Holcim is exploring the use of char as a sustainable alternative to fossil fuels in cement manufacturing. As part of the Plastics2Olefins project, the company is testing char’s potential to reduce emissions and support the circular economy.
“As a global leader in innovative and sustainable building solutions, Holcim brings its industrial expertise to the Plastics2Olefins project by playing a critical role in validating and integrating char, a by-product of the plastic pyrolysis process, as an alternative fuel source in cement production,” explains Cristina Gómez, Plant Manager of Geocycle, a part of Holcim.
The Holcim Group is a global leader in innovative and sustainable building solutions. With over 1,000 employees in Spain and sustainability at the heart of its strategy, Holcim is redefining the future of construction with solutions that are circular, resilient, low-carbon, energy-efficient, and smart.
A key ambition for Holcim is to become a net-zero emissions company by 2050. To get there, the company’s strategy focuses on four main pillars: climate, circularity, nature, and people.
Holcim’s Role in P2O: Driving Sustainability in Cement Manufacturing
Holcim actively contributes to the Plastics2Olefins initiative through its involvement in Work Packages (WP) 3 and 6, focusing on char characterization and industrial-scale trials.
In WP3, Holcim is evaluating char samples made from different types of plastic waste.
“Since char properties can vary depending on the feedstock, the company is conducting detailed evaluations – looking at calorific value, moisture content, heavy metals, halogens, and sulfur levels, among other parameters,” says Gómez.
These tests help determine whether the char can safely and effectively replace fossil fuels like petroleum coke or coal in cement kilns.
In WP6, Holcim is running full-scale industrial trials at its cement plants. These trials aim to understand how char behaves during combustion, how it affects emissions like CO₂, NOx, and SOx, and whether it impacts the stability of the production process or the quality of the cement itself.
Current Status and Findings
Holcim has already made significant progress in the project.
Char samples produced at the Repsol pilot plant are being tested at two of Holcim Group’s specialized facilities: the Quality Central Laboratory (LCC) and Geocycle Albox.
“These comprehensive tests provide a solid understanding of char’s properties and help anticipate how it will perform in real-world industrial conditions,” notes Plant Manager Gómez.
Holcim has also started experimenting with blends of petroleum coke and char, looking to fine-tune a mix that balances energy performance, sustainability, and compliance with environmental regulations.
