Carbon capture, utilisation and storage (CCUS) is the lynchpin for the cement industry’s net zero hopes. But while you’re developing your carbon capture investment plans, you should also prepare your process to optimize the overall approach.
Carbon capture technologies are highly energy-intensive. These energy demands – whether thermal or electrical – can double the existing energy consumption of your cement plant. This equates to high ongoing OPEX costs in addition to the high CAPEX costs of installing a carbon capture plant. But there is potential to reduce this energy demand with a few relatively small modifications to your pyro process.
Our CCUS optimisation service helps prepare your plant for successful carbon capture. We’ll identify the simple, low-risk modifications to your pyro system that can increase the consistency of your gas flow rate and the concentration of CO2 within the process, so you can reduce the CAPEX and OPEX of a capture plant. At the end of this project, we will outline the site-specific modifications/improvements you can implement for best results.
We’ll use our proprietary process simulation tool to model the modifications and results and even save the plant model for future reference. Therefore, if you decide you want to make further process changes, for example O2 enrichment, H2 firing, alternative fuel change, etc. you can evaluate the impact on the process and on your carbon capture plant.
After optimisation, the amount of CO2 to be captured will be the same. However, the CO2 concentration in the flue gas to the carbon capture unit will increase – making the process more efficient. As a result, the cost of capture will be reduced by 15 – 20%, depending on your specific energy costs – a saving that could equate to millions of dollars. Savings regarding your CAPEX investment may also be achieved in some cases.
Brochure
Help your plant maximise the success and reduce the cost of carbon capture
17.02.2026 |
827.38 KB |
English
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Fuller leads new consortium to accelerate carbonation technologies in the cement industry
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Successful transfer of waste heat over 350m reduces carbon footprint
Cemento PANAM has achieved fantastic success reducing its carbon footprint and fossil fuel bill by implementing a 350 m long waste heat bypass system, using waste heat from the cooler to dry materials in its cement mills.
Fuller leads new consortium to accelerate carbonation technologies in the cement industry
To further eliminate CO2 emissions from the production of cement, Fuller will lead a new consortium to mature and deploy carbonation technologies in the industry. Funded by the EU Commission, world-class specialists will work alongside Fuller R&D engineers and experts from leading universities, technology providers and research institutions to solve one of the cement industry’s biggest challenges.
