Digitally Decarbonising Cement

Cement production plays a crucial role in modern infrastructure. It drives the construction of buildings, roads, and bridges that support global economic development. However, this important industry also faces a major challenge: it is one of the largest industrial emitters of greenhouse gases, accounting for around 7 – 8% of global CO₂ emissions. As the world moves towards more sustainable practices, the cement industry must find innovative ways to balance growth demand with environmental responsibility. Two transformative trends, digitalisation and decarbonisation, will reshape the industry and provide new opportunities for efficiency, sustainability, and growth.

The cement production process: a short overview

The cement production process begins with the extraction of raw materials, such as limestone and clay, from quarries. These materials are then crushed and mixed to form a raw meal, which is fed into a kiln where temperatures exceed 1400°C. In this high-temperature environment, the chemical transformation known as calcination takes place, creating clinker, the main component of cement. The clinker is cooled and mixed with gypsum and other additives before being ground into the fine powder, known as cement.

Although the process is simple, it is very energy-intensive. The kiln phase, in particular, is responsible for the majority of carbon dioxide (CO₂) emissions in cement production, both through burning fossil fuels and the chemical reaction during the deacidification of limestone. One parameter that is often mentioned in this context is the specific CO₂ emission. This describes how much CO₂ is emitted during the production of one ton of cement. According to the German Emissions Trading Authority (DEHSt), the value in 2018 was around 0.59. This results in CO₂ emissions of 590 kg/t of cement. In 2018, a total of around 33.7 million t of the building material was produced in Germany.

In addition, the grinding and mixing processes consume significant amounts of electricity, making energy efficiency an important issue. Understanding these emission hotspots is the first step in addressing the environmental impact of cement production.

Current state of the cement industry

Globally, the cement industry is both a cornerstone of development and a major source of environmental setbacks. Demand for cement continues to rise, driven by urbanisation and the expansion of infrastructure in emerging countries. At the same time, the industry is under increasing pressure to reduce its environmental footprint. Regulatory frameworks like the UN SDGs or the EU taxonomy, consumer expectations from around the globe, and investor interest in sustainable investment are forcing companies to adopt more sustainable practices.

Challenges such as fluctuating raw material prices, complex supply chains, and strict emissions standards are making the industry's path more difficult. However, these challenges also offer opportunities for innovation and change. Companies that successfully navigate this environment can gain a competitive advantage while contributing to global climate goals.

Digitalisation in cement production

Digitalisation represents a paradigm shift in the way cement is produced, managed, and distributed. By using advanced technologies such as the internet of things (IoT), artificial intelligence (AI) and machine learning, companies can optimise their processes and improve sustainability.

Process optimisation is a key application of digital technology. Sensors embedded in equipment and pipelines – such as flow meters, temperature and pressure sensors, or high-end laser-sensor-systems like Yokogawa’s tunable diode laser spectrometers (TDLS) in combustion areas – gather real-time data on combustion gases to identify inefficiencies and reduce energy consumption while improving product quality. Predictive maintenance systems use AI to predict equipment failure, allowing companies to proactively address issues and minimise downtime.

Digital twins, virtual replicas of physical processes, allow operators to simulate and optimise production scenarios without interrupting actual operations. Systems like Visual MESA® Greenhouse Gas Emissions Management (VM-GEM), which, amongst other things, can autonomously control processes based on stoichiometric calculations while taking into account weather forecasts, market trends or things like supply/energy contacts, are valuable for improving energy efficiency while reducing waste. In addition, digital platforms are transforming supply chain management by increasing transparency, streamlining logistics, and reducing costs. These advances not only improve operational efficiency, but also set the stage for more sustainable practices, which Yokogawa can support with a huge range of solutions.

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Read the article online at: https://www.worldcement.com/special-reports/07032025/digitally-decarbonising-cement/