Concrete is the most widely used material in the world, second only to water. As global demand for concrete increases, so does the need for cement, its primary binding agent. However, cement production is a major contributor to carbon dioxide (CO2) emissions, accounting for approximately 5% of global emissions attributed to human activities. The Cement Sustainability Initiative (CSI) has prioritized climate protection, aiming to mitigate the environmental impact of cement production.
Half of the CO2 emissions from cement production arise from the chemical process of obtaining clinker, the main ingredient in cement. Another 40% results from the combustion of fuels, while the remaining 10% is due to electricity use and transportation. To reduce these emissions, the industry has embraced modern, energy-efficient plants and alternative materials.
The CSI CO2 protocol and industry commitments were developed in 2002 by CSI member companies, the main purpose was to standardize the calculation and reporting of emissions. The key commitments of CSI companies include:
- Using the CO2 Protocol for monitoring and reporting baseline emissions.
- Developing mitigation strategies for climate change.
- Publishing reduction targets and progress reports.
- Annually disclosing CO2 emissions according to protocol guidelines.
Votorantim Cimentos has implemented CO2 tracking tools across its cement and grinding plants in Brazil, the U.S., and Canada, with data validated by external audits. Through strategic carbon management, the company has launched several initiatives, including Increasing the use of additives in cement to reduce clinker consumption, expanding biomass utilization in plants and replacing fuel oil with cleaner alternatives such as natural gas.
Originally aiming for a 10% reduction in CO2 emissions by 2012 (compared to 1990 levels), the cement company exceeded this goal, achieving a 26.9% reduction by 2011. They continue to explore further innovations to lower its carbon footprint.
One effective strategy for reducing CO2 emissions is replacing clinker with alternative materials that maintain cement quality while emitting less CO2. By 2011, the percentage of clinker in Votorantim’s final product had dropped by 9.3% compared to 1990, demonstrating significant progress.
Votorantim is investing in innovative projects, such as artificial pozzolana production in key U.S. regions, to further reduce emissions. Its strategy focuses on minimizing clinker use through research and development, improving thermal efficiency with advanced technology, and optimizing energy sources by incorporating biomass and industrial waste. These efforts are complemented by rigorous measurement and assessment of CO2 reduction progress.
In 2010, the president of Votorantim Cimentos signed the WBCSD’s Manifesto for Energy Efficiency in Commercial Buildings. This initiative promotes sustainable energy use and has led to the development of CO2 inventories for corporate centers in Brazil, validated by external audits.
In the U.S., St. Marys Cement’s Charlevoix plant in Michigan is set to become the first cement facility to deploy Membrane Technology and Research’s Polaris polymeric membrane-based carbon capture technology. This pilot project aims to capture three tons of CO2 per day over a six-month testing period, targeting a 95% CO2 capture rate.
Membrane Technology and Research is a company specializing in membrane-based separation systems and has been a leader in developing solutions for the petrochemical, natural gas, and refining industries since its founding in 1982. This new application in cement production could mark a turning point in emissions reduction efforts across the industry.
About Votorantim Cimentos and St. Marys Cement
Votorantim Cimentos is a global leader in cement production with operations across the Americas, Europe, Asia, and Africa. The company is committed to sustainability and continues to invest in innovative solutions to reduce its carbon footprint.
St. Marys Cement, a subsidiary of Votorantim, operates in North America and is known for its dedication to high-quality cement production. The company is actively involved in sustainable initiatives, including the development of carbon capture technology.
Seal Plus by Motofrenos and Votorantim Cimentos
Seal Plus has been a trusted supplier for Votorantim since 2012, providing premium seal solutions and spare parts for their cement kilns. Recently, Seal Plus installed an inlet seal at the St. Marys Bowmanville plant in Canada, that will enhance efficiency and significantly reduce CO2 emissions. This seal solution minimizes air intake in the kiln system, lowering kilocalorie consumption per kilogram of clinker. By optimizing operating conditions, the solution increases production capacity, reduces material loss, and supports Votorantim’s commitment to sustainability and environmental preservation.
As the cement industry evolves, these efforts in carbon reduction and sustainability will play a critical role in combating climate change while meeting the growing global demand for concrete.
Source: cemnet.com