Replacing Fossil Fuels with Waste-Based Fuels for Cement Production
During this project, Heidelberg Materials installed systems and infrastructure to receive, store, and feed waste-based alternative low carbon fuels (ALCF) to replace fossil fuels in the cement kiln system at their Edmonton plant. The project was awarded funding through the Shovel Ready Challenge in 2021, and after its successful completion in 2024, Heidelberg has plans to develop low-carbon fuels at its 14 North American plants that have not already integrated ALCF.
The cement industry is a large emitter of CO2, accounting for nearly 8% of global emissions. These emissions are emitted from the conversion of limestone and other minerals to clinker – a key ingredient in cement – and the fossil fuels used in those thermal processes. In the Canadian cement industry, currently, over 90% of fuels used are coal, petcoke, natural gas, and other high-carbon-content fuels. To reduce greenhouse gas (GHG) emissions, Heidelberg integrated waste-based ALCF into the cement kiln system. The ALCF is sourced from municipal, construction, and demolition waste materials, which would otherwise end up in landfills. By replacing fossil fuels with a fuel that emits significantly less CO2 and diverting waste from landfills, the project can reduce nearly 25 kilotonnes of CO2 annually, and cumulative reductions of 150 kilotonnes by 2030. This approach also reduces fuel costs and generates savings from avoided emissions credits, highlighting the potential for both environmental and economic benefits.
Understanding Fuel Performance and Integration
This project demonstrated that waste-derived fuels can be successfully integrated into cement production at commercial scale while maintaining product quality, environmental compliance, and reliable plant operations. During the project, Heidelberg designed, built, and commissioned a fully integrated system to receive, store, blend, convey, and precisely feed alternative low-carbon fuels into its kiln, advancing the technology from TRL 8 to TRL 9. In the operation phase, the facility achieved 82% system uptime and successfully replaced up to 30% of kiln heat demand with alternative fuels during steady operation.
The project provided valuable insights into the practical realities of deploying low-carbon technologies at scale. During the operation phase of the project, the new equipment performed reliably, and kiln operations remained stable; however, the team found that variations in fuel quality and supply could affect performance. Differences in moisture content, fuel consistency, and material size created operational challenges that required ongoing adjustments to equipment settings, process controls, and fuel management practices. Rather than disrupting the project, these challenges provided valuable learning opportunities. By working closely with suppliers, analyzing operating data, and identifying the root causes of performance issues, the team developed solutions that will improve fuel handling, increase replacement rates, and enhance overall reliability.
What’s next?
Overall, the project achieved its environmental and operational objectives and generated practical knowledge that Heidelberg plans to apply to future alternative fuel projects across their North American operations, helping accelerate the adoption of lower-carbon cement production. Building on the foundation of this project, Heidelberg will improve the ALCF and kiln systems at the Edmonton plant by removing bottlenecks and building and maintaining a strong, reliable long-term supply of ALCF.