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<p>Cement production remains a highly energy-intensive process and a major contributor to global CO<sub>2</sub> emissions, particularly in emerging economies such as India. This study presents a comprehensive life cycle assessment (LCA) of energy use, carbon emissions, and resource utilization associated with the production of clinker, ordinary portland cement (OPC), and Pozzolana portland cement (PPC) at two representative Indian cement plants. The assessment is based on detailed plant-level operational data covering all major production stages, thereby providing India-specific, process-level insights beyond conventional reliance on generic international databases. Also, by integrating primary plant-specific data with process-wise LCA and scenario-based analysis, this study offers a more realistic evaluation of energy and emission drivers in the Indian cement industry. Results indicate energy intensities of 4568.96–4063.59&#xa0;MJ/tonne for clinker, 4310.95–3886.58&#xa0;MJ/tonne for OPC, and 3311.22–2994.67&#xa0;MJ/tonne for PPC. Corresponding CO<sub>2</sub> emissions range from 1023.66 to 967.22 kg/tonne (clinker), 959.56 to 913.87 kg/tonne (OPC), and 676.22 to 637.48 kg/tonne (PPC). Compared to global benchmarks, OPC production in India consumes 12.73% more energy and emits 18.59% more CO<sub>2</sub>, highlighting significant efficiency gaps within the sector. Scenario-based assessments indicate that clinker substitution and alternative fuel adoption can reduce emissions by up to 70%, demonstrating substantial potential for decarbonization. The findings provide actionable insights for industry and policymakers, supporting the implementation of low-carbon strategies and enhancing the sustainability of cement production in India.</p>

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Life cycle assessment of energy and CO2 emission in clinker, OPC, and PPC production: case studies and pathways to emission reduction

  • 期刊论文

  • 发表日期：

    2026年5月26日

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  • Bipul Sharma,
  • Aditya Singh Rajput,
  • Salim Barbhuiya

摘要

Cement production remains a highly energy-intensive process and a major contributor to global CO2 emissions, particularly in emerging economies such as India. This study presents a comprehensive life cycle assessment (LCA) of energy use, carbon emissions, and resource utilization associated with the production of clinker, ordinary portland cement (OPC), and Pozzolana portland cement (PPC) at two representative Indian cement plants. The assessment is based on detailed plant-level operational data covering all major production stages, thereby providing India-specific, process-level insights beyond conventional reliance on generic international databases. Also, by integrating primary plant-specific data with process-wise LCA and scenario-based analysis, this study offers a more realistic evaluation of energy and emission drivers in the Indian cement industry. Results indicate energy intensities of 4568.96–4063.59 MJ/tonne for clinker, 4310.95–3886.58 MJ/tonne for OPC, and 3311.22–2994.67 MJ/tonne for PPC. Corresponding CO2 emissions range from 1023.66 to 967.22 kg/tonne (clinker), 959.56 to 913.87 kg/tonne (OPC), and 676.22 to 637.48 kg/tonne (PPC). Compared to global benchmarks, OPC production in India consumes 12.73% more energy and emits 18.59% more CO2, highlighting significant efficiency gaps within the sector. Scenario-based assessments indicate that clinker substitution and alternative fuel adoption can reduce emissions by up to 70%, demonstrating substantial potential for decarbonization. The findings provide actionable insights for industry and policymakers, supporting the implementation of low-carbon strategies and enhancing the sustainability of cement production in India.