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:
- Process-related emissions (~60 %): Release of CO₂ during the calcination of the limestone (CaCO₃ → CaO + CO₂)
- 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
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The integration of a plasma process for CO₂ conversion can significantly reduce fossil CO₂ emissions from CO₂-intensive heating processes such as clinker production.
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CO₂ certificate costs of around CHF 120/t CO₂ are saved.
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Existing infrastructure can continue to be used and expensive conversions can be avoided (CAPEX)
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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!