
Displaying items by tag: innovation
US: A research team led by the University of Michigan’s Charles McCrory, in collaboration with the University of California, Davis (UCD) and the University of California, Los Angeles, has developed a process to capture CO₂ and convert it into metal oxalates for use in cement production. The method uses electrodes to transform carbon dioxide into oxalate, which binds with metal ions and precipitates as a solid suitable for alternative cement. The researchers reduced the required lead catalyst to parts per billion by modifying the polymer environment around the catalyst, mitigating environmental risks. The researchers next want to focus on scaling up the process and are working on electrolysis on a large scale.
UCD associate professor Jesús Velázquez said “Metal oxalates represent an underexplored frontier – serving as alternative cementitious materials, synthesis precursors and even carbon dioxide storage solutions.”
Decarbonising in the US
04 June 2025A week ago, there were two fully-financed cement plant carbon capture, utilisation and storage (CCUS) projects underway in the US.1 Now, there aren’t.
Projects to decarbonise National Cement Company’s Lebec, California, plant and Heidelberg Materials North America’s Mitchell, Indiana, plant were each set to receive up to US$500m in US Department of Energy (DoE) funding on a one-for-one basis with private investments. The projects were to include eventual 950,000t/yr (Lebec) and 2Mt/yr (Mitchell) carbon capture installations. Additionally, the Lebec plant was to transition to limestone calcined clay cement (LC3) production and the use of alternative fuels (AF), including pistachio shells. Both were beneficiaries of the DoE’s US$6bn Industrial Demonstrations Program (IDP), touted by former US Secretary of Energy Jennifer Granholm as ‘Spurring on the next generation of decarbonisation technologies in key industries [to] keep America the most competitive nation on Earth.’ Disbursement of funding under the programme was frozen by executive order of President Trump in January 2025.2, 3
On 30 May 2025, Trump’s Secretary of Energy announced that the government in which Granholm served had approved spending on industrial decarbonisation without a ‘thorough financial review.’ He cancelled remaining project funding in signature Trumpian style, in list form.4 Among 24 de-funded projects, Lebec and Mitchell accounted for US$1bn (27%) of a total US$3.73bn in allocated funds that have now been withdrawn.
It's hard not to feel sorry for the management of the Lebec and Mitchell plant and the teams that had been working to deliver these projects. Heidelberg Materials has yet to comment, though CEO Dominik von Achten was in North America in late May 2025. National Cement Company parent Vicat, meanwhile, conceded the setback with a strong statement of its commitment to CO2 reduction, to 497kg/t of cementitious product globally.5 There was a diplomatic edge to the statement too, however. Echoing the Secretary of Energy, Vicat said that its target remains ‘solely based on existing proven technologies, including energy efficiency, AF substitution and clinker rate reduction’ – as opposed to ‘any technological breakthroughs’ like carbon capture. There are currently no public details of possible back-up financing arrangements for these projects; for now, the best guess at their status is ‘uncertain.’
Alongside these group’s local subsidiaries, another organisation that has to do business daily with the DoE is the American Cement Association (ACA). President and CEO Mike Ireland has continually acknowledged the complex needs of the government, while stating the association’s case for keeping support in place. With regard to these funding cuts, Ireland’s emphasis fell on the latter side: “Today’s announcement is candidly a missed opportunity for both America’s cement manufacturers and this administration, as CCS projects have long been supported by bipartisan members in Congress and bipartisan administrations.”6 He reasserted the ACA’s understanding that carbon capture aligns with the administration’s strategy to bolster domestic manufacturing and innovation.
