Displaying items by tag: demonstration

Canada/Greece: Titan Group and Carbon Upcycling Technologies have entered into a memorandum of agreement to explore the commercial deployment of Carbon Upcycling’s technology for producing local, low-carbon building materials. Carbon Upcycling will conduct feasibility studies at two Titan cement plants, with the aim of producing supplementary cementitious materials using captured CO₂ and local materials.

Carbon Upcycling’s demonstration plant is currently operating in western Canada, and the company is now developing its flagship commercial-scale project in eastern Canada.

US: Queens Carbon has secured US$10m in seed funding to scale up production of its novel cement and supplementary cementitious materials (SCMs). The start-up will build a 2000t/yr demonstration plant at strategic partner Buzzi Unicem USA's Stockertown, Pennsylvania, cement plant. The plant will demonstrate Queens Carbon’s low-energy Q-Reactor technology, which employs novel hydrothermal chemistry, with the help of steam and pressure, to combine standard cement feedstocks into carbon-neutral hydraulic cement and SCMs. The company’s flagship product, Q-SCM, is capable of replacing up to 50% of cement in concrete mixes. Queens Carbon says that it will now also begin preparations for its first full-scale commercial plant.

Buzzi Unicem USA was among investors in the seed funding round, led by Climate technologies investor Clean Energy Ventures, with participation from fellow venture capital firm Plug and Play.

Queens Carbon CEO Daniel Kopp said "With support from Clean Energy Ventures, Buzzi Unicem USA and the US Department of Energy, we're building next-generation technology and assembling the creative talent needed to drive industry revenues to move cement innovation forward and significantly reduce CO₂ emissions from cement production, all without a green premium."

Luigi Buzzi, Chief Technology Officer at Italy-based Buzzi, said "We know that achieving our goal of net-zero carbon emissions by 2050 demands forward-thinking solutions to enhance both our operations and our environmental performance.”

UBE Mitsubishi Cement recently released an update on its commercial scale demonstration using ammonia as a fuel at its Ube plant. It is currently testing the use of ammonia in both the cement kiln and calciner at the site. It has set the aim of reaching a 30% coal substitution rate with ammonia in the cement kiln by the end of March 2025. It has described the project as a world first. Planned future work includes running ammonia combustion tests alongside post-consumer plastics.

The company announced the three-year project in mid-2023. Utilities company Chubu Electric Power has been working on it and UBE Corporation has been supplying the ammonia for the test. The scheme dates back to before Mitsubishi Materials and Ube Industries merged their cement businesses in 2022. Ube Industries previously took part in a government research project looking at the topic, running combustion tests and numerical analysis in small industrial furnaces.

Another ammonia research project in the cement sector was revealed in 2024 by Heidelberg Materials in the UK. The company was awarded just under €0.40m in funding by Innovate UK through its UK Research and Innovation (UKRI) fund, together with engineering consultants Stopford and Cranfield University. The 12-month feasibility study aimed to assess the use of ammonia as a hydrogen carrier and evaluate the most economical method of on-site ammonia cracking to generate hydrogen for use by clinker kilns. It also intended to investigate the various tiers of the UK's existing ammonia supply chain network for the suitable transportation, offloading and storage of ammonia.

The UK project explained that it was looking at ammonia as a hydrogen carrier due to its high volumetric energy density. This, potentially, makes ammonia easier and cheaper to store and transport than hydrogen. It pointed out that storing and transporting hydrogen is difficult and the chemical is expensive. It also noted that the volumetric energy density of ammonia is 45% higher than that of liquid hydrogen. The benefit of switching to a zero-carbon fuel was that it could cut CO₂ emissions by the cement and concrete sector in the UK by 16%.

The attraction of ammonia to the cement industry is similar to that of hydrogen. Both are versatile chemicals that can be produced and used in a variety of ways. The production processes and supply chains of both chemicals are linked. The Haber–Bosch process, for example, uses hydrogen to manufacture ammonia. It can also be cracked to release the hydrogen. When used as fuels neither release CO₂ emissions directly. This comes down to the method of production. Like hydrogen, there is a similar informal colour scheme indicating carbon intensity (Grey, Blue, Green and Turquoise). Despite the advantages listed above, the disadvantages of using ammonia include toxicity and NO_x emissions, as well as the fact that there is little experience of using ammonia as a fuel. The worldwide ammonia market was bigger by volume in 2023 with production of just under 200Mt compared to hydrogen production of just under 100Mt.

Back in Japan, the national government has been promoting the use of ammonia technology for the power generation sector. It added ammonia to the country’s national energy plan in the early 2020s following research on running power plants with a mixture of ammonia and coal. The ambition is to build up levels of ammonia co-firing at power plants, develop the necessary technology and grow supply chains. This, it is hoped, will broaden, diversify and decarbonise the domestic energy mix and pull together a new international market too. Unfortunately, this strategy has had criticism. One study by BloombergNEF in 2022 estimated, for example, that the electricity cost of Japan-based power stations switching to firing ammonia by 2050 would be more expensive than generation from renewables such as solar or wind.

This explains why the ammonia project by UBE Mitsubishi Cement is leading the way. The interest by a European cement company shows that others are thinking the same way too. Yet again, the potential decarbonisation solution for cement is likely to lead towards more complex industrial supply chains. The next steps to watch will be whether a cement plant in Japan actually starts to co-fire ammonia on a regular basis and if any more ammonia projects pop up elsewhere around the world.

