Cementing a Sustainable Future: Pathways to Decarbonization in the Cement Industry

Cement is fundamental to modern construction and infrastructure, forming the backbone of urbanization and industrial growth. As the world grapples with the urgency of climate change, this critical material – responsible for 7 percent of global CO2 emissions – presents both a challenge and an opportunity for fugitive emissions and decarbonization. With projections of substantial urban population growth by 2050, the demand for cement will only increase, making it imperative for the industry to lead the charge toward sustainability.

Concrete, made from cement, aggregates, sand, and water, is the second most widely used material in the world after water. 90 percent of its carbon footprint comes from cement production. As such, the cement industry occupies a pivotal role in the global effort to mitigate climate change. However, decarbonization of cement production is fraught with complexities, from inherent emissions tied to calcination to the industry’s heavy reliance on fossil fuels.

By Bodil Recke, Global Manager, Business Unit Cement, ABB Process Industries

To achieve the needed transformation, technological innovation and collaboration across the value chain are vital. As an industry, we must come together to realize the potential of collaboration while examining both the obstacles to decarbonization and the potential pathways to reducing the cement industry’s environmental footprint.

The collaboration imperative

Decarbonizing cement production requires collective action from producers, technology providers, policymakers, and end-users. Impelling these diverse stakeholders to march to the same drumbeat is no small feat. Collaboration in this context involves pooling resources, sharing knowledge, and fostering innovation.

A major player like ABB partnering with cutting edge tech companies like Captimise, Coolbrook, CarbonRe and SaltX Technology exemplifies this approach. By combining ABB’s expertise in electrification, automation, and digital solutions with partners’ innovations in carbon capture, utilization, and storage (CCUS) and alternative heating technologies, they demonstrate how shared goals can help drive substantial progress. The integration of digital tools designed to optimize operations while fostering partnerships aimed at bringing the latest innovations in technology to market further highlights the benefits of collaborative efforts.

Decarbonization pathways

Electrification

Electrification is pivotal in reducing emissions during the cement pro duction process. Creating a cohesive system of operations and processes is essential. Technologies like Coolbrook’s RotoDynamic Heater and SaltX’s Electric Arc Calciner replace traditional fossil fuel-based heating methods with electric alternatives, cutting CO2 emissions significantly. These solutions also integrate seamlessly with electrified automation systems, enhancing process control and scalability.

The RotoDynamic Heater, for instance, replaces conventional fossil fuel burners in kilns with electrically powered heating solutions, addressing one of the major sources of emissions in cement manufacturing. SaltX’s Electric Arc Calciner offers a complementary technology, using electric plasma to achieve the high temperatures required for cement precalciners and kilns. These innovations represent a leap forward in electrifying high-temperature processes traditionally reliant on carbon-intensive fuels. In addition to equipment, digitalization plays a critical role. Great leaps have been taken in developing technology that helps facilities optimize their energy consumption by aligning operations tasks with periods of lower energy costs, further reducing emissions and operational expenses. Automation and predictive maintenance systems are also increasingly adopted to reduce energy wastage and improve operational efficiency.

Carbon capture, utilization, and storage

CCUS is essential for addressing fugitive emissions from calcination, a chemical process inherent to cement production that accounts for approximately 50 percent of its CO2 emissions. Major players like ABB are collaborating with tech companies to enable cement producers to evaluate and adopt the most suitable CCUS technologies for their specific operations. A tech company like Captimise provides independent comparisons of over 25 carbon capture methods. Fugitive CO2 emissions, captured from kiln flue gases using CCUS technologies, can also be utilized in chemical production or stored in geological formations. Norwegian oil companies, for example, have successfully implemented carbon capture since the 1990s, storing millions of tons of CO2 annually. For the cement sector, widespread adoption of CCUS could mitigate a significant portion of emissions.

Flexibility for future technological advancements is another benefit offered through the adoption of CCUS. As global infrastructure for CO2 transport and storage expands, cement facilities equipped with CCUS will be positioned to adapt, making it a forward-looking investment for the industry. Collaborative projects, like ABB’s partnership with Captimise, also provide practical frameworks for scaling these technologies across diverse geographies.

Alternative materials and fuels

Reducing clinker in cement and incorporating supplementary materials like fly ash, calcined clay, recycled concrete, slag, and pozzolans, can lower emissions. These materials not only decrease the carbon footprint of cement but also enhance its performance in specific applications. However, regulatory constraints often limit the use of these alternatives. Industry leaders are advocating for performance-based standards to replace ingredient-focused regulations, enabling the broader adoption of low-carbon blends.

