Cement producers pursue 'green' cement

Cement producers are increasingly focusing on sustainability initiatives to produce "green" cement, with several companies recently launching low-CO2 products or pursuing other projects with the goal of producing net-zero CO2 cement.

This push for green cement is driving cement makers away from petroleum coke and coal, kiln fuels that produce high amounts of CO2.

Cement makers have been increasing the amount of alternative fuels in their kilns for several years, and they do so especially when the price of traditional fuels like coke rise.

The world's largest cement maker, LafargeHolcim, is planning to double the recycling of materials to 100mn t, increase usage of green building materials and operate its first net-zero carbon cement facility by 2030.

"We have 52 projects in Europe to increase the use of alternative fuel, and they have actually a very high payback based on cheaper fuel, but also on saving on CO2 certificates," LafargeHolcim chief executive Jan Jenisch said.

In Europe, cement makers must purchase carbon credits as part of an emissions trading scheme. Jenisch is also encouraging higher CO2 prices, which would result in their projects having better returns.

LafargeHolcim sees huge demand for green products from consumers, not just in Europe where regulators have ambitious carbon reduction goals, but in the US and India as well.

"We want to have a green product offering in any of our markets, no matter if it's a mature market or emerging market," Jenisch said. "Even in emerging markets, people have big interest to have a good sustainability footprint."

Mexico-based multinational Cemex is also increasing its focus on sustainability and reducing CO2 emissions. The company is targeting a 35pc reduction in CO2 emissions in cement by 2030, and net-zero CO2 concrete by 2050.

Cemex's European region will reach the 35pc target by the end of this year — 10 years ahead of schedule — and net-zero CO2 concrete is already being offered in that region, chief executive Fernando Angel Gonzalez Olivieri said. He expects Europe to reach a 55pc reduction in CO2 by 2030.

"To deliver fully on our 2050 ambition, the industry will need to find new technologies that can be scaled easily," Olivieri said.

Cemex is currently participating in 20 projects worldwide with the goal of reducing CO2 emissions, including partnering with Swiss-company Synhelion to develop solar power technology that will replace fossil fuel use, and with UK-based Carbon Clean to develop low-cost carbon capture technology.

A pilot installation for Synhelion is expected by the end of 2022, and a carbon capture pilot will be conducted during the first quarter of 2021.

Fellow large multinational Heidelberg Cement has also stepped up research and development efforts in order to reduce its CO2 footprint. The company's Italcementi subsidiary has developed a lower CO2-content concrete paste, dubbed "i.tech 3D", for use in 3D printing applications. The technology is now being used to build Germany's first 3D-printed house.

Heidelberg is also pursuing carbon capture projects and has entered into a consortium with other European cement producers to turn captured CO2 into synthetic fuels.

Cutting their carbon footprint has become so important to these companies that they are in some cases willing to pay higher energy costs in order to reduce emissions, especially as they approach these target dates.

Although natural gas is usually more expensive than coal or coke, it has lower CO2 emissions. "We may even substitute coal by natural gas in order to reduce emissions, even if that costs a little bit more," Heidelberg chief financial officer Lorenz Nager said.

One way that companies are offsetting additional costs involved in producing greener cement is by marketing this cement under its own brands. Although the construction industry may be purely cost-focused, individual consumers are willing to pay a higher price for a greener product.

Lafargeholcim and Cemex have launched green labels to distinguish their reduced or net-zero carbon concrete and cements. Both are available in Europe and are or will be available in other regions soon.

"I think it's important that for those products, we are not waiting for regulation or for any new standards or something," Jenisch said. "We are really selling those products to the consumer who wants greener products. And there is quite a demand."

By Sarah Tucker