clinker

AI and greener cement

July 28, 2025 By EarthWise Leave a Comment

Cement pretty much holds the modern world together. The amount of cement required to create our infrastructure is almost incomprehensible. By weight, humanity consumes more cement than food, about 3 pounds per person per day. The cement industry produces around eight percent of global CO₂ emissions, which is more than the aviation industry. So, if the amount of emissions produced making concrete could be reduced by even a few percent, it would make a significant impact.

Cement plants utilize rotary kilns heated to 2,500 degrees Fahrenheit to burn ground limestone down to a substance called clinker. That energy-intensive combustion process emits large amounts of carbon dioxide. However, the combustion process accounts for much less than half of the emissions associated with making concrete. The majority comes from the raw materials needed to produce clinker.

One strategy to reduce concrete emissions is to modify the cement recipe itself, replacing some of the clinker with alternative materials. Some producers already make use of materials like slag from iron production and fly ash from coal-fired power plants.

A team of researchers at the Paul Scherrer Institute in Switzerland is making use of machine learning to simulate and optimize cement formulations that would emit significantly less CO₂ while maintaining the same high level of mechanical performance. This AI-based approach eliminates time-consuming experiments and conventional complex simulations.

The Scherrer Institute seeks to discover new materials and the effort has already yielded some promising candidates. The next steps will be testing some of these recipes in the laboratory.

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AI paves the way towards green cement

Photo, posted July 3, 2007, courtesy of Tim Shortt via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio

Concrete And Carbon | Earth Wise

May 8, 2023 By EarthWise Leave a Comment

After water, concrete is the world’s second most consumed material. It is the cornerstone of modern infrastructure. Its production accounts for 8% of global carbon dioxide emissions. The carbon dioxide is a result of chemical reactions in its manufacture and from the energy required to fuel the reactions.

About half of the emissions associated with concrete come from burning fossil fuels to heat up the mixture of limestone and clay that ultimately becomes ordinary Portland cement. These emissions could eventually be eliminated by using renewable-generated electricity to provide the necessary heat. However, the other half of the emissions is inherent in the chemical process.

When the minerals are heated to temperatures above 2500 degrees Fahrenheit, a chemical reaction occurs producing a substance called clinker (which is mostly calcium silicates) and carbon dioxide. The carbon dioxide escapes into the air.

Portland cement is then mixed with water, sand, and gravel to produce concrete. The concrete is somewhat alkaline and naturally absorbs carbon dioxide albeit slowly. Over time, these reactions weaken the concrete and corrode reinforcing rebar.

Researchers at MIT have discovered that the simple addition of sodium bicarbonate (aka baking soda) to the concrete mixture accelerates the early-stage mineralization of carbon dioxide, enough to make a real dent in concrete’s carbon footprint. In addition, the resulting concrete sets much more quickly. It forms a new composite phase that doubles the mechanical performance of early-stage concrete.

The goal is to provide much greener, and possibly even carbon-negative construction materials, turning concrete from being a problem to part of a solution.

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New additives could turn concrete into an effective carbon sink

Photo, posted April 4, 2009, courtesy of PSNH via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio

Reducing Emissions From Cement Manufacturing | Earth Wise

December 7, 2021 By EarthWise Leave a Comment

Cement is the basic ingredient of concrete, which is the most widely used construction material in the world. About 8% of global carbon dioxide emissions are associated with cement production.

More than half of these emissions come from making clinker, which is a major component of cement produced by heating ground limestone and clay to a temperature of over 2500 degrees Fahrenheit. Some of the emissions come from burning fossil fuels to heat the materials, but much of them come from the chemical reaction that creates the clinker.

The Portland Cement Association, which represents 92% of US cement manufacturing capacity, has recently released its “Roadmap to Carbon Neutrality”, which lays out a plan to reach carbon net zero across the cement and concrete value chain by 2050.

