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We are using AI to developour process control

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Dr Paula Carey, Co-Founder & Chief Scientific Officer, Carbon8 explains the impact of carbon capture technology at Carbon8 on the productivity, efficiency and circular economy of cement plants.

Tell us about your carbon capture technology.
Carbon8’s carbon capture utilisation and storage (CCUS) technology is known as Accelerated Carbonation (ACT). In the process, carbon dioxide derived directly from flue gas generated by a cement plant is reacted with calcium minerals within the cement by-pass or kiln dust produced by the same plant without the need for purification.

The reaction occurs at atmospheric temperatures and pressures over 20-30 minutes and can be engineered so that a carbon negative lightweight aggregate is produced, through granulation of the fine grained dusts.

The technology is delivered in a containerised plant (known as the CO2ntainer) with a small footprint that is plugged directly into the flue stack of the cement plant without affecting the cement manufacturing process.

What role can your technology play when implemented in a carbon intensive industry like the cement industry?
The amount of carbon dioxide that is captured is limited by the amount of residue available, but the economics of our system means that a profit can be made for every tonne of CO2 captured without the need for subsidies, or large energy penalties or the use of expensive toxic chemicals such as amines. The process results in the sustainable management of an industrial residue that might otherwise be destined for landfill and produces a low carbon product for the construction industry reducing the need for the extraction of natural aggregate.

What is the impact of your technology on the productivity and cost of cement manufacturing?
The installation of our technology has no effect on the productivity of the cement plant, it has a low energy requirement and its installation adds to the bottom line of the cement production.

How does your technology impact the energy efficiency of a cement plant?
Because our technology operates at atmospheric temperatures and pressures, it has a low energy demand and does not have an impact on the efficiency of the cement plant.

How does your tech support the circular economy?
Carbon8’s technology produces a carbon negative, lightweight aggregate from an industrial residue, breaking the route to landfill disposal and producing a sustainable product for the construction industry that replaces the need for the extraction of natural virgin aggregate. On our website – www.carbon8.co.uk – we describe ourselves as a “circular impact company

What are the major challenges in implementation and execution of your technology?
Because the amount of CO2 captured is relatively small compared with large-scale, expensive carbon capture projects, it has been more challenging to demonstrate the economic and environmental benefits of deploying and operating our technology within the global cement industry. A Vicat cement plant in France has been using our CO2tainer since 2020, after successful trials with CRH in Canada and Hanson (now part of Heidelberg Cement Group) in the UK.

The variability of the waste streams that are available to Carbon8 also raises a challenge; every cement works is slightly different and demands a unique solution in terms of mix design for our process.

What innovations can the world expect from Carbon8 in the near future?
We are using AI to develop our process control to overcome the variability of the residues that are generated by the different hard-to-abate industries, and so facilitate the deployment of ACT solutions into other sectors, like Energy From Waste, biomass and steel.

Concrete

Star Cement launches ‘Star Smart Building Solutions’

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Star Cement has launched ‘Star Smart Building Solutions,’ a new initiative aimed at promoting sustainable construction practices, as per a recent news report. This venture introduces a range of eco-friendly products, including tile adhesives, tile cleaners and grouts, designed to enhance durability and reduce environmental impact. The company plans to expand this portfolio with additional value-added products in the near future. By focusing on sustainable materials and innovative building solutions, Star Cement aims to contribute to environmentally responsible construction and meet the evolving needs of modern infrastructure development.

Image source:https://www.starcement.co.in/

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Concrete

Nuvoco Vistas reports record quarterly EBITDA

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Nuvoco Vistas reported its highest-ever quarterly consolidated EBITDA of Rs.556 crore in Q4 FY25, with annual EBITDA at Rs.1,391 crore. Cement sales reached 19.4 MMT in FY25, with Q4 contributing 5.7 MMT. Revenue rose 4 per cent YoY to Rs.3,042 crore in Q4. Net debt reduced by Rs.390 crore to Rs.3,640 crore. The company received NCLT approval for acquiring Vadraj Cement, targeting 31 MMTPA capacity by FY27. Key marketing initiatives, expanding RMX and MBM businesses, and a focus on sustainability (457 kg CO2/tonne) drove performance. Nuvoco remains focused on premiumisation, operational efficiency, and market expansion.

Image source:nuvoco.com

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Concrete

UltraTech Cement increases capacity by 1.4Mt/yr

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UltraTech Cement has expanded its production capacity by 1.4 million tonnes per annum (Mt/yr) through a combination of debottlenecking efforts and operational efficiency upgrades across several of its plants. The enhancements include an addition of 0.6Mt/yr in grinding capacity at the Nagpur facility in Maharashtra and a combined 0.8Mt/yr at the Panipat and Jhajjar units in Haryana. With these upgrades, the company’s total domestic grey cement capacity has risen to 184.8Mt/yr, while its global capacity now stands at 190.2Mt/yr.

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