Key players are racing toward the commercialization of breakthrough technologies for cement kiln electrification, novel cement types and carbon capture. Even so, given the trends in urbanization and population growth, decarbonizing cement will not be possible unless we take a hard look at how cement and concrete are used and consumed.
Proven technologies
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4. Industry / Cement / Proven technologiesGrinding and crushing: vertical roller mills for locally-produced cement
LOESCHE GmbH
Getty Images /© BilanolRaw materials and cement clinker have traditionally been grinded in ball mills with poor energy efficiency. Vertical roller mills reduce cement grinding energy consumption and are suitable for very fine cements and aggregates. These mills have existed for several decades and are in operation around the world, but have undergone various innovations over the years. In the 1960s, the LOESCHE company introduced rotary kilns with heat exchangers. In the 1990s, they introduced vertical roller mills able to grind both cement clinker and granulated slag (a by-product of ironmaking) in a single process and use kiln exhaust gases for dry grinding. LOESCHE currently supplies a compact cement grinding plant with a vertical roller mill suitable for small-scale cement plants within small but growing markets.
- Contracting type: For sale
- Technology level: Medium
- Country of origin: Germany
- Availability: Worldwide
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4. Industry / Cement / Proven technologiesGrinding and crushing: energy-saving raw material and clinker grinding
Fives Group
© Peter OksenFCB Horomill® is a ring roller mill originally developed by French plant manufacturer FCB-Ciment and Italian cement producer Buzzi Unicem Group. The mill can grind raw materials, clinker and cement additive materials, such as limestone and slag, without requiring injected water to control temperature. An integrated gas circuit enables efficient drying and processing of wet raw materials. Today, the Fives Group company provides the mills. According to the provider, they enable up to a 65 percent energy saving compared to ball mills and 10 to 20 percent compared to vertical roll mills.
- Contracting type: For sale/service
- Technology level: Medium
- Country of origin: France
- Availability: Worldwide
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4. Industry / Cement / Proven technologiesGrinding and crushing: high-pressure grinding roll
Takraf
© TakrafHigh-pressure grinding roll technology for crushing feed materials in cement-making consume less energy than conventional mills and crushers. The technology involves two counter-rotating grinding rolls subjecting a column of material to high pressure. This results in micro-cracks in the material’s particles, leading to mineral liberation and smaller-sized particles. These micro-cracks increase the particle contact surface leading to improved leaching performance and flotation efficiency. High-pressue grinding roll technology is more cost-efficient than traditional mills and crushers. The technology also consumes less power than alternatives and the large amount of fine cracks created in the material reduces the power needed for the ball mill downstream.
- Contracting type: For sale
- Technology level: High
- Country of origin: Germany
- Availability: Worldwide
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4. Industry / Cement / Proven technologiesWaste heat recovery: boilers for cement on-site power generation
Thermax Ltd.
© ThermaxCement plants can recover waste heat at different stages of the cement-making process. This strengthens a plant’s energy security while also lowering its CO2 emissions. Thermax’s waste heat recovery system is based on the Rankine Cycle. The company provides waste heat recovery boilers that leverage hot waste gases to generate steam for power-producing turbines, or for heating feedwater for the on-site powerplant. Waste heat is recovered at two points in the cement process: pre-heaters/calciners and clinker coolers. The company also collaborates with external partners to provide full heat recovery systems, including boilers, turbines and generators.
- Contracting type: For sale/service
- Technology level: Medium
- Country of origin: India
- Availability: Worldwide
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4. Industry / Cement / Proven technologiesWaste heat recovery: turbines for cement on-site power generation
Triveni Turbines
Getty Images /© industryviewIn cement plants, small-scale powerplants can be installed that run on waste heat from various processes. Recovered hot gases are passed through boilers to generate steam to drive electricity-producing turbines and generators. This can meet up to 30 percent of a cement plant’s power requirements. Electricity generated through such a heat recovery practice also reduces CO2 emissions, especially in countries with a high level of fossil fuel use. Waste heat recovery in cement power plants is based on thermodynamic cycles such as the Organic Rankine Cycle, the Kalina Cycle or the Steam Rankine Cycle. Triveni Turbines supplies and installs turbines based on SRC systems across India.
- Contracting type: For sale/service
- Technology level: Medium
- Country of origin: India
- Availability: India
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4. Industry / Cement / Proven technologiesEnergy efficiency: cement kiln insulation and lining material
Morgan Advanced Materials
Getty Images /© jmsilvaIn cement production, most emissions originate from the cement kiln. Ensuring kilns operate as efficiently as possible means making good use of the high temperatures achieved and avoiding unnecessary heat lost to the environment. Morgan Advanced Materials supplies a range of products for thermal management of the cement kiln and related components. These include insulators and materials for the pre-calciners, retainer ring, dropout area and so on. Among the company’s products is the WDS Microporous back-up insulation material. This material extends kiln lining life-span and has a very low thermal conductivity coefficient which enhances thermal efficiency.