The early 2020s heyday of US carbon capture was founded on gradual, consensus-based politics – unlike its demise. Table 1 (below) gives a non-exhaustive account of recent and on-going front-end engineering design (FEED) studies and the funding they received:
|
Capture target |
DoE funding |
Programme |
Amrize Florence7 |
0.73Mt/yr |
US$1.4m (52%) |
Fossil Energy Research and Development |
Amrize Ste. Genevieve |
2.76Mt/yr |
US$4m (80%) |
NETL Point Source Carbon Capture |
Ash Grove Foreman8 |
1.4Mt/yr |
US$7.6m (50%) |
Carbon Capture Demonstrations Projects Program |
Cemex USA Balcones9 |
0.67Mt/yr |
US$3.7m (80%) |
Fossil Energy Research and Development |
Heidelberg Materials North America Mitchell |
2Mt/yr |
US$3.7m (77%) |
Fossil Energy Research and Development |
TOTAL |
7.56Mt/yr |
US$20.2m |
N/A |
Additionally, MTR Carbon Capture, which is executing a carbon capture pilot at St Marys Cement’s Charlevoix plant in Michigan, previously received US$1.5m in Fossil Energy Research and Development funding towards a total US$3.7m for an unspecified cement plant carbon capture study.10
Market researcher Greenlight Insights valued industrial decarbonisation initiatives under the Office of Clean Energy Demonstrations (ODEC – the now defunct DoE office responsible, among other things, for the IDP) at US$65.9bn in cumulative returns in April 2025.11 The government has yet to publish any account of how it might replace this growth, or the 291,000 anticipated new jobs that would have come with it. Given all this (along with the extensive financial and technical submissions that accompanied each project), the issues raised by the DoE are presumably budgetary, or else founded in a perception of CCUS as essentially uneconomical.
Carbon capture is very, very expensive. A fatuous reply is that so is climate change, just with a few more ‘verys.’ Hurricane Ian in September 2022 cost US$120bn, more than enough to fund carbon capture installations at all 91 US cement plants, along the lines of the former Lebac and Mitchell agreements.12 Unlike climate change, however, carbon capture remains unproven. Advocates need to continually justify taxpayer involvement in such a high-risk venture.
At its Redding cement plant in California, Lehigh Hanson successfully delivered a funding-free FEED study, with its partner Fortera raising US$85m in a Series C funding. This presents an alternative vision of innovation as fully-privatised, in which the government might still have the role of shaping demand. This is borne out in the IMPACT Act, a bill which ‘sailed through’ the lower legislature in March 2025.13 If enacted, it will empower state and municipal transport departments to pledge to buy future outputs of nascent reduced-CO2 cements and concretes.
A separate aspect of the funding cancellation that appears decidedly cruel is the targeted removal of grants to start-ups. Two alternative building materials developers – Brimstone and Sublime Systems – were listed for a combined US$276m of now vapourised liquidity. Both are commercially viable without the funding, but the effect of this reversal – including on the next generation of US innovators who hoped to follow in their footsteps – can only be chilling. As non-governmental organisation Industrious Labs said of the anticipated closure of the ODEC in April 2025: “We may see companies based in other geographies start to pull ahead.”
Heidelberg Materials’s Brevik carbon capture plant came online in June 2025, 54 months after the producer secured approval for the project. The term of a presidency is 48 months. This probably means that producers in the US will no longer see CCUS as a viable investment, even under sympathetic administrations.
Even as government funding for CCS flickers from ‘dormant’ to ‘extinct,’ the sun is rising on other US projects. Monarch Cement Company commissioned a 20MW solar power plant at its Humboldt cement plant in Kansas on 27 May 2025. The global momentum is behind decarbonisation, even if economics determines that it will only take the form of smaller-scale mitigation measures at US cement plants into the medium-term future. We can hope that these, at least, might include the AF and LC3 aspects of National Cement Company’s plans at Lebec.