Fuels derived from biological or municipal waste present another opportunity to replace fossil fuels in kilns. While this approach reduces emissions, it introduces sustainability challenges related to waste management and transportation. Integrating these fuels requires robust regulatory compliance and community engagement. Examples from the industry demonstrate that successful implementation often hinges on fostering community trust and aligning waste processing infrastructure with industrial needs.

Ongoing innovations in bio-based fuel technology are expanding the options available to cement producers. By leveraging advances in waste-to-energy systems, the industry is making strides towards reducing dependence on fossil fuels and achieving long-term energy security.

Methodologies for collaboration

To motivate change and ensure collective action, several strategies emerge, one of which is the importance of building trust and transparency. This can be affected by open communication among stakeholders. ABB acts as a neutral facilitator, bridging gaps between manufacturers, technology innovators, and policymakers. This approach accelerates technology adoption and aligns efforts towards shared goals. Transparent reporting on progress and outcomes also strengthens credibility and motivates further collaboration.

To support this, there must be a switch towards standardized definitions and metrics. The lack of a universal definition for sustainable cement hinders progress as we focus on the ‘what’ instead of the ‘how’. Collaborative efforts, such as those led by the Global Cement and Concrete Association (GCCA), aim to establish common standards and performance-based specifications to replace ingredient-focused regulations. Such standards will enable producers to innovate while ensuring product integrity.

Alongside industry-wide understanding and standardized definitions is the necessity for knowledge sharing and training. Education plays a vital role in fostering innovation and collaboration. Sharing best practices and providing training for industry professionals ensures that new technologies are implemented effectively and sustainably. Partnerships between technology providers and academia can also drive research and development efforts, creating a pipeline of future solutions.

However, we must also address the financial barriers. Decarbonization technologies often entail high upfront costs. Governments, industry groups, and companies must work together to create financial incentives, such as carbon pricing, subsidies, and tax credits, to make sustainable solutions economically viable. Without these mechanisms, the widespread adoption of transformative technologies remains out of reach. Innovative financial models, such as shared investment in carbon transport infrastructure, could also accelerate progress.

Resilience in the face of change

One significant obstacle to decarbonization is the variability in government policies and standards. Shifting regulatory landscapes can create uncertainty, potentially allowing companies to backtrack on their commitments. Proactive engagement with policymakers and flexible strategies are essential to navigate these challenges.

In addition, outdated specifications that mandate high clinker content in cement blends prevent the adoption of greener alternatives, emphasizing the need for global performance-based standards. Such standards would allow innovative materials to compete fairly while meeting or exceeding structural benchmarks.

These challenges highlight the importance of adaptive management within organizations. Cement producers must remain agile, investing in flexible technologies and building long-term partnerships that can weather policy fluctuations. Industry-wide resilience requires a shared commitment to maintaining momentum, even when up against external pressures.

Broader implications for Scope 1 and 2 emissions

Cement’s environmental impact extends beyond its industry. Every sector that builds infrastructure relies on cement, making its decarbonization critical for reducing Scope 1 and 2 emissions across the board. The construction of renewable energy facilities, urban housing, and transportation infrastructure depends heavily on concrete. Any progress in the cement industry will therefore have immense benefits for achieving broader climate goals.

For instance, wind turbine foundations and hydroelectric dams rely on large quantities of concrete. Decarbonized cement could significantly lower the lifecycle emissions of these renewable energy projects. This ripple effect underscores why cement must be a priority in global climate strategies.

By adopting sustainable cement practices, industries reliant on construction materials can enhance their overall environmental performance. Incorporating low-carbon cement in building designs and infrastructure projects is an actionable step towards aligning with global sustainability targets.

Paving the way together

The cement industry’s decarbonization journey highlights the power of collaboration and innovation. By embracing electrification, CCUS, alternative materials, and shared goals, the sector can achieve meaningful progress.

The commitment of companies like ABB to advancing automation, electrification, and digitalization ensures that the cement industry has the solutions and tools needed to navigate its sustainability challenges. As the industry strives to meet net-zero targets by 2050, the lessons learned here can inspire other industries to adopt similar approaches. Through collective effort, the cement industry can lay the foundation for a sustainable future, contributing to global climate goals while continuing to build the world around us.

REFERENCES

1. https://www.worldcementassociation.org/about-us/
2. https://medium.com/extantia-capital/green-concretebuilding-a-solid-future-b744c283bfc9 sustainability
3. https://www.deloitte.com/uk/en/issues/climate/zeroin-on-scope-1-2-and-3-emissions.html