The cement industry cannot operate without emitting carbon dioxide, so it is searching for ways to minimize its environmental impact. The only known technologies for tackling so-called process emissions are CCS (Carbon Capture and Storage) technologies. While producers are working on their development, the main challenges are the high installation costs, their energy consumption, and the infrastructure required for CO2 transport and storage. Without state and EU support, these efforts may not succeed.
“Green transformation is crucial for the cement industry because this sector cannot produce without emitting greenhouse gases. This is due to the chemical process that occurs when calcium carbonate is burned, and it is unavoidable. Aware of this, we have developed technologies in collaboration with the AGH University of Science and Technology that can capture these emissions and store them for future generations. Most importantly, they prevent emissions from entering the atmosphere and exacerbating the current climate crisis,” says Krzysztof Kieres, Chairman of the Association of Cement Producers, in an interview with Newseria.
In 2023, Poland emitted 377 million tons of greenhouse gases, with the cement industry responsible for approximately 12 million tons, or around 3.5% of the total emissions.
“This cannot be ignored. I believe that every emitter should make efforts to reduce emissions as much as possible. In our case, the only known technologies are CCS/CCU – Carbon Capture and Storage – and potentially injecting CO2 into underground rock formations for future use,” Kieres explains.
Two Categories of Cement Industry Emissions
Greenhouse gas emissions in the cement industry fall into two categories. Process emissions, which account for two-thirds of the total, result from the chemical reactions occurring when clinker is burned. These emissions are unavoidable. The remaining one-third comes from fuels used in production.
“Right now, we have some control over fuel-related emissions. We are significantly reducing the use of fossil fuels, primarily coal, which has been a major source of CO2 emissions, and replacing them with alternative fuels. Currently, the industry has replaced coal by about 80% with these fuels. We are the absolute leader in Europe,” says Kieres. “However, when it comes to process emissions, the only available solutions are carbon capture and storage technologies.”
The Polish cement industry is at the forefront of decarbonization efforts, having already reduced CO2 emissions by over 30%, with a goal of reaching a 40% reduction by 2030. However, achieving climate neutrality will not be possible without CCS technology. The industry is pioneering its implementation, but these are highly expensive investments. A feasibility study conducted by experts from AGH University in Kraków estimates that the costs for a medium-sized cement plant range from PLN 0.5 billion to PLN 1.5 billion. The potential carbon capture rate is around 85% of annual CO2 emissions.
The Need for Financial and Energy Support
“This clearly requires financial support because, as noted in the Draghi Report, not all environmental and investment decisions have a business justification. In a broader context of global climate protection, we expect support from European Union funds,” Kieres emphasizes.
Support is needed not only due to the high costs of CCS/CCU investments but also because of their significant energy consumption. Electricity costs will account for 70% of the operational expenses of these technologies.
“Beyond what we already consume in the cement production process, we would need to use the same amount or even 1.5 times more electricity to capture CO2. If this electricity were to come from conventional sources, we would create a kind of perpetual motion machine—capturing CO2 while generating similar amounts in electricity production. Therefore, for these efforts to be effective, renewable or nuclear energy is essential; only then does it make sense,” says the Chairman of the Association of Cement Producers.
Urgency in Implementing CO2 Transport and Storage
The industry asserts that it is ready to implement carbon capture processes, with specific projects already in development. However, it requires support for CO2 transportation and storage, an area where it expects government initiative. Since preparing such infrastructure will take several years, decisions must be made soon. This urgency is driven by the upcoming expiration of free CO2 emission allowances, set to end in 2034, which could pose significant challenges to the sector’s competitiveness.
At the Ministry of Climate and Environment, a team has been established to focus on the development of carbon capture, storage, and utilization technologies, with the task of drafting key legislative projects.
According to last year’s EY report “Economic Analysis of the Impact of CCS Implementation in the Cement Industry on the Construction Sector and the Economy,” commissioned by EY, implementing CCS technology in the cement industry will not only reduce the carbon footprint of building materials but also help limit price increases for these products, create more jobs in construction, and boost GDP growth across the economy.