References
1. Clean Air Task Force, ‘Global Carbon Capture Activity and Project Map,’ accessed 3 June 2025, www.catf.us/ccsmapglobal/
2. Democrats Appropriations, ‘Issue 5: Freezing the Industrial Demonstrations Program Undermines U.S. Manufacturing Competitiveness and Strands Private Investment,’ January 2025, www.democrats-appropriations.house.gov/sites/evo-subsites/democrats-appropriations.house.gov/files/evo-media-document/5%20DOE%20Frozen%20Funding%20-%20Industrial%20Demos.pdf
3. Colorado Attorney General, ‘Attorney General Phil Weiser secures court order blocking Trump administration’s illegal federal funding freeze,’ 6 March 2025, www.coag.gov/press-releases/weiser-court-order-trump-federal-funding-freeze-3-6-25/
4. US Department of Energy, ‘Secretary Wright Announces Termination of 24 Projects, Generating Over $3 Billion in Taxpayer Savings,’ 30 May 2025, www.energy.gov/articles/secretary-wright-announces-termination-24-projects-generating-over-3-billion-taxpayer
5. Vicat, ‘Cancellation of funding agreement for the Lebec Net Zero project by the US Department of Energy,’ 3 June 2025, www.vicat.com/news/cancellation-funding-agreement-lebec-net-zero-project-us-department-energy
6. American Cement Association, ‘Statement from the American Cement Association on Department of Energy’s Cancellation of Clean Energy Grants,’ 30 May 2025, www.cement.org/2025/05/30/statement-from-the-american-cement-association-on-department-of-energys-cancellation-of-clean-energy-grants/
7. Gov Tribe, ‘Cooperative Agreement DEFE0031942,’ 30 September 2022, www.govtribe.com/award/federal-grant-award/cooperative-agreement-defe0031942
8. Higher Gov, ‘DECD0000010 Cooperative Agreement,’ 13 May 2024, www.highergov.com/grant/DECD0000010/
9. Gov Tribe, ‘Cooperative Agreement DEFE0032222,’ 7 February 2025, www.govtribe.com/award/federal-grant-award/cooperative-agreement-defe0032222
10. Higher Gov, ‘DEFE0031949 Cooperative Agreement,’ 1 May 2023, www.highergov.com/grant/DEFE0031949/
11. Center for Climate and Energy Solutions, ‘Jobs, Economic Impact of OCED Closure,’ 11 April 2025, www.c2es.org/press-release/oced-closure-could-cost-65-billion-290000-jobs/
12. National Centers for Environmental Information, ‘Events,’ accessed 4 June 2025, www.ncei.noaa.gov/access/billions/events/US/2022?disasters%5B%5D=tropical-cyclone
13. US Congress, ‘H.R.1534 - IMPACT Act,’ 26 March 2025, www.congress.gov/bill/119th-congress/house-bill/1534
India: The Department of Science and Technology (DST) has launched five carbon capture and utilisation (CCU) testbeds in the cement sector, forming a research and innovation cluster to help accelerate industrial decarbonisation. The five testbeds are collaborative industrial pilot projects between Indian research institutions and local cement manufacturers under a public-private partnership model. The testbeds aim to help India reach carbon neutrality by 2070.
Each testbed targets a specific CCU approach. Testbed 1, in partnership with JK Cement in Ballabhgarh, will be a pilot plant capable of capturing 2t/day of CO₂ and converting it into lightweight blocks and olefins through oxygen calcination. Testbed 2, by IIT Kanpur and JSW Cement, will explore CO₂ mineralisation. Testbed-3, with IIT Bombay and Dalmia Cement, will develop catalyst-based capture at a cement plant. Testbed-4, by CSIR-IIP, IIT Tirupati, IISc and JSW Cement, will use vacuum swing adsorption technology. Testbed-5, with IIT Madras, BITS Pilani Goa and UltraTech Cement, will focus on carbon-lowering process innovations.
Cimpor to launch research and development centre
07 May 2025Portugal: Cimpor will invest €155m in establishing a new research and development centre focused on sustainable construction, CO₂ reduction and digital transformation. The investment will also cover the modernisation of Kiln 7 at the producer’s Alhandra cement plant. The new centre will focus on technologies such as low-clinker cement development, carbon capture and alternative fuels, using recycled concrete and 3D printing. The building itself will incorporate calcined clay-based cement and recycled aggregates.
The new centre will create over 100 jobs and serve as a hub for collaboration with universities and startups, as well as serve as a location for conferences and workshops. The building will operate as a ‘living lab’, with real-time monitoring of its thermal and structural performance and energy consumption.
The chair of Cimpor Global Holdings, Suat Çalbiyik, said “In 2018, we operated only in Portugal and Cape Verde with around 1800 employees. Today, we are the world’s third-largest cement group… with 8000 employees in 14 countries and a production capacity of 112.5Mt/yr of cement.”
Global Cement and Concrete Association launches Innovandi Open Challenge 2025 for low-carbon concrete
21 February 2025Global: Global Cement and Concrete Association (GCCA) has launched the Innovandi Open Challenge 2025, inviting start-ups to wok together with cement manufacturers around the world in developing low carbon concrete technologies.
The Open Challenge is looking for start-ups working on next generation materials for net zero concrete, including low-carbon admixtures, supplementary cementitious materials, activators or binders. The challenge aims to find ways to reduce clinker use and incorporate new materials to lower CO₂ emissions.
The programme follows three previous Open Challenges.
Chief executive Thomas Guillot said "Advanced production methods which are decarbonising our sector are already being used in cement and concrete production in many parts of the world. Through the Innovandi Open Challenge, start-ups can bring in even newer ideas and further accelerate our industry's push."
“If you are a start-up from anywhere in the world with an innovative idea or technology, then we want to hear from you."
Start-ups can find more information and apply to take part in the Innovandi Open Challenge by going to the GCCA Open Challenge 4 webpage: Innovandi Open Challenge 4 : GCCA
Cemvision deploys low-carbon cement at UK’s Sunbury STOREX site
22 January 2025UK: Cemvision has launched one of the UK’s first commercial applications of its low-carbon Re-ment cement technology at a STOREX self storage development in Sunbury, near London. The foundational slabs for the site employ Cemvision's Re-ment Massive product, which replaces traditional Portland cement. Recent laboratory tests have shown that the product achieves a 75% CO₂ reduction and a 28-day compressive strength, that reaches the C50/60 classification, compared to traditional Portland cement. STOREX and Cemvision have signed a Letter of Intent for further collaboration in the UK and other markets.
“This project is a landmark achievement for Cemvision as we bring the benefits of green cement to UK customers,” said Oscar Hållén, CEO of Cemvision.
Cemvision says that its Re-Ment Massive technology reaches different levels of CO₂ reduction depending on application and local conditions, with the product already having achieved more than a 95% reduction compared to Portland cement in demo production in the EU, according to the company.
JK Cement signs MoU to support manufacturing industry
10 January 2025India: The Department for Promotion of Industry and Internal Trade under the Ministry of Commerce & Industry has signed a memorandum of understanding (MoU) with JK Cement to support startups, entrepreneurs and innovation in manufacturing. The partnership will provide access to JK Cement’s infrastructure, manufacturing and research and development facilities, mentorship programmes, pilot projects and university resources.
Indian startup develops ‘eco-friendly’ cement alternative
19 December 2024India: A Bangalore-based startup formed at the Indian Institute of Science (IISc) has developed an ‘eco-friendly’ cement alternative using geopolymer technology. The product claims to reduce CO₂ emissions by 21.5kg/m2 of pavers produced compared to ordinary Portland cement, according to The Economic Times. It also claims to eliminate water use and offer a 15-20% cost advantage. The product achieves full strength in just three days, compared to the 28 days required for Portland cement.
Nanjunda Rao, one of four cofounders of Novacret and chief research scientist at IISc, said “The benefits are significant, geopolymer-based materials achieve full strength in just three days in tropical climates like India, compared to the 28 days required for Portland cement.”
Azerbaijan: Cemex has won the Net-Zero Industries Award for its clinker decarbonisation process using concentrated solar power. The award was presented at COP29 in Baku. Cemex’s solar clinker project is a collaboration with cleantech company Synhelion, which developed the high-temperature solar heat technology it uses. Cemex and Synhelion partnered in 2019 and achieved the first successful production of solar clinker in 2022.
Davide Zampini, vice president of Global R&D at Cemex, said "Together with Synhelion, we are pioneering solar-powered clinker production, a breakthrough process that can contribute to decarbonising cement manufacturing."
UCLA team develops ZeroCAL to cut cement CO₂ emissions
15 October 2024US: Researchers at UCLA's Institute for Carbon Management have developed a new method called ZeroCAL that could eliminate ‘nearly all’ of the carbon dioxide emissions from the process of cement production, according to the UCLA Newsroom. The team created a process using limestone and a water-based solution containing ethylenediaminetetraacetic acid. Through membrane nanofiltration and an electrochemical process, they produced calcium hydroxide.
To meet ZeroCAL’s water demand, the team suggests focusing on cement plants near coasts or rivers. The researchers are reportedly working with Ultratech Cement to build a demonstration plant that will produce ‘several’ tonnes of lime per day using the ZeroCAL process. Currently, the process requires more energy than traditional lime production methods, but ongoing research aims to reduce its energy consumption.
Gaurav Sant, director of the Institute and professor at UCLA Samueli School of Engineering, said “The ZeroCAL approach offers an elegant solution to eliminate carbon dioxide emissions associated with the process of cement production. First, it addresses the carbon emissions resulting from limestone’s decomposition while providing clean hydrogen and oxygen to heat the cement kiln. Second, it enables onsite decarbonisation while making use of existing kilns and limestone feedstocks without having to build separate carbon capture and storage facilities.”