- Contracting type: For sale
- Technology level: Medium
- Country of origin: United Kingdom
- Availability: Worldwide
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4. Industry / Cement / Proven technologiesEnergy efficiency: pre-drying alternative fuels using waste heat
stela Laxhuber GmbH
Getty Images /© CasarsaGuruPre-drying fuel for the cement kiln can enable better energy usage and a more homogenous input. Company stela Laxhuber provides customized solutions for a range of alternative fuels, including refuse derived fuel and solid shredded waste. The pre-drying belts run on waste heat from upstream production processes, which enhances energy efficiency further. The company provides two types of belt dryer, one more compact than the other. Belt widths vary between 2 and 8.4 m. Both are modular plant systems with top-down ventilation and low heat and electricity consumption.
- Contracting type: For sale
- Technology level: Medium
- Country of origin: Germany
- Availability: Worldwide
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4. Industry / Cement / Proven technologiesClinker substitute: Portland limestone cement
Cemex
Getty Images /© alvarezClinker production is responsible for the majority of cement emissions. Replacing some of the clinker in cement can have a big impact on emission reduction. Portland limestone cement is a type of cement that has a higher limestone content, which partly replaces clinker. This blended cement can consist of up to 35 percent limestone (although this is not yet standard in many countries). In Mexico, the Cemex company supplies Cem II B-L 32.5N cement containing nearly 33 percent limestone. Although this type of limestone-blended cement was developed in the 1960s, it has gained popularity in recent years owing to its emissions-lowering ability.
- Contracting type: For sale
- Technology level: Medium
- Country of origin: Mexico
- Availability: Worldwide
Frontier technologies
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4. Industry / Cement / FrontierAlternative cement: bonded sand particles as cement substitute
University of Tokyo
© University of TokyoResearchers at the University of Tokyo have invented a novel production method for producing an alternative construction material to cement that uses readily available materials such as sand and gravel. The method relies on the bonding particles of silica (SiO2) contained within the natural materials used. The method comprises several stages. First, the raw material containing silica is mixed together with an alcohol compound plus either an alkali metal compound or an alkaline earth metal compound. The mixture is then heated to produce a hardened body that can be used as a cement substitute in construction.
- Contracting type: For collaboration
- Technology level: Low
- Country of origin: Japan
- Availability: Japan
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4. Industry / Cement / FrontierAlternative cement plus material efficiency: ceramic waste regeneration
Yi Design Company Limited
Getty Images /© Dinesh AhirYi Design has developed a binding material plus a process for recycling large volumes of ceramic waste material and other industrial solid waste, such as glass and blast furnace slag. Materials are reprocessed into porous ceramic bricks and tiles by mixing crushed waste with a binder before sintering. Final product consists of 90 percent recycled material and intended to replace cement in construction. The bricks are absorbent therefore suitable for pavements to alleviate flooding.
- Contracting type: For sale
- Technology level: Medium
- Country of origin: China
- Availability: China
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4. Industry / Cement / FrontierMaterial efficiency: geopolymer concrete
Polycare
Polycare is developing and manufacturing a circular micro-modular masonry system. These cement-free hollow blocks consist of up to 95 percent secondary raw materials. They are not glued or mortared, but joined together by inserted connecting elements. This masonry system allows construction professionals to meet regulatory requirements and achieve a 70 percent CO2 reduction. Polycare considers buildings to be temporary "storage" for materials that can be reused in the future. The aim is cost savings, asset preservation and the avoidance of secondary costs like demolition and disposal. The company’s research and development center is located in central Germany and production due to be piloted in Germany in 2024.
- Contracting type: For collaboration
- Technology level: Medium
- Country of origin: Germany
- Availability: Namibia
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4. Industry / Cement / FrontierMaterial efficiency: biocement for concrete restoration
Basilisk
© BasiliskExtending the life of existing concrete infrastructure instead of demolishing and building from scratch avoids greenhouse gas emissions. Small cracks in concrete, for example, can be avoided or repaired using bio-based self-healing techniques. Biomineralization is a method that uses a bacterial calcium carbonate deposit to fill microcracks and which can also be used as binder. The technology was first applied in the 1990s. Basilisk supplies a product which, when blended into any concrete mix, exhibits self-healing properties.
- Contracting type: For sale
- Technology level: High
- Country of origin: Netherlands (Kingdom of the)
- Availability: Worldwide
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4. Industry / Cement / FrontierCarbon capture: carbon mineralization in concrete
CarbonCure
© CarbonCureCarbonCure provides technology that injects CO2 into fresh concrete as a way of storing emissions and thereby reducing the cement sector’s overall climate impact. Once injected along with water, the CO2 undergoes a mineralization process that embeds it within the concrete. This has the added benefit of improving compressive strength and reducing cement use in designs. The company acquires CO2 from local industrial gas supply companies that have CO2 recovery plants. These companies in turn access, capture and purify flue gas streams from other industries (refineries, ethanol plants etc.) whereby the captured gases are distributed for reuse via road, rail or direct pipeline.
