Electrification: a powerful path to decarbonising cement production

In 2022—the latest year for which there is data—global emissions from cement manufacturing reached 2.3 billion tons of CO?, driven by the production of more than 4 billion tons of cement¹. As one of the most carbon-intensive industries, and with growing demand, cement plays a vital role in construction but contributes significantly to global emissions, responsible for 8% of total emissions². Decarbonising this sector is critical to achieving net-zero goals, and electrification, especially if powered by renewable energy, offers a transformative solution to reshape the industry while enhancing sustainability, efficiency, and profitability.

Cement production emits CO? through both chemical and thermal processes. During calcination, limestone (CaCO?) is heated to around 900°C, releasing CO? as it decomposes into lime (CaO). This step contributes approximately 60% of total emissions. The remaining emissions come from burning fossil fuels to generate the extreme heat—up to 1,450°C—needed to produce clinker, the main ingredient in cement. 

Electrification, especially if powered by renewable energy, offers a transformative solution to reshape the industry while enhancing sustainability, efficiency, and profitability

Electrification reduces emissions from burning fossil fuels by replacing fossil fuels with electric heating powered by renewables. Technologies like electric kilns and precalciners can obtain the high temperatures required for cement production through electrified heat systems, without relying on fossil fuels, ensuring energy efficiencies often exceeding 90% and increased cement yields³. Electrified heat can also be used for the drying and preheating of raw materials and fuels used in clinker production, drying of cement constitutes like slag, and production of clinker replacements like calcined clay, further reducing carbon footprint and improving efficiencies.

Moreover, electric heating powered by renewables eliminates nitrogen and argon from exhaust gases, creating a purer CO? stream that lowers the cost and complexity of carbon capture and storage. While carbon capture remains essential to address emissions from calcination, electrification reduces reliance on outdated, inefficient fossil fuel systems. Together, these technologies create a powerful synergy to address the full spectrum of cement production emissions.

Unlike green hydrogen or biofuels, electrified systems avoid the infrastructure challenges and operational complexities associated with alternative solutions, minimising setup costs and risks. In fact, heating systems harnessing hydrogen gas can only offer a maximum of 60% energy efficiency. Therefore, as demand grows for low-carbon materials in the construction industry, electrification is emerging as a cornerstone of sustainable cement production.

Electrification is no longer a distant goal—it is becoming a reality across the cement industry. Pilot projects in Europe demonstrate the feasibility of electrified heating systems at scale, while leading manufacturers like CEMEX and UltraTech Cement are partnering with technology providers to integrate electric heaters into existing kilns. These hybrid systems allow manufacturers to cut emissions incrementally while maintaining production continuity. 

Innovative technologies that use renewable electricity to achieve the high temperatures required for clinker production offer energy efficiency, scalability, and compatibility with existing industrial systems. Such systems meet temperature demands and enable modular deployment, ensuring smoother integration into diverse production environments. If this technology is implemented throughout manufacturing sites globally, it is estimated to slash over a third of all industrial CO? emissions—1 billion tons in the cement industry alone⁴.

A collaborative path

The successful decarbonisation of the cement industry will require collective action. Partnerships between manufacturers, technology providers, and policymakers are crucial to scaling electrification solutions and accelerating their adoption. Policymakers can drive progress by offering financial incentives for renewable energy integration and electrification projects, while industry leaders must prioritise innovation and collaboration.

Unlike green hydrogen or biofuels, electrified systems avoid the infrastructure challenges and operational complexities associated with alternative solutions, minimising setup costs and risks

Economic benefits also bolster the case for electrification. Estimates show that decarbonising cement could unlock a €1 trillion market by transitioning to electric-powered systems and renewable energy sources⁵. Manufacturers that adopt these innovations will be at the forefront of this market, making themselves available to sustainability-focused investors. Electrification also minimisses maintenance costs and operational downtime, enabling manufacturers to boost output and profitability. As renewable energy becomes more affordable, and carbon pricing becomes stricter, electrified plants will gain a competitive edge over fossil fuel-dependent operations, ensuring long-term resilience and avoiding steep penalties.

Electrification offers the cement industry a viable pathway to a zero-carbon future. By leveraging renewable energy and advanced electric technologies, manufacturers can reduce their carbon footprint, align with international climate targets like the Paris Agreement, and secure a competitive advantage in a rapidly evolving market.

As highlighted at COP29, decarbonising heavy industries is both a necessity and an opportunity to redefine global manufacturing. Cement producers have the tools to transform their operations. Strategic investment in electrification technologies today will ensure the cement industry’s relevance and profitability in a carbon-conscious economy. The transition to electrification is no longer optional—it is the way forward to a cleaner, more sustainable future.

Pic: Coolbrook's RotoDynamic Technology at the pilot site in the Netherlands

References

1. https://www.weforum.org/stories/2024/09/cement-production-sustainable-concrete-co2-emissions/, https://www.google.com/url?q=https://www.iea.org/energy-system/industry/cement&sa=D&source=docs&ust=1734457300561776&usg=AOvVaw12MPmSU-UyCrkDWI-Mmp_4
2. https://www.weforum.org/stories/2024/09/cement-production-sustainable-concrete-co2-emissions/
3. https://www.forbes.com/sites/gauravsharma/2024/03/13/game-changing-electric-factories-will-reshape-heavy-industries-says-european-developer-coolbrook/
4. https://www.economist.com/science-and-technology/2023/06/07/a-finnish-firm-thinks-it-can-cut-industrial-carbon-emissions-by-a-third?utm_source=flipboard&utm_content=user%2FTheEconomist
5. https://ambientasgr.com/ambienta-sustainability-lens-electrifying-industrial-heat-a-trillion-euro-opportunity-hiding-in-plain-sight/