening identifies three priority tiers. Tier 1 (immediate feasibility study candidates): three plants in Rajasthan with high dry kiln capacity, proximity to Deccan Traps storage, and ownership by companies with active Net Zero commitments. Tier 2 (medium-term candidates, 2026–2028): five plants in Andhra Pradesh and Karnataka with good storage proximity but requiring more detailed site investigation. Tier 3 (longer-term, post-2028): four plants in Madhya Pradesh and Maharashtra where storage geology requires further characterisation.
For each priority cement plant, NCM is developing a capture technology comparison matrix — evaluating PCC, partial oxy-fuel, and calcium looping on CAPEX, OPEX, energy penalty, water consumption, carbon credit potential, and CBAM compliance value. The optimal technology varies by plant: water-stressed Rajasthan plants favour dry-cooled PCC variants or partial oxy-fuel; plants with waste heat from WHR power generation favour LDAC or PCC with heat integration; coastal Andhra Pradesh plants benefit from access to seawater cooling.
Indian cement plants screened by NCM across Rajasthan, AP, Karnataka, MP, Maharashtra, and Gujarat
Tier 1 priority plants ready for immediate CCUS feasibility study commissioning
Combined annual production of India's Rajasthan cement cluster — top priority for shared CCUS infrastructure
CO₂ captured annually by world's first full-scale cement CCS plant (Heidelberg Brevik, Norway)
NCM is developing the technical and commercial framework for India's first bankable cement CCUS project — a pre-FEED level study for a 2.5 MT/year kiln in Rajasthan that will demonstrate the complete CCUS pathway from capture through to Deccan Traps basalt mineralisation storage. This project is structured to attract DFI co-financing through ADB's Industry Decarbonisation Programme and GCF's enhanced mitigation facility.
The project incorporates three innovations specific to Indian conditions: a water-minimised PCC design using dry coolers and solvent-based rather than water-based absorption, validated against performance data from water-stressed cement plants in the Middle East; an integrated CO₂ utilisation component producing enhanced concrete for the Rajasthan construction market, generating near-term revenue before full storage infrastructure is operational; and a CBAM compliance documentation system that creates verifiable, audit-ready carbon accounting from day one.
NCM is also engaged with the Cement Manufacturers' Association of India (CMA) on a sector-level CCUS roadmap — mapping the technology pathway, financing requirements, and policy enablers needed to deploy capture across 15% of India's cement capacity by 2030 and 50% by 2040. This roadmap will serve as the primary technical input to the Ministry of Industry's cement sector decarbonisation strategy and the National CCUS Mission's sector implementation plan.
Whether you are a government body seeking policy advice, an industrial company facing CBAM exposure, or an investor seeking CCUS project opportunities — our team is ready to engage.