How can the cement industry deploy CCUS at scale on the road to net zero?

CCUS is a key part of decarbonisation strategies across the cement industry. But so far, deployment is falling short.

Cement producers know the importance of CCUS. But that doesn’t mean applying and integrating carbon capture into their operations is straightforward. In many cases, the challenge lies in not knowing where to start.

Finding the optimal technology solutions

Technology selection is a common complexity. Carbon capture technologies – from amine scrubbing to membrane-assisted CO₂ separation – have widely differing costs, risks, energy demands and effects on manufacturing. Some can seamlessly slot into existing production processes while others are only suitable for new build plants.

Carbon capture technologies must also be chosen and configured to maximise ease of adoption. Factors such as the availability of water supply, steam and electricity, and nearby CO₂ storage capacity must be considered. Storage and transportation options also vary from site to site based on the proximity to infrastructure such as CO₂ pipelines or storage hubs.

At Worley, we adopt a technology neutral approach to ensure the optimal mix of CCUS solutions. For cement, this is customised to each plant’s production processes, flue gas compositions, energy use, physical layout and proximity to transportation and storage infrastructure.

Optioneering is also essential for finding the most efficient and cost competitive solutions for each cement plant.

Forming partnerships to make CCUS projects viable

To deploy CCUS at scale, the cement industry will have to transform the way it collaborates with other industries and break down traditional silos between sectors and disciplines.

Instead of a carbon capture unit operating in isolation from the rest of the production process, all relevant specialisms must be brought together at the design phase. To ensure a holistic implementation considering all the costs and risks.

Utilising shared infrastructure would reduce collective costs while helping to scale CCS delivery faster. For example, cement players could share existing infrastructure with the oil and gas or power sectors to repurpose pipelines, wells and depleted reservoirs for CO₂ transportation and storage.

In other locations, it might mean forming industrial clusters to create centralised hubs. These hubs could see industrial emissions captured at a large scale, and then efficiently transported and stored. Not only reducing collective carbon footprints but bolstering the long-term business case for the stakeholders. Potentially safeguarding against potential future increases in carbon pricing.

At Worley, we’re partnering with Mitsubishi Heavy Industries (MHI) Group to help develop the first carbon capture-enabled cement works in the UK at Heidelberg Materials’ cement plant in Padeswood, North Wales. This is one of several carbon capture projects we’re collaborating with MHI Group on and is also a key establishing project within the HyNet industrial cluster.

This is a key example of the bringing together of cross sector expertise. And signals the growing movement towards industrial clusters in helping to accelerate the deployment of CCUS projects for decarbonisation.

Commercial challenges for decarbonized cement

It’s still unknown whether global market demand for lower carbon cement will support the increased cost of production. The cost of cement production is about US$30 – 80/t unabated, and about US$60 – 130/t decarbonised, roughly double the price.

Under the European Union Taxonomy, three-quarters of cement plants in the EU are at risk of not aligning with the emissions criteria for sustainable activities risking their licenses to operate and future commercial viability.

In the UK, the cement industry currently receives CO₂ allowances for free, but under anticipated reform, at least half of those will need to be paid by 2030. The phase out of the free allowances is scheduled to begin in 2026, and it's estimated that the cumulative cost to the cement industry by 2030 could total €13 billion.

But the good news is that eventually, economies of scale balance out.

If we look at the power sector, the price of solar power has decreased by almost 90% in the last decade. Beyond 2030, the cost of carbon capture is projected to decrease significantly due to an increase in operational CO₂ storage hubs, efficiencies in capture capacity, and advancements in modularized design approaches.

A path forward

While carbon capture may remain an expensive option, for the cement industry, it’s the only tried, tested and available decarbonisation pathway.

Cement will play a vital role in building the infrastructure and energy systems needed for a net zero world. So as demand continues to grow, decarbonisation of the cement industry must remain a priority. And accelerating the adoption of CCUS across cement production alongside it.

Cement is your expertise – CCUS is ours

At Worley, we’ve delivered over 350 carbon capture, transport, storage and utilisation projects and studies to date. From concept to execution, our customers benefit from a full value chain experience and an integrated service for consulting, engineering, fabrication and construction. And with over 100 CCUS subject matter experts and six CCUS communities of excellence, we help our cement customers around the world conquer the complexities of CCUS.

Learn more: https://comms.worley.com/decarbonizing-the-cement-industry-with-ccus

Read the article online at: https://www.worldcement.com/special-reports/03062024/how-can-the-cement-industry-deploy-ccus-at-scale-on-the-road-to-net-zero/