Can We Solve One of the World’s Most Critical Climate Challenges?

Commercial carbon capture systems for cement facilities are currently being rolled out, signaling a potential turn towards net-zero emissions for one of the most challenging sectors in the industry.

As reported by German company Heidelberg Materials, the inaugural carbon capture cement plant has been operational in Norway since June, with the first “carbon cement” products slated for delivery to the UK and other European countries next month.

In tandem, construction of carbon capture infrastructure at the Padeswood cement plant in North Wales is set to commence shortly, following a subsidy agreement revealed this week between the UK government and Heidelberg representatives. Several similar facilities are also in the pipeline for Sweden, Germany, and Poland.

This advancement represents a critical leap forward in the cement industry’s quest to cut emissions, a long-recognized hurdle in decarbonization efforts. “That’s significant progress,” states Paul Fennell of Imperial College London, referring to the projects in Norway and the UK.

Cement contributes to roughly 8% of global carbon emissions, according to Chatham House, a think tank. Much of this carbon dioxide is emitted by the chemical processes that create clinkers, the primary component of Portland cement, the most widely used construction material. “Regular Portland cement production inherently generates substantial CO2 due to essential chemical reactions,” Fennell explains.

Capturing CO2 generated from these processes is regarded as the only viable option for significantly decarbonizing cement production. Yet, this method is costly, with estimates ranging from 50-200 euros needed to capture, transport, and permanently store large amounts of carbon from European cement operations, as outlined in an analysis by the Bank of Netherlands here.

The Brebik plant in Heidelberg, Norway, benefits from government subsidies. Its carbon capture infrastructure accounts for 50% of the cement facility’s overall emissions. It operates by removing CO2 from the exhaust of cement plants using an ammonia-based solvent known as amines. The extracted CO2 is then released from the solvent, liquefied, and stored beneath the seabed in Norway.

The Padeswood Plant employs similar amine technology, but when the carbon capture and storage systems become operational in 2029, it is projected to eliminate around 95% of the plant’s emissions, according to the UK CEO of Heidelberg Materials, Simon Willis. This translates to approximately 800,000 tons of CO2 annually. The Padeswood facility is anticipated to sequester more CO2 than the Brevik plant, but that is largely due to the lack of additional energy supplies required to achieve the 95% reduction at Brevik.

Construction is expected to start in the coming weeks, with the UK government agreeing to subsidize the operational costs of the technology—although details of this funding agreement remain undisclosed. “The fundamental premise is that the government is providing us with funds to assist in establishing and operating carbon capture facilities,” Willis states.

According to Leon Black from the University of Leeds, UK, government financial backing is crucial for constructing the initial fleet of cement plants focused on carbon capture and storage. “Carbon capture and storage would not be feasible without governmental aid,” he asserts.

However, emerging technologies hold the promise of enhanced energy efficiency, and costs are anticipated to decrease over time. In Germany, for instance, Heidelberg is collaborating with a consortium exploring Oxifuer technology, which involves recirculating exhaust gases back to the burner, increasing the CO2 concentration in exhaust gases to around 70%, thereby making the carbon capture process more efficient.