- Contracting type: For sale/service
- Technology level: Medium
- Country of origin: Canada
- Availability: Worldwide
Horizon technologies
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4. Industry / Cement / HorizonAlternative cement: carbon-negative Portland cement
Brimstone
Getty Images /© CopridThe Brimstone ProcessTM is described as a carbon-negative process for making Portland cement. Instead of using limestone, the company makes cement with lime from calcium silicate rocks. Because limestone calcination is responsible for more than 60 percent of cement emissions, eliminating limestone has significant climate benefits. Furthermore, the process generates a magnesium-based waste product able to absorb atmospheric CO2 from fuel combustion. The cement itself is physically identical to conventional Portland cement. The technology is at an early stage of development. But this startup is planning toward advancing the process from laboratory to a demonstration plant.
- Contracting type: For collaboration
- Technology level: High
- Country of origin: United States
- Availability: N/A
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4. Industry / Cement / HorizonElectrification: electrified hot gas production for the cement industry
Coolbrook
© CoolbrookCoolbrook has developed a RotoDynamic Heater (RDHTM). This technology electrifies high-temperature process heating across industry, including the steel and cement sectors. RDHTM is capable of producing temperatures of up to 1,700°C. Air, nitrogen and process gases are heated to a high temperature inside the heater. This replaces the traditional fossil fuel burning to reach the temperatures required by furnaces and kilns. Powered by renewable electricity, this is likely to result in a 30 percent reduction in production process CO2 emissions, once implemented at scale. RDHTM is designed for retrofitting into existing facilities, as well as for new greenfield projects. The technology is being tested at a large-scale pilot plant in the Netherlands. The aim is for commercial demonstration projects to take place in 2024 and full commercial deployment to start around 2025.
- Contracting type: For collaboration
- Technology level: High
- Country of origin: Finland
- Availability: N/A
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4. Industry / Cement / HorizonCarbon capture: calcium looping carbon capture technology
Sumitomo Corporation
Getty Images /© chinaphotographerCalcium looping uses calcium oxide to remove carbon from flue gases. At the same time, heat can be recirculated in the process. With calcium looping, flue gas is mixed with calcium oxide in a fluidized bed. The gas is then mineralized into calcium carbonate and clean flue gas exits the unit. The calcium carbonate is then regenerated back to calcium oxide in the presence of fuel and oxygen, which is then circulated back to the carbonator. By-products such as calcined lime with ash and minerals are used as feedstock for the cement and lime industry.
- Contracting type: For sale/service
- Technology level: High
- Country of origin: Japan
- Availability: N/A
Innovation examples
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4. Industry / Cement / Innovation examplesIndustrial-scale cement plant carbon capture and storage
Getty Images /© AlbertPegoCement manufacturer HeidelbergCement (now Heidelberg Materials) is working toward delivering low-carbon cement by developing the world’s first industrial-scale carbon capture and storage (CCS) project at a cement production facility. The plant in question is being constructed in Brevik, Norway, and scheduled to be fully operational by 2024. The plan is to capture 400,000 tonnes of CO2 annually by using a mixture of water and organic amine solvents to absorb the CO2. It will then be compressed and shipped for storage in reservoirs below the seabed. In addition to these CCS efforts, the company is making greater use of alternative fuels and alternative secondary cementitious materials. It is also developing technologies for recycling concrete paste for use in capturing CO2 through enforced carbonation.
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4. Industry / Cement / Innovation examplesDistrict heating using local cement plant surplus heat
Getty Images /© ewg3DAalborg Portland, a large cement manufacturer in Denmark, is recovering flue gas to provide heating for the local population. Heated gas – that would otherwise go to waste – is collected at the kiln and treated through a combined gas cleaning and heat recovery system. Impurities such as sulphur are removed before the heat is forwarded for district heating use. The company has supplied surplus heat to the local grid since the 1990s. Today, this recovered heat provides 25 percent of district heating in the Aalborg municipality of Denmark.
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4. Industry / Cement / Innovation examplesLow-carbon cement use in major construction projects
Getty Images /© alex_skpWhat have the Olympic Village in Paris and the United Kingdom’s new HS2 high-speed railway line got in common? They are both large-scale construction projects under development using low-carbon cement with reduced clinker content supplied by Ecocem. A completed project using the same low-carbon cement is the Aviva Stadium, the Republic of Ireland’s national rugby and football stadium. Covering 6.4 hectares and having a 50 m tall façade, the company estimates the project to have saved approximately 4,000 tonnes of CO2. During the stadium’s construction, 8,000 precast concrete units were produced off-site and 72,000 tonnes of concrete made at the location. While details on the composition and method are sparse, the Ecocem company has delivered 20 million tonnes of its low-carbon cement to various projects.
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See Notes here