How Autodesk helps Novacem create carbon negative cement

Cement holds the building and construction industry together. Globally, the cement market is worth around £100bn and the industry supplies 2.9bn tonnes of cement to support global economic development every year. This is set to grow to 5bn tonnes a year by 2030, mainly due to rapidly increasing development needs in India and China.

However, the environmental impact of this huge industry is equally significant. Figures show the cement industry contributes 5 per cent of the world’s CO₂ emissions, making it one of the biggest polluters. Cement plants are large CO₂sources, producing 1-3 megatonnes per year, equivalent to around half the emissions of a medium coal-fired power station. Mitigating emissions in the cement industry needs to be an important part of any overall strategy to meet global emission reduction targets.

The production of 1,000 kg of cement emits approximately 800kg of CO₂, 50 per cent comes from the release of CO₂bound to the main raw material limestone; 40 percent from the combustion of fossil fuels needed for the main chemical reaction and the remainder from electricity use and transport.

In an effort to reduce emissions, the cement industry is working to adapt its processes. This includes the reduction of clinker (by partially replacing it with materials such as slag, limestone and fly ashes); the partial use of alternative fuels; and energy efficiency techniques. Yet all of these steps to address environmental impact will only have incremental impact on the cement industry’s emissions.

Novacem’s Solution 

Novacem is developing a solution, which has the potential to significantly reduce the cement industry’s CO₂ output. The company is currently using Digital Prototyping software from leading vendor Autodesk, including, most prominently, the AutoCAD Plant 3D solution, to help it achieve its goals.

The firm, which was launched in 2007 as a spin-out from Imperial College, London, is developing a carbon negative cement and related cement-making process, which has the potential to revolutionise the industry. Novacem was recently listed on the Global Cleantech 100, drawn up by the Cleantech Group in conjunction with a 60-person international panel of experts to highlight the most promising private clean technology companies from around the world.

Meeting the Challenge 

The emissions from the present cement industry, based on the production of Portland Cement, arise from two principal sources. Firstly, calcination of limestone (Calcium Carbonate) releases the carbon stored in the limestone. Secondly, the energy needed to achieve the necessary temperature (c. 1,400^o C) and to grind the clinker produced by calcination requires significant amounts of fossil fuel.

Instead of being based on limestone (calcium carbonate), Novacem’s cement is based on magnesium oxides and carbonates, which are produced from naturally occurring magnesium silicates raw materials. So there is no stored carbon in the raw material to be released during processing. It is believed there are magnesium silicate reserves of more than 20 trillion tonnes. The Novacem process requires temperatures of around 700^o C, which means that low carbon or carbon neutral fuel can be utilised. Finally, the Novacem process produces a magnesium carbonate compound which absorbs CO₂ during production, and which is included in the final cement composition. Inclusion of this magnesium carbonate in the composition means that an already low-carbon production process can become carbon negative. Overall, the Novacem process could reduce emissions by 850kg per tonne of Novacem cement used instead of traditional cement.

Pilot Plant 

Novacem is already operating a laboratory pilot plant which is continually being upgraded. To support development and upgrades, Novacem is using Autodesk design software provided through Autodesk’s Clean Tech Partner Program. Novacem uses the software to provide a template design which will be used to develop engineering drawings, and it is also making use of the tool to do digital design, supporting fine tuning and cost control.

An important element of using the Autodesk design software is to visualise the systems before they are physically built and installed. Virtual realisations of the plant with walk-throughs and three dimensional representations can be developed which not only help design work but also help to provide images to third parties such as investors, partners, and planning, environmental and safety agencies. AutoCAD Plant 3D brings modern 3D design to plant designers and engineers to help streamline the placement of piping, equipment, and support structures, reducing complexity and evaluating different designs quickly and easily. As part of the programme, Novacem has been working with recognised AutoCAD Plant 3D consultants who are supporting Novacem in training its engineers to use the programme efficiently.

The Clean Tech Partner Program program supports early-stage clean technology companies by providing design and engineering software that accelerates their development of solutions to the world's most pressing environmental challenges. Clean tech companies in North America, Europe and Japan who can benefit from Autodesk solutions for Digital Prototyping are invited to apply to receive up to €120,000* worth of software for only €50. To find out more, including how to apply, visit www.autodesk.co.uk/cleantech.

Future development 

With the help of Autodesk software, Novacem will continue to upgrade its existing production capacity and scale up to the next stages towards commercial production. Throughout this process, Digital Prototyping technology will be key in enabling Novacem to digitally design, visualise and simulate how the planned automated control systems will work under real-world conditions before they are built and installed. This approach allows for the exploration of range of different concepts. Novacem’s design team will have the freedom to be creative and to try pioneering new ideas in pursuit of new solutions that improve its production process, with the aim of making it the standard for the construction industry.

* Value is based on up to five commercial licenses of each application.