01
Efficiency
Reduce energy demand.
MEASURES
- Kiln optimisation
- Waste heat recovery
- Grinding efficiency
- Advanced process control
4–7%
emissions reduction
PROJECT · CEMENT & LIME
Building a 2040 transition roadmapfor an integrated cement producer.
A European cement producer needed to determine how far existing technologies could reduce emissions — and when major investments in alternative fuels, clinker reduction and carbon capture should be made.
Terravia developed a portfolio-wide pathway connecting plant-level opportunities with asset cycles, infrastructure and long-term capital decisions.
- Decarbonisation Strategy
- Technology & Economics
- Investment Roadmaps
AT A GLANCE
Four plants.One transition pathway.
- 4
- integrated cement plants
- 72%
- reduction potential mapped
- €310m
- investment programme assessed
- 2040
- transition horizon
- Client
- European cement producer
- Sector
- Cement & Lime
- Geography
- Europe
- Scope
- Multi-plant decarbonisation strategy
- Expertise
- Decarbonisation Strategy · Technology & Economics · Investment Roadmaps
THE CHALLENGE
Efficiency alonecould never reach the target.
The producer had already improved the efficiency of its operations, but the majority of remaining emissions came from the fundamental chemistry of clinker production.
Reaching deep reductions would require multiple technologies deployed over different time horizons — while maintaining production, competitiveness and capital discipline.
THREE QUESTIONS
- 01
How far can existing assets go?
Identify the emissions reductions available through efficiency, alternative fuels and clinker optimisation without fundamentally changing the production system.
- 02
Which technologies close the gap?
Evaluate the role of electrification, new materials and carbon capture in addressing emissions that conventional measures cannot eliminate.
- 03
When should capital be committed?
Align major investments with kiln rebuilds, infrastructure availability and technology maturity.
PORTFOLIO BASELINE
The same chemistry.Different plants.
Terravia established a common emissions and asset baseline across four integrated cement plants.
Each site differed in fuel mix, clinker intensity, equipment age, alternative-fuel capability and access to future CO₂ infrastructure.
BASELINE INCLUDED
- Process emissions
- Thermal energy demand
- Electricity consumption
- Fuel mix
- Clinker factor
- Alternative-fuel substitution
- Kiln and grinding assets
- Asset replacement cycles
- Local infrastructure
| Plant | Annual Production | Alternative Fuels | Clinker Factor | Asset Position | Transition Readiness |
|---|---|---|---|---|---|
| Plant A | 1.8 Mt | 62% | 0.71 | Kiln rebuild approaching | High |
| Plant B | 1.4 Mt | 41% | 0.74 | Mid-life | Medium |
| Plant C | 1.1 Mt | 73% | 0.69 | Modern | High |
| Plant D | 0.9 Mt | 35% | 0.76 | Major upgrades required | Medium |
DECARBONISATION LEVERS
Build the portfoliobefore choosing the pathway.
Rather than beginning with a preferred technology, Terravia mapped the full range of technically credible interventions and quantified their potential contribution.
02
Alternative Fuels
Displace fossil thermal energy.
MEASURES
- Biomass
- Waste-derived fuels
- Fuel preparation systems
- Higher substitution rates
8–14%
emissions reduction
03
Clinker Reduction
Reduce process emissions per tonne.
MEASURES
- Supplementary cementitious materials
- Calcined clay
- Product reformulation
- Lower clinker factors
10–18%
emissions reduction
04
Electrification
Move suitable loads toward electricity.
MEASURES
- Electrified auxiliaries
- Material processing
- Selected thermal applications
- Emerging kiln technologies
3–8%
emissions reduction
05
Carbon Capture
Address residual process emissions.
MEASURES
- Post-combustion capture
- Oxyfuel concepts
- CO₂ conditioning
- Transport and storage
35–55%
emissions reduction
STRATEGIC OPTIONS
Three pathways.Different commitments.
Terravia combined the individual interventions into alternative portfolio pathways to understand what could be achieved under different technology and infrastructure futures.
PATHWAY A · OPTIMISE
Maximise proven measures.
- Capital Requirement
- Low–Moderate
- Infrastructure Dependency
- Low
- Strategic Character
- Lower risk, but insufficient for deep decarbonisation.
INCLUDES
- Efficiency
- Alternative fuels
- Clinker reduction
- Limited electrification
~38%
2040 reduction
PATHWAY B · TRANSFORM
Push process and material change.
- Capital Requirement
- Moderate–High
- Infrastructure Dependency
- Medium
- Strategic Character
- Substantial reduction while delaying large-scale carbon capture.
INCLUDES
- Efficiency
- High alternative-fuel substitution
- Deep clinker reduction
- Electrification
- New production technologies
~52%
2040 reduction
PATHWAY C · DEEP DECARBONISATION
Combine transformation with carbon capture.
- Capital Requirement
- High
- Infrastructure Dependency
- High
- Strategic Character
- Strongest pathway to deep portfolio decarbonisation.
INCLUDES
- All major efficiency and material measures
- Electrification
- Carbon capture
- CO₂ transport and storage
~72%
2040 reduction
COMPARING THE LEVERS
Not every tonne of CO₂costs the same to remove.
