Our expertise in oxyfuel process conversion prepares the way for practical and cost-effective carbon capture by increasing the CO2 concentration in plant exhaust gases.
Cement beyond Carbon –
The journey begins now
Alternative fuel processing with Pyrorotor®
Energy-efficient grinding with the KHD Roller Press
Lower-carbon cements with clay calcination
Empowering carbon capture with oxyfuel technology
Technology leaders
Products & solutions
KHD products have defined the modern cement plant. They will define the plant of the future as well. Backed by an ongoing process of research and product development, our state-of-the-art clean solutions are proven to increase process efficiency and reduce emissions.
Engineering excellence
Consulting
How do you succeed on your decarbonization journey? With a documented history of innovation and engineering excellence in the cement industry, we know better than most how to answer that question. Contact us today for your free initial consultation, and let’s start the journey together.
The journey to cement beyond carbon
When we look at the road to decarbonizing cement production, we see two phases: the road to 2030 and the road after 2030.
Until 2030
Step-by-step.
The road to 2030 will use existing solutions or those close to commercialization. Things like roller presses for energy-efficient grinding; the Pyrorotor® to maximize alternative fuels; advanced digital solutions that optimize process efficiency, such as our KHD ProMax® suite; and clay calcination. These technologies and approaches are available today to reduce CO2 emissions.
After 2030
The next
chapter.
The road after 2030 will take use to complete decarbonization of the cement process with the help of future solutions, including carbon capture and storage. Alongside strategic partners in the industry, we are already working hard to develop and bring these important new technologies to commercial viability.
One journey, many pathways
All that said, we also recognize that every cement plant is unique.
That means there’s not one pathway to Cement beyond Carbon; there will be many, depending on a range of factors:
Plant location
Distance and connectivity to infrastructure, e.g., for alternative fuels supply or carbon transportation and storage, may determine possible decarbonization pathways.
Available raw materials
Some decarbonization solutions require certain feedstock materials.
Available fuels
Some decarbonization and fuel switching solutions require certain alternative fuels.
Plant size & layout
Some decarbonization solutions require a certain plant footprint or space for their installation.
Commercial realities
Any decarbonization solution must be commercially feasible, taking into account the real cost of production.
This will require solutions that are adaptable to individual plant conditions and customer needs. The journey will also be taken over a time horizon measured not just in years, but multiple decades. Our approach therefore focuses on long-term partnership and honest collaboration to customize your best possible pathway to our common goal: reduced carbon emissions and more sustainable cement production.
We can do this thanks to our longstanding and deep technical insight into the cement production process. Few know this process as well as our experts, who work with you at each step of your decarbonization journey. From initial assessment through to project execution and commissioning, we are here to ensure excellence at every stage.
Our products and solutions
Our plant-ready range of products and solutions enables cement plants to cut their emissions today.
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Oxyfuel
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KHD Promax® RTO
Our state-of-the-art digital solution optimizes plant performance to achieve an efficient and productive process for more sustainable operations.
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Clay Calcination
Our expert clay calcination solutions provide a high-quality supplementary cementitious material for a lower-carbon cement.
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Pyrorotor®
Discover the Pyrorotor – our most advanced technology for processing alternative fuels.
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Roller Press
It’s the most energy-efficient grinding machine on the market. And we are the company that introduced it to the cement industry.
Our products and solutions
KHD offers a range of technologies that can be utilized today to reduce carbon emissions.
The following table shows how our solutions fit within the main decarbonization pathways set out by the Global Cement and Concrete Association to help cement plants become cleaner, while also reducing operating costs.
| Savings in clinker production | Savings in cement and binders | Carbon capture, utilization, and storage (CCUS) | Emission reduction | |
|---|---|---|---|---|
| Oxyfuel operation | ||||
| Clay calcination | ||||
| KHD ProMax® RTO | ||||
| Plant modernization | ||||
| Pyrorotor® | ||||
| Roller Press |
Our products and solutions
From our beginnings back in 1856, we have continuously pushed to create value and deliver the most efficient equipment and plant for the production of cement.
This aspiration continues to drive us, with a particular focus on the need to decarbonize the cement industry. Our products and technologies are tried and tested to reduce carbon emissions today and come backed by the world-leading process understanding that has created our reputation worldwide.
Our products and solutions
Oxyfuel
Oxyfuel is a key enabling technology for successfully implementation of carbon capture in the cement industry. We have long recognized its importance. Our experts have been involved in oxyfuel development since 2010 and stand ready to provide complete oxyfuel system design and equipment supply for both new and existing plants.
Our products and solutions
Clay calcination
Calcined clay has only marginally lower hydraulic properties than clinker. Fortunately, however, the raw materials do not emit CO2 during calcination; energy and fuel requirements are also lower. When used to reduce the clinker factor of cement, calcined clay therefore reduces carbon intensity per tonne of cement.
Our products and solutions
KHD ProMax®
KHD ProMax® is a suite of intelligent digital solutions that connects to and delivers real-world optimization of your cement plant equipment and process. The result is improved process efficiency – reducing energy consumption, as well as Scope 1 and Scope 2 greenhouse gas emissions.
Our products and solutions
Plant modernization
Delivering a zero-carbon cement industry will require existing plant equipment and processes to be optimized and upgraded with the latest emissions-reduction solutions. Our process knowledge and plant engineering expertise ensure that these essential modernization projects are achieved in the best-possible way for each specific plant application.
Our products and solutions
Pyrorotor®
The innovative design of our Pyrorotor® enables very high thermal substitution rates of >85% in the calciner – with almost no fuel pre-processing. This not only delivers a substantial reduction in CO2 emissions in itself; it also means you can switch to locally-available fuels, reducing carbon emissions associated with global fossil fuel supply chains.
Our products and solutions
Roller press
When compared to other grinding options, the roller press is simply the most energy-efficient of the lot. It is also flexible and can be used to grind various feed materials, supporting the use of alternative cementitious materials and the production of lower-carbon composite cements.
Why KHD?
There’s no doubt that achieving Cement beyond Carbon is a challenge.
We’d be lying if we pretended otherwise. It’s going to fundamentally reshape the way cement is produced. Fortunately, here at KHD, we have experience in such fundamental shifts: we have been responsible for a fair few of them in our time.
This realignment is also going to look differently at different plants. Regional, technical, and commercial variation will require different approaches, taken over varying timeframes. First to 2030, and then beyond. Here, again, you need a partner that has practical experience working in every major cement producing region, for all types of clients – from single-plant producers to global majors, and that values long-term, collaborative relationships to deliver plant-specific solutions.
Finally, you need a partner who is always working toward the future. A partner with the deep industry knowledge to understand what is needed, and who prioritizes and invests in R&D and innovation to make what is needed a reality. In short, you need KHD.
Related topics
Interested in finding out more?
Explore some related products and solutions.
01
Oxyfuel
Efforts to decarbonize the cement industry will require carbon capture. And that’s likely to need oxyfuel.
02
Clay Calcination
Our expert clay calcination solutions provide a high-quality supplementary cementitious material for a lower-carbon cement.
03
Pyrorotor®
Discover the Pyrorotor – our most advanced technology for processing alternative fuels.