International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 06 | Jun 2025
p-ISSN: 2395-0072
www.irjet.net
Sustainable Cement Production: Utilizing Seawater and Alternative Components to Reduce Freshwater Consumption Vrishank Malik1, Raj Shah1, Lavanya Kundurthy1, and Hemant N. Joshi1,2 1Tara Innovations LLC, East Hanover, New Jersey, USA 2Founder, Tara Innovations LLC, hemantjoshi@tarainnovations.com ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - Cement production is a highly water-intensive
of the Total Environment in 2018, producing approximately 95 million cubic meters of freshwater generates 141.5 million cubic meters of brine (water containing high concentrations of salt), a harmful waste product2. High amounts of brine can cause severe environmental damage when discharged into oceans or other bodies of water, as its high salinity can disrupt marine ecosystems and harm aquatic life.
process that negatively contributes to freshwater depletion amid the growing global freshwater scarcity. This study explores the feasibility of using seawater as a sustainable alternative to freshwater in concrete construction and aims to reduce concrete’s heavy dependence on rapidly depleting water resources. Accordingly, we conducted unique experiments to analyze the effects of seawater concentrations, salts, surfactants, and polymers on curing, strength, and durability to determine the optimal formulation: 40% seawater, 60% freshwater, and 1% magnesium chloride. The ideal formulation discovered appears to be associated with a faster curing rate. The findings of this research suggest that concrete quality can be maintained while conserving freshwater by replacing a portion of freshwater with seawater. Our approach not only addresses water scarcity but also aims to mitigate the environmental concerns from desalination and cement manufacturing.
2 Environmental Effects of Cement Consumption The issues related to the shortage of freshwater in the world are particularly relevant to the construction industry, as cement production relies on freshwater. Over the years, cement production has experienced a dramatic increase due to global industrialization and urbanization. In the early 1900s, global cement production was relatively modest: in 1950, global production was approximately 80 million metric tons3. By 1980, global cement production surged to about 800 million metric tons4. This increase was further accelerated by the construction booms in developing countries and the rise of modern infrastructure. By 2010, global cement production had surpassed 3 billion metric tons annually. Today, cement production levels have continued to rise, exceeding 4 billion metric tons annually5,6. Demolition of thousands of buildings in recent wars has increased the demand for cement. Also, we have a limited supply of lime and silica, the two major components of cement.
Key Words: Cement, Concrete, Seawater, Water, Curing, Hardness.
1 Introduction Water is essential for both Earth and humans because it supports life. About 70% of Earth’s surface is covered with water, and about 97.5% of the total water is seawater. Out of the remaining 2.5% that is freshwater, a significant portion is locked in glaciers and ice caps or buried underground, leaving less than 1% of Earth's total water available for human use. The human population was 2 billion in 1930 and is currently about 8.2 billion. The human body has an average of 60% water. Therefore, if the average body weight is 55 kg, we have 33 kg of water trapped in our body. Thus, more water gets locked in human bodies as the global population increases, reducing the total available water for consumption.
While this growth reflects cement’s critical role in construction and modern life, it also underscores the associated environmental challenges, specifically high carbon emissions and water usage. On average, it takes about 1,200 to 1,500 liters of water to produce one metric ton of cement. This water is used for processes such as cooling, mixing, and curing. Therefore, producing the required amount of cement annually (4 billion metric tons) would require between 4.8 and 6 trillion liters of water. This means that every year, cement production uses between 0.045% and 0.057% of Earth’s total water supply, highlighting the criticality of this issue.
To meet the water demands of 8.21 billion people and a greater number of mammals, birds etc., seawater must be converted into freshwater. Plenty of seawater is available. However, the desalination process is highly energy-intensive and expensive. According to a Bloomberg report, about 15,000 kilowatt-hours of power are used for every million gallons of freshwater produced1. This high energy consumption contributes to carbon emissions and global warming. Secondly, according to a study published in Science
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Cement production not only exhausts a substantial amount of water, but also relies on freshwater, which is often produced by desalination. If 50% of the freshwater used for cement undergoes the desalination process (a conservative
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