Each intervention was evaluated against emissions impact, capital requirements, operating economics, maturity and infrastructure dependency.
| Lever | Abatement Potential | CAPEX | Economic Attractiveness | Maturity | Infrastructure Dependency |
|---|---|---|---|---|---|
| Efficiency | Low | Low | High | High | Low |
| Alternative fuels | Medium | Moderate | High | High | Medium |
| Clinker reduction | Medium | Moderate | High | High–Developing | Medium |
| Electrification | Low–Medium | Moderate | Scenario-dependent | Developing | High |
| Carbon capture | Very high | Very high | Carbon-price dependent | Developing | Very high |
DO NOW
Measures with strong economics and limited regret.
PREPARE NOW
Infrastructure and asset changes required for future technologies.
COMMIT LATER
Large investments whose value depends on future technology, energy or infrastructure conditions.
TIMING THE TRANSITION
The roadmap followsthe life of the plant.
The strongest technology pathway can still fail if it ignores the investment cycle.
Terravia mapped major kiln, grinding and infrastructure decisions across the portfolio to identify the windows where transition investments could be introduced with the least disruption and stranded capital.
2027
Plant A — Major Kiln Rebuild
- Alternative-fuel expansion
- Capture-ready modifications
- Electrical infrastructure
2029
Plant D — Grinding Upgrade
- High-efficiency grinding
- Lower-clinker product capability
- Electrical optimisation
2031
Plant B — Major Maintenance Window
- Thermal-efficiency programme
- Alternative-fuel expansion
- Capture preparation
2034
Plant A — CO₂ Infrastructure Available
- Carbon-capture deployment
2036
Plants B & C — Capture Decision
- Deploy based on infrastructure and economics
2040
Portfolio Configuration
- Integrated low-carbon production system
INVESTMENT ROADMAP
Reduce now.Prepare next.Transform when ready.
2027–2029 · NO-REGRET ACTIONS
Deploy proven measures.
- Reduction
- ~15%
ACTIONS
- Deploy remaining efficiency measures
- Increase alternative-fuel substitution
- Reduce clinker intensity
- Begin Plant A upgrades
- Establish portfolio measurement framework
€45m
Indicative investment
2029–2032 · ENABLE
Build enabling capability.
- Reduction
- ~28% cumulative
ACTIONS
- Expand alternative-fuel infrastructure
- Introduce calcined-clay capability
- Reinforce electrical systems
- Make major assets capture-ready
- Develop CO₂ transport partnerships
€70m
Indicative investment
2032–2036 · TRANSFORM
Deploy major technologies.
- Reduction
- ~52% cumulative
ACTIONS
- Deploy first carbon-capture project
- Scale lower-clinker products
- Introduce additional electrification
- Connect first plant to CO₂ infrastructure
€115m
Indicative investment
2036–2040 · SCALE
Complete the portfolio transition.
- Reduction
- ~72% cumulative
ACTIONS
- Expand carbon capture across priority plants
- Complete portfolio infrastructure
- Deploy next-generation technologies where viable
- Address remaining high-cost emissions
€80m
Indicative investment
THE RESULT
A 2040 pathwaybuilt around real decisions.
- 72%
- Reduction potential mapped
- €310m
- Investment programme assessed
- 4
- Integrated plants
- 2040
- Transition horizon
A credible portfolio of interventions was identified across process, fuel, materials, electricity and carbon capture.
Capital requirements were connected to specific technologies, plants and investment windows.
Each site received a transition pathway reflecting its assets, emissions profile and infrastructure position.
Immediate measures were connected to major technology and infrastructure decisions extending over more than a decade.
PROJECT DELIVERABLES
From emissions baselineto capital roadmap.
Portfolio Emissions Baseline
Plant-level mapping of process, thermal and electrical emissions across the production portfolio.
Abatement Opportunity Portfolio
Quantified assessment of efficiency, alternative fuels, clinker reduction, electrification and carbon capture.
Technology & Economic Models
Comparable analysis of technical performance, capital requirements and operating economics.
Transition Scenarios
Alternative pathways showing how different technology combinations affect emissions, capital and infrastructure requirements.
Asset & Infrastructure Plan
Alignment of kiln cycles, electrical systems, CO₂ infrastructure and other enabling investments.
2040 Investment Roadmap
A phased portfolio programme connecting near-term action with future decision gates and major capital commitments.
EXPERTISE USED
Strategy, technologyand investment in one pathway.
Decarbonisation Strategy
Build the portfolio of interventions required to move from incremental improvements toward deep emissions reductions.
Explore Decarbonisation StrategyTechnology & Economics
Compare alternative fuels, materials, electrification and carbon capture across technical and economic scenarios.
Explore Technology & EconomicsInvestment Roadmaps
Align major interventions with kiln cycles, infrastructure availability and long-term capital planning.
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What should your plants do before 2040?
If you are trying to turn a long-term cement decarbonisation target into specific technology, asset and capital decisions, Terravia can help build the pathway from today's plants to the next generation of production.
Talk to our team