The plan includes the greater use of alternative fuels to reduce emissions from energy use. It also involves the adoption of newer versions of cement such as Portland limestone cement, which reduces CO2 levels. The industry has already reduced emissions by some shifting to Portland limestone cement, but it still only represents a small fraction of cement production.

The most significant strategy would be the adoption of carbon capture, utilization, and storage (or CCUS) technologies. The idea is to capture the CO2 generated in the production of clinker and inject it into the fresh concrete. It would actually be permanently sequestered in the concrete and would not be released even if a structure is demolished in the future.

It will take a combination of technologies and initiatives for the cement industry to reduce its emissions. Fortunately, the industry appears to be committed to that goal.

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US cement manufacturers release their road map to carbon neutrality by 2050

Photo, posted March 26, 2014, courtesy of Michael Coghlan via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.

Decarbonizing The Most Polluting Heavy Industries | Earth Wise

November 23, 2021 By EarthWise Leave a Comment

The production of steel, cement, and ammonia accounts for about 20% of the carbon dioxide humans pour into the atmosphere. Modern cities are largely constructed from concrete and steel and most of our food is grown using fertilizer made from ammonia.

The most widely discussed solutions to decarbonizing these industries are green hydrogen and carbon capture and storage or CCS.

Steel manufacture is responsible for 11% of society’s emissions. Most production starts by burning coal in a blast furnace. Using CCS could reduce emissions from burning the coal. But the blast furnace could be eliminated entirely by the use of electrolysis to produce the pure iron needed to make steel. This would be extremely energy-intensive but using a low-carbon source like green hydrogen could greatly reduce the emissions from making steel.

Ammonia is made by producing hydrogen from natural gas and then combining it with atmospheric nitrogen. Both the hydrogen production and ammonia synthesis are energy intensive. Using green hydrogen would eliminate emissions from the hydrogen production itself and new research on catalysts aims at lower-temperature, less-energy intensive ammonia synthesis.

Decarbonizing cement manufacturing is perhaps the toughest challenge. Cement is made in a high-temperature kiln, typically heated by burning fossil fuels. The process converts calcium carbonate and clay into a hard solid called clinker. The main byproduct of that is even more carbon dioxide. Burning green hydrogen and capturing carbon emission are about the best hope for reducing cement manufacturing emissions.

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Can the World’s Most Polluting Heavy Industries Decarbonize?

Photo, posted June 30, 2009, courtesy of Portland Bolt via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.

Emissions-Free Cement

October 29, 2019 By EarthWise Leave a Comment

The production of cement – which is the world’s leading construction material – is a major source of greenhouse gas emissions, accounting for about 8% of global man-made emissions.

Cement production produces carbon dioxide in two ways: from a key chemical process and from burning fuel to produce the cement. The process of making “clinker” – the key constituent of cement – emits the largest amount of CO2. Raw materials, mainly limestone and clay – are fed into huge kilns and heated to over 2,500 degrees Fahrenheit, requiring lots of fossil fuel. This calcination process splits the material into calcium oxide and CO2. The so-called clinker is then mixed with gypsum and limestone to produce cement.

A team of researchers at MIT has come up with a new way of manufacturing cement that greatly reduces the carbon emissions. The new process makes use of an electrolyzer, where a battery is hooked up to two electrodes in water producing oxygen at one electrode and hydrogen at the other. The oxygen-evolving electrode produces acid and the hydrogen-evolving electrode produces a base. In the new process, pulverized limestone is dissolved in the acid at one electrode and calcium hydroxide precipitates out as a solid at the other.

High-purity carbon dioxide is released at the acid electrode, but it can be easily captured for further use such as the production of liquid fuels or even in carbonated beverages and dry ice. The new approach could eliminate the use of fossil fuels in the heating process, substituting electricity generated from renewable sources.

The process looks to be scalable and represents a possible approach to greatly reducing one of the perhaps lesser known but nevertheless very significant sources of greenhouse gas emissions.

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New approach suggests path to emissions-free cement

Photo, posted March 26, 2014, courtesy of Michael Coghlan via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.