Alpacem aims to save 21 000 t of CO2 at the Wietersdorf cement plant

With the modernisation programme ZEUS (strengthening cement grinding in an energy-efficient and environmentally friendly way), which is to be implemented by the beginning of 2027, modern production concepts will be implemented in the Wietersdorf cement plant. The aim is to reduce the CO₂ footprint of Alpacem products, increase energy efficiency and relieve the strain on the power grid. Alpacem is hoping to achieve a reduction of 21 000 tpy of CO₂. The company is investing around €50 million in the site, thereby underlining the importance of the Wietersdorf cement plant within the Alpacem Group.

"With the ZEUS project, we are investing in a sustainable future for the Alpacem site in Wietersdorf and are laying the foundation for energy-efficient and environmentally conscious cement grinding. This is not only an investment in the cement plant in Wietersdorf, but also in the entire region. Around half of the investment volume of €50 million remains directly in the region by commissioning local companies. In this way, we are creating added value locally and securing regional jobs", explained Florian Salzer, technical director of Alpacem Zement Austria.

Energy-efficient and environmentally conscious cement production

The precursor of every type of cement is cement clinker. This is produced by burning limestone at high temperatures – also known as deacidification. During deacidification, CO₂ that is bound in the limestone is released, therefore accounting for 60 – 70% of CO₂ emissions in the manufacturing process. In order to produce low-emission cements, it is important to reduce the clinker content in the finished product and replace it with alternative grinding materials.

The core of the modernisation programme is therefore a new cement grinding plant, which is to be implemented in three project stages. In project stage 1, a new plant configuration with two storage silos as the core will be built, which will, in the future, take over the pre-grinding and drying of some of the clinker-saving additives. It will operate using the waste heat from the clinker kiln. This sub-project is currently being approved by the relevant authority and is scheduled to go into operation in the first half of 2025 – depending on the approval process.

Project stage 2 includes the construction of a cement silo plant. The focus here is on increasing storage capacity. This will ensure that green energy can be used optimally. Increasing storage capacity also allows for more flexible production planning, which in turn relieves the load on the power grid. The cement silo plant is also equipped with a modern rail loading system in order to make greater use of this transport route in the future. Completion is planned for 2026.

The commissioning of the new cement mill in project stage 3, which is planned for 2027, will enable more efficient production of low-emission cement. It will also bring further flexibility in production planning.

Compass points towards CO₂ neutrality

The ZEUS project is part of a 3-phase plan by Alpacem, which aims to make cement production CO₂-neutral by 2035. In phase 1, the focus is on exploiting known technologies that should lead to a reduction in CO₂ emissions. The modernisation programme presented here is part of phase 1. After implementation of the ZEUS project in Wietersdorf, around 21 000 tpy CO₂ will be saved. The electricity requirement will be reduced by around 7800 MWh. This corresponds to a 10% energy saving in the Wietersdorf cement plant. In addition, the natural gas requirement will also fall by more than 400 000 m³.

"Alpacem has a clear goal: CO₂-neutral production by 2035. To achieve this ambitious goal, we need a package of measures and a concrete path, which we have set out in our 3-phase plan. Reducing the clinker content through modern, energy-efficient technologies is an effective measure to save CO₂ emissions in cement production. We have therefore made an investment volume of around €50 million available at the Wietersdorf site to take another step closer to our goal of CO₂ neutrality", said Alpacem Zement Austria Managing Director Lutz Weber.

The ZEUS project complements the measures already implemented at the Wietersdorf cement plant. For example, fossil fuels are being replaced by low-CO₂ fuels, electricity is being produced from the plant's own hydropower and the proportion of alternative raw materials is being continuously increased. All of these measures are part of the 3-phase plan.

 

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