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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

India Sets Up First Carbon Capture Testbeds for Cement Industry

Five CCU testbeds launched to decarbonise cement production

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The Department of Science and Technology (DST) recently unveiled a pioneering national initiative: five Carbon Capture and Utilisation (CCU) testbeds in the cement sector, forming a first-of-its-kind research and innovation cluster to combat industrial carbon emissions.
This is a significant step towards India’s Climate Action for fostering National Determined Contributions (NDCs) targets and to achieve net zero decarbonisation pathways for Industry Transition., towards the Government’s goal to achieve a carbon-neutral economy by 2070.
Carbon Capture Utilisation (CCU) holds significant importance in hard-to-abate sectors like Cement, Steel, Power, Oil &Natural Gas, Chemicals & Fertilizers in reducing emissions by capturing carbon dioxide from industrial processes and converting it to value add products such as synthetic fuels, Urea, Soda, Ash, chemicals, food grade CO2 or concrete aggregates. CCU provides a feasible pathway for these tough to decarbonise industries to lower their carbon footprint and move towards achieving Net Zero Goals while continuing their operations efficiently. DST has taken major strides in fostering R&D in the CCUS domain.
Concrete is vital for India’s economy and the Cement industry being one of the main hard-to-abate sectors, is committed to align with the national decarbonisation commitments. New technologies to decarbonise emission intensity of the cement sector would play a key role in achieving of national net zero targets.
Recognizing the critical need for decarbonising the Cement sector, the Energy and Sustainable Technology (CEST) Division of Department launched a unique call for mobilising Academia-Industry Consortia proposals for deployment of Carbon Capture Utilisation (CCU) in Cement Sector. This Special call envisaged to develop and deploy innovative CCU Test bed in Cement Sector with thrust on Developing CO2 capture + CO2 Utilisation integrated unit in an Industrial set up through an innovative Public Private Partnership (PPP) funding model.
As a unique initiative and one of its first kind in India, DST has approved setting up of five CCU testbeds for translational R&D, to be set up in Academia-Industry collaboration under this significant initiative of DST in PPP mode, engaging with premier research laboratories as knowledge partners and top Cement companies as the industry partner.
On the occasion of National Technology Day celebrations, on May 11, 2025 the 5 CCU Cement Test beds were announced and grants had been handed over to the Test bed teams by the Chief Guest, Union Minister of State (Independent Charge) for Science and Technology; Earth Sciences and Minister of State for PMO, Department of Atomic Energy, Department of Space, Personnel, Public Grievances and Pensions, Dr Jitendra Singh in the presence of Secretary DST Prof. Abhay Karandikar.
The five testbeds are not just academic experiments — they are collaborative industrial pilot projects bringing together India’s top research institutions and leading cement manufacturers under a unique Public-Private Partnership (PPP) model. Each testbed addresses a different facet of CCU, from cutting-edge catalysis to vacuum-based gas separation.
The outcomes of this innovative initiative will not only showcase the pathways of decarbonisation towards Net zero goals through CCU route in cement sector, but should also be a critical confidence building measure for potential stakeholders to uptake the deployed CCU technology for further scale up and commercialisation.
It is envisioned that through continuous research and innovation under these test beds in developing innovative catalysts, materials, electrolyser technology, reactors, and electronics, the cost of Green Cement via the deployed CCU technology in Cement Sector may considerably be made more sustainable.
Secretary DBT Dr Rajesh Gokhale, Dr Ajai Choudhary, Co-Founder HCL, Dr. Rajesh Pathak, Secretary, TDB, Dr Anita Gupta Head CEST, DST and Dr Neelima Alam, Associate Head, DST were also present at the programme organized at Dr Ambedkar International Centre, New Delhi.

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Concrete

JK Lakshmi Adopts EVs to Cut Emissions in Logistics

Electric vehicles deployed between JK Puram and Kalol units

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JK Lakshmi Cement, a key player in the Indian cement industry, has announced the deployment of electric vehicles (EVs) in its logistics operations. This move, made in partnership with SwitchLabs Automobiles, will see EVs transporting goods between the JK Puram Plant in Sirohi, Rajasthan, and the Kalol Grinding Unit in Gujarat.
The announcement follows a successful pilot project that showcased measurable reductions in carbon emissions while maintaining efficiency. Building on this, the company is scaling up EV integration to enhance sustainability across its supply chain.
“Sustainability is integral to our vision at JK Lakshmi Cement. Our collaboration with SwitchLabs Automobiles reflects our continued focus on driving innovation in our logistics operations while taking responsibility for our environmental footprint. This initiative positions us as a leader in transforming the cement sector’s logistics landscape,” said Arun Shukla, President & Director, JK Lakshmi Cement.
This deployment marks a significant step in aligning with India’s push for greener transport infrastructure. By embracing clean mobility, JK Lakshmi Cement is setting an example for the industry, demonstrating that environmental responsibility can go hand in hand with operational efficiency.
The company continues to embed sustainability into its operations as part of a broader goal to reduce its carbon footprint. This initiative adds to its vision of building a more sustainable and eco-friendly future.
JK Lakshmi Cement, part of the 135-year-old JK Organisation, began operations in 1982 and has grown to become a recognised name in Indian cement. With a presence across Northern, Western, and Eastern India, the company has a cement capacity of 16.5 MTPA, with a target to reach 30 MT by 2030. Its product range includes ready-mix concrete, gypsum plaster, wall putty, and autoclaved aerated fly ash blocks.

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Concrete

Holcim UK drives sustainable construction

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Holcim UK has released a report titled ‘Making Sustainable Construction a Reality,’ outlining its five-fold commitment to a greener future. The company aims to focus on decarbonisation, circular economy principles, smarter building methods, community engagement, and integrating nature. Based on a survey of 2,000 people, only 41 per cent felt urban spaces in the UK are sustainably built. A significant majority (82 per cent) advocated for more green spaces, 69 per cent called for government leadership in sustainability, and 54 per cent saw businesses as key players. Additionally, 80 per cent of respondents stressed the need for greater transparency from companies regarding their environmental practices.

Image source:holcim

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