Could we have cracked one of the world’s toughest climate problems?

In a groundbreaking development towards achieving net-zero emissions in challenging industrial sectors, commercial-scale carbon capture systems for cement manufacturing are now being deployed. The world’s premier carbon capture plant within a cement facility has been operational in Norway since June, with plans to deliver the inaugural “zero-carbon cement” products to the UK and across Europe in the coming month, as confirmed by Heidelberg Materials, the plant’s owner based in Germany.

Additionally, the imminent construction of a carbon capture installation at the Padeswood cement plant in North Wales is set to commence shortly, following a subsidy arrangement finalized this week between the UK government and Heidelberg Materials. Similar projects are also in the pipeline for Sweden, Germany, and Poland.

This initiative marks a significant stride in decarbonizing the cement industry, recognized as a particularly challenging sector for emission reductions. Paul Fennell from Imperial College London commented, “It’s a good step forward,” reflecting on the promising endeavors in both Norway and the UK.

Cement production contributes approximately 8% of global carbon emissions, as reported by the think tank Chatham House. A substantial part of this carbon dioxide is generated by the chemical processes involved in creating clinker, the main component of Portland cement, which is the most prevalent type of cement utilized globally. “If you’re going to use ordinary Portland cement, this poses a challenge in terms of CO2 emissions from its intrinsic chemistry,” Fennell adds.

Therefore, capturing the carbon dioxide produced during cement manufacturing is widely considered the sole scalable method to reduce emissions in this area. However, the financial implications are significant, with estimates suggesting costs of €50-200 for capturing, transporting, and permanently storing each tonne of carbon generated in cement production in Europe, according to analysis from Dutch bank ING.

The Brevik plant in Norway, developed by Heidelberg, has benefited from governmental support. This carbon capture infrastructure effectively captures 50% of the cement plant’s total emissions by utilizing an ammonia-derived solvent known as amine, which extracts CO2 from exhaust gases. The extracted CO2 is subsequently liquefied and stored beneath the seabed.

Conversely, the upcoming Padeswood facility will adopt a similar amine-based approach, aiming to eliminate approximately 95% of the plant’s emissions by the time its carbon capture and storage system becomes operational in 2029. This reduction is anticipated to amount to around 800,000 tonnes of CO2 annually. Padeswood’s capacity to capture more carbon is facilitated by its access to additional energy resources required for enhanced efficiency compared to the Brevik plant.

Groundbreaking activities are anticipated to begin shortly, with the UK government committing to subsidize operational costs for this innovative technology, though specific details concerning the financial agreement remain undisclosed. Willis, the UK CEO of Heidelberg Materials, explains, “The fundamental principle is that the government is going to provide funding to assist in the construction and operation of a carbon capture facility.”

As emphasized by Leon Black from the University of Leeds, governmental financial support is critical for establishing the initial fleet of carbon capture and storage cement plants. “There is no feasible way for carbon capture and storage to become commercially viable without state backing,” he states.

Looking towards the future, there are optimistic prospects for lowering associated costs as emerging technologies enhance energy efficiency. In Germany, for instance, Heidelberg is collaborating with several companies to test oxyfuel technology, which recirculates exhaust gases back into the burner, significantly increasing the concentration of CO2 in the released exhaust gases, potentially reaching around 70%. This advancement could streamline the carbon capture process.