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Defossilization of industrial processes via plasma

A plasma process that uses renewable electricity to convert CO₂ emissions into a fuel gas without using H₂ significantly reduces the use of fossil fuels. A plasma process offers decisive economic and ecological advantages for cement and clinker production, but also for other heat-intensive industries:

1. reduction of fossil CO₂ emissions & improvement of the carbon footprint

The cement industry is one of the largest CO₂ emitters in the world. Around 8% of global CO₂ emissions come from cement and clinker production. CO₂ emissions arise from two main sources:

  1. Process-related emissions (~60 %): Release of CO₂ during the calcination of the limestone (CaCO₃ → CaO + CO₂)
  2. Fuel-related emissions (~40 %): Use of fossil fuels such as gas, oil or coal and alternative secondary fuels for the kilns (e.g. CH₄ → CO₂ + H₂O)

2. saving of CO₂ certificates & regulatory advantages

  • The price for CO₂ certificates is currently CHF 120/t CO₂ in Switzerland and € 80 – 100/t CO2 in the European Emissions Trading System (EU ETS) and is expected to rise further.
  • Switzerland and the EU are pursuing a net-zero strategy until 2050 and a gradual reduction in free certificates for emissions-intensive industries.
  • Companies with high CO₂ emissions must increasingly develop carbon capture strategies or use alternative fuels.
  • By using a recycling-based fuel made from CO₂, the cement industry could drastically reduce its costs for CO₂ certificates and establish CO₂-neutral processes with regard to fuels in the long term.

3. economy & energy efficiency

  • The direct use of a plasma-based CO/O₂-rich mixture avoids conversions to existing clinker kilns, which saves enormous investments.
  • Existing plant infrastructures remain usable, as the plasma fuel can be used directly in conventional burners.
  • H₂-based processes are expensive, complicated and time-consuming, yet a CO/O₂ mixture with -283 kJ/mol has roughly the same calorific value as hydrogen (H₂) with -285 kJ/mol

4. sustainability & independence from fossil fuels

  • Geopolitical uncertainties and rising import costs for fossil fuels are jeopardizing security of supply.
  • Plasma-based fuel provides a local, renewable and CO₂-neutral source of energy.

5. political framework conditions & funding opportunities

  • The “Green Deal”, net zero strategy and EU taxonomy for sustainable investments call for a drastic reduction in fossil CO₂ emissions.
  • Many governments therefore support and promote technologies for CO₂ avoidance, reduction and use by means of subsidies or tax incentives.
  • Plasma processes could become part of the Carbon Contracts for Difference (CCfD), in which companies are compensated by the state for CO₂ reductions.

Conclusion: A competitive advantage through plasma

  • The integration of a plasma process for CO₂ conversion can significantly reduce fossil CO₂ emissions from CO₂-intensive heating processes such as clinker production.

  • CO₂ certificate costs of around CHF 120/t CO₂ are saved.

  • Existing infrastructure can continue to be used and expensive conversions can be avoided (CAPEX)

  • Independence from fossil fuels is achieved.

    Investing in this technology at an early stage secures competitive advantages and positions you as a pioneer in a climate-neutral building materials industry!

Talk to us.

This technology is breaking new ground. Naturally, we would like to prove the performance of our fuel in practice and quantify it more precisely. Are you interested in practical applications? Then let us find out.

Alnewa AG
Eschenstrasse 6
8603 Schwerzenbach
Switzerland