Green cement of the future: CemShale + CemTower

Project Information

CemShale CemTower

Grant agreement ID: 101009382

DOI

10.3030/101009382

Project closed

EC signature date 24 November 2020

Start date 1 October 2020

End date 31 March 2023

Funded under

• PRIORITY 'Societal challenges

Total cost

€ 2 168 142,36

EU contribution

€ 1 517 699,00

Coordinated by

CEMGREEN APS
Denmark

Periodic Reporting for period 2 - CemShale CemTower (Green cement of the future: CemShale + CemTower)

Reporting period: 2021-10-01 to 2023-03-31

Summary of the context and overall objectives of the project

Cement production is responsible for approx. 9% of the anthropogenic CO2 emissions globally. As a consequence, reducing the CO2 emissions from cement production is of paramount importance in the combat against global warming and in alleviating the resulting climate changes. The EU-funded CemShale™ CemTower® project offers an innovative solution, which will reduce CO2 emissions, lower operational costs, and hence offer a clear path towards a sustainable construction industry.

CemGreen develops innovative solutions for the cement and concrete industries within the field of Supplementary Cementitious Materials (SCMs) based on clay mineral rich materials. SCMs reduce the CO2 emissions from cement production by substituting parts of the cement. CemGreen has developed CemShale™ and CemClay™, processes for production of high-quality clay-based SCMs. In addition, CemGreen has developed and patented CemTower®, a game-changing production unit that vertically integrates preheater, kiln, and cooler, allowing for optimized heat treatment and reduced operational costs and energy resources. Production of CemGreen’s SCM on CemTower® results in 98% lower CO2 emission rates compared to cement production. Clay-based SCMs are allowed to substitute 35% of cement, and full implementation of CemGreen’s solution thus has the potential to lower the global CO2 emissions by approx. 3%. CemGreen’s SCM products – based on globally abundant clay-rich materials – will also provide cement producers supply chain flexibility, significant cost savings, and the possibility to meet Green Deal CO2 emission targets.

The objectives of the EU-funded CemShale™ CemTower® project includes the erection of a CemTower® pilot plant with a capacity of 10 tonnes CemShale™ SCM per day, which will prove CemGreen’s innovation. The pilot plant will also serve as the basis for a subsequent 500 tonne per day demonstration plant proving scalability of CemGreen’s technology. Other objectives are the preparation of the demonstration plant, ensuring IP and knowledge protection and partnership agreements for maximum exploitation of CemGreen’s innovation, and preparation of market entry through communication and dissemination to key market players and stakeholders. Based on the results of the project, CemShale™ has the potential to become the predominant SCM and CemTower® the state-of-the-art production equipment for clay-based SCMs.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

From the initiation of the project to the end the period covered by the report, CemGreen has carried out the following tasks in accordance with work package descriptions:
Planning phase: Careful finalisation of all plan details has been carried out in due time, resulting in a precise flow sheet of the plant, dimensioned drawings of all CemTower® modules, identification of suppliers, and description of the control system.
Building of CemTower® pilot plant: The CemTower® pilot plant has been erected. This includes conducting a test run showing the viability of the chosen concept for the erection of CemTower®, casting of the foundation, erection of the frame, installation of all elements and components (elevator, combustion chamber, gas supply, and instrumentation), and erection of CemTower® itself. Thus, the erection of the CemTower™ pilot plant – including control room – has been concluded.
Testing, running, optimisation: CemGreen has initiated cold commissioning/testing of the CemTower® pilot plant. The results from the tests performed under ambient conditions are very promising. Cold commissioning is expected to be concluded towards the end of September, 2021, allowing for hot commissioning to commence.
IPR strategy update and IPR strategy execution: It has been decided to continue CemGreen’s EP applications as PCT applications. The EP application pertaining to the CemShale™ process was transferred to a PCT application in November, 2020. The EP application pertaining to CemTower® was transferred to a PCT application in May, 2021. Both applications are currently with the EPO for further evaluation and are awaiting national filings. A third EP application for a complementary process solution based on clay-rich raw materials was filed in December, 2020, and CemGreen is currently preparing a follow-up application to the generic CemTower® design to entail specific details of the demonstration plant based on the experience with the operation of the pilot plant.
Dissemination plan and dissemination plan execution: The dissemination plan has been established as an ongoing work based on incoming results from the pilot plant and opportunities arising from communication with potential investors and partners. Due to the pro-active inquiry by a major EU-based global stakeholder, the plan has been revised, allocating dissemination resources towards securing maximum focus on any and all critical areas regarding a future financial commitment on their part. Multiple presentations of the technologies and the demonstration plant have been given to relevant municipal council officials, regional government officials, and other potential stakeholders, and CemGreen has participated in numerous relevant events in accordance with the initial plan.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Taking the innovative nature of both CemShale™ and CemTower® into account, the successful erection of the CemTower® pilot plant and the very promising results from the initial testing indicate the high potential to progress beyond the current state-of-the-art production of SCMs based on conventional rotary kilns or complex cyclone solutions, when regarding both CO2 emission reduction potential, product quality, and operational costs.

The interest shown by a major, EU-based global stakeholder and its ability to both co-fund the full-scale demonstration plant and to market the SCM product is a testament to the potential economic and societal impact of CemShale™ produced on CemTower®: In producing a low-CO2, high-quality SCM product based on globally abundant clay-rich materials and in entering a marketing and distribution collaboration with a global stakeholder, the potential to disrupt and re-shape the structures of the cement and concrete industries both nationally and internationally is evident. The SCM product produced on CemTower® – offering significant CO2 emission reductions at a highly competitive price – marketed and distributed in collaboration with a major global stakeholder will introduce a new industry standard and will pave the way for a more environmentally sustainable construction industry. This collaboration has been furthered by the erection of the CemTower® pilot plant and the preliminary testing that has been conducted as well as by the dissemination of project results.

CemTowerTM Pilot Plant