Over the years, industrial decarbonization in India has witnessed gradual progress; however, several bottlenecks continue to slow the pace and depth of transition. Key barriers include the sector’s heavy reliance on coal-based captive power plants, the high costs associated with shifting to renewable energy, and the adoption of new energy-efficient technologies. The aluminium sector has been a significant contributor to India’s economic growth, accounting for nearly 5.5% of global aluminium production. Despite this, it remains one of the most energy-intensive industries, alongside iron and steel, cement, etc. In 2023, India’s aluminium sector contributed approximately 8% of total greenhouse gas emissions, largely due to its energy-intensive production processes. Aluminium production involves two major stages, alumina refining and aluminium smelting with the smelting process requiring a continuous and uninterrupted power supply. Producing one tonne of aluminium typically requires around 70 to 80 GJ of energy, making reductions in energy intensity critical for decarbonizing the sector. At the same time, aluminium production in India has expanded significantly to meet rising demand from sectors such as automotive, aerospace, packaging, and electrical applications. This growth further underscores the need for strategic and timely carbon abatement measures. Adding to this urgency, emerging trade measures such as the Carbon Border Adjustment Mechanism (CBAM) are expected to increase the risk to the global competitiveness of India’s aluminium exports. In this context, decarbonizing the aluminium sector is no longer a peripheral sustainability concern but a core industrial and trade strategy issue.

From the previous and past experiences, it has been observed that the most impactful pathway for decarbonising India’s aluminium industry lies in transitioning to low-carbon electricity. Renewable energy integration, particularly wind and solar, offers significant abatement potential, given that electricity consumption accounts for the bulk of sectoral emissions. However, the uninterrupted power requirement of aluminium smelting poses challenges for large-scale renewable adoption. Hybrid renewable systems combined with battery storage and grid-balancing mechanisms are emerging as partial solutions, although they entail higher capital and operational costs. While several producers have begun investing in captive renewable capacity and long-term power purchase agreements, scaling these solutions across the sector will require substantial grid upgrades and stronger regulatory support.
In parallel, improvements in energy efficiency have played an important role in reducing emissions. The adoption of energy-efficient technologies, such as electric extrusion melting, copper-inserted collectors in potlines, and magnetic compensation loops, holds considerable potential to lower the energy intensity of aluminium smelting processes. Another underutilised decarbonization lever is aluminium recycling. Secondary aluminium production consumes only a fraction of the energy required for primary production and can significantly reduce emissions intensity. However, India’s aluminium recycling ecosystem is largely dominated by informal players, leading to challenges such as inconsistent quality and limited adoption of advanced technologies. A more formalised and scaled recycling system, supported by policy incentives and extended producer responsibility frameworks, could substantially reduce demand for carbon-intensive primary aluminium.

Despite the availability of multiple decarbonization pathways, progress remains constrained by structural and policy gaps. One of the most significant missing links is the absence of a clear, sector-specific decarbonization roadmap. India currently lacks binding emissions benchmarks, green product standards, and differentiated incentives for low-carbon aluminium. Financing constraints further complicate the transition, as estimates suggest that achieving net-zero aluminium production would require tens of billions of dollars in additional capital expenditure. These investments are likely to raise production costs in the near to medium term, posing competitiveness challenges, particularly in price-sensitive domestic markets. In the absence of carbon pricing, green public procurement, or demand-side incentives, producers have limited avenues to recover these costs. Grid infrastructure and energy system readiness also remain critical bottlenecks. Parallel investments in transmission and energy storage are essential to support large-scale integration of renewable energy and reduce dependence on fossil-based backup power.
Analytically, decarbonising India’s aluminium industry requires coordinated action across energy policy, industrial policy, and finance. Without such alignment, the sector risks losing its competitive edge relative to global markets. Renewable electricity, efficiency improvements, recycling, and emerging technologies together can lead to significant emissions reductions, but only when supported by coherent policy frameworks, targeted financial instruments, and enabling infrastructure. Decarbonization should therefore be viewed not as a constraint on growth, but as a strategic investment in the long-term viability of India’s aluminium industry. The real challenge lies not in the absence of solutions, but in bridging the policy, financing, and coordination gaps between ambition and implementation.
(Views expressed are the authors’ own and don’t necessarily reflect those of ICRIER)