Japan: Mitsubishi UBE Cement Corporation has started a commercial-scale demonstration test using ammonia as a heat energy source in a cement kiln and calciner at Ube cement plant.

The project, supported by Yamaguchi Prefecture’s 2023 Carbon Neutral Complex Development Promotion Subsidy, follows an ammonia co-combustion test in 2023. In collaboration with UBE Corporation, a test facility for ammonia co-firing was installed.

The company has set a target of replacing 30% of its coal consumption with ammonia in the cement kiln, with similar levels targeted for the calciner by the end of the 2025 financial year. Mitsubishi UBE Cement is also planning further ammonia combustion tests with post-consumer plastics and other materials as energy sources.

Lithuania: Capsol Technologies has commenced its first CapsolGo demonstration campaign at the Akmenės Cementas plant in Lithuania, owned by Schwenk, to evaluate its carbon capture technology.

Schwenk plans to test Capsol’s technology at two cement plants, with a combined CO₂ capture potential of 1.5Mt/yr. Following the demonstration campaign at the Akmenės plant in Lithuania, the CapsolGo unit will be transferred to Schwenk’s Brocēni cement plant in Latvia, where a feasibility study was conducted in 2024.

Germany: Capsol Technologies has signed a cooperation agreement with Holcim to deliver a CapsolGo carbon capture demonstration campaign at Holcim’s Dotternhausen plant in southern Germany. The CapsolGo campaign will test Capsol’s carbon capture technology using its hot potassium carbonate (HPC) solvent. Capsol Technologies will provide the demonstration as a turnkey solution, including testing and validation to supply critical data and insight into the technology.

Dieter Schillo, plant manager of Holcim (Süddeutschland), said “The CapsolEoP (End-of-Pipe) unit’s design, requiring no external steam supply and exhibiting low energy consumption, makes it an attractive option for our Dotternhausen plant.”

If successful, Holcim plans to deploy Capsol’s technology across multiple cement plants globally. This builds on a feasibility study conducted by Aggregate Industries UK, a Holcim subsidiary, for the Cauldon cement plant in Stoke-on-Trent. Testing at Dotternhausen will run for four months, starting in the second quarter of 2025.

India: UltraTech Cement has entered a collaboration agreement with the Institute for Carbon Management (ICM) at the University of California (UCLA) to develop new technology that aims to reduce carbon dioxide emissions from cement production. The partnership will see the construction of a demonstration plant at one of UltraTech's integrated cement plants. Further details on the technology are available in Global Cement’s news story from 15 October 2024.

Latvia/Lithuania: Capsol Technologies has won a contract to carry out two CapsolGo carbon capture demonstration campaigns at the Brocēni cement plant in Latvia and the Akmenės Cementas cement plant in Lithuania. Both plants are owned by Germany’s Schwenk Zement. Following a feasibility study earlier in 2024, the demonstrations will run from the fourth quarter of 2024 to the fourth quarter of 2025 and will showcase the CapsolEoP capture technology.

Philipp Staggat, chief product officer of Capsol Technologies, said "CapsolEoP offers lower energy consumption with higher CO₂ concentration than competitive technologies, and the capture cost for cement owners is reduced further as it doesn't require external steam supply. We are looking forward to demonstrating our technology on Schwenk's cement plants.”

CEO of Akmenės Cementas, Arturas Zaremba added "In collaboration with our clients and stakeholders, we are dedicated to addressing these challenges. The implementation of CapsolEoP technology at our Latvian and Lithuanian plants is a testament to our commitment, marking a significant stride towards the goal of capturing over 1.5Mt/yr of CO₂.”

Australia: Woodside Energy and Cemex have invested US$6.7m in Melbourne-based KC8 Capture Technologies to support its efforts in achieving net zero emissions via carbon capture and storage.

KC8 is partnering with Cement Australia to construct a commercial demonstration plant in Gladstone, Queensland, aiming to capture 15t/day of CO₂. A partnership with Cemex aims to capture over 100t/day of CO₂ at one of its major plants. Additionally, KC8 plans a commercial pilot at the US Department of Energy’s National Carbon Capture Centre to capture 10-15t/day of CO₂ from natural gas combustion flue gas. The initiative has also secured US$6m from Low Emission Technology Australia and US$11.26m from the US government.

Executive director Greg Ross said "The funds will be used to expand KC8’s team and expedite deployment of its technology into hard-to-abate industries, such as cement – through a number of key projects."

Germany: Calix's subsidiary Leilac and Heidelberg Materials have formed a joint venture to build the Leilac-2 low emission cement demonstration plant at Heidelberg's Ennigerloh facility. Construction is set to begin in 2025, with the plant's commissioning scheduled for mid-2026. The Leilac-2 plant will showcase a module capable of capturing up to 100,000t/yr of CO₂ emissions from cement and lime production. Following construction and commissioning, Leilac-2 will be operated for up to three years to test the performance of the technology.

The project benefits from €16m in funding from the EU's Horizons 2020 programme and contributions from partner cement companies. Following construction, Heidelberg Materials may repay Leilac's capital contribution, and the partners will consider a full-scale commercial installation of Leilac technology at a Heidelberg plant. Plans for Leilac-3 envisage a significantly increased capture capacity, potentially capturing 0.5–1Mt/yr of CO₂.

Leilac CEO Daniel Rennie said "The formation of a joint venture with Heidelberg Materials for the Leilac-2 plant marks another important milestone for commercialisation of the Leilac technology. We look forward to continuing to collaborate with Heidelberg Materials to demonstrate and deploy cost-effective solutions to decarbonise cement production at commercial scale.”