Carbon capture at a cement plant separates CO₂ from kiln exhaust—or isolates it as limestone is heated—then conditions the captured gas for transport to a use or geological storage site. The most established cement-sector route described by the sources is post-combustion chemical absorption with an amine solvent; oxy-fuel, calcium looping and direct separation are other approaches at different stages of development.
Why cement plants need more than one capture approach
Cement-making releases CO₂ in two main ways. Burning fuel to heat the kiln produces emissions in the exhaust, while heating limestone releases process CO₂ as the rock decomposes. Capture systems can treat a mixed exhaust stream containing both kinds of emissions, or separate process CO₂ from combustion gases at the calciner. The distinction matters: a system that captures one stream does not automatically eliminate emissions from the other. The IEA’s CCUS overview describes these routes and the wider capture-and-transport chain.
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The options differ in what they capture, how much of the plant must change, and how much additional heat or electricity they need. The following maturity descriptions reflect the cited overviews, not a guarantee that a system is commercially available or suitable at every site.
| Approach | Where it fits | Cement-sector status described by the sources |
|---|---|---|
| Post-combustion amine absorption | Treats kiln exhaust after combustion. | IEA describes cement-specific trials at Brevik; GCCA describes a scale-up target. See IEA and GCCA. |
| Oxy-fuel | Changes combustion conditions across the pyroprocess or at calcination. | GCCA describes full and partial configurations and indicative capture ranges. GCCA overview. |
| Calcium looping | Uses a circulating calcium-based sorbent to capture CO₂ and then release it. | IEA describes the technology generally as pilot/pre-commercial and notes cement-manufacturing tests. GCCA overview. |
| Direct separation | Separates process CO₂ during limestone heating. | IEA cites the LEILAC pilot at HeidelbergCement’s Lixhe plant in Belgium as a test example. IEA overview. |
How the main capture methods work
Post-combustion amine capture
In the common chemical-absorption setup, kiln flue gas passes through an absorber and contacts an amine solvent. The solvent selectively takes up CO₂. The resulting CO₂-rich liquid then moves to a desorber, where heat releases the CO₂ and regenerates the solvent so it can return to the absorber. The released gas still needs conditioning before it is transported.
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Regeneration requires substantial heat, while the capture train also uses electricity. The IEA’s technology-gap analysis reports up to 95% CO₂ capture for chemical-absorption post-combustion systems, with estimated additional demand of 1–3.5 GJ of heat and 50–90 kWh of electricity per tonne of clinker. These are source-reported estimates, not guaranteed results for an individual plant; the cited IEA report page is not a 2026 measurement. IEA, “Industry – Innovation Gaps”.
Solvent choice and exhaust quality affect integration. Monoethanolamine (MEA) is a commonly used solvent, but sensitivity to flue-gas impurities can make sulfur-oxide and nitrogen-oxide cleanup necessary. That means the capture unit may depend on gas treatment upstream as well as on the kiln and the plant’s energy supply. GCCA’s post-combustion overview discusses this approach.
At Norcem’s Brevik plant, the IEA reports an amine-sorbent trial that operated for around 8,000 hours and captured 2 kilotonnes of CO₂ between 2013 and 2016. Separately, GCCA describes a Brevik scale-up project intended to reach up to 400,000 tonnes per year. The trial total and the project’s stated target measure different things; the target should not be read as a report of current annual output. IEA; GCCA.
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Oxy-fuel combustion
Conventional kiln combustion uses air, which contains nitrogen that dilutes the exhaust. Oxy-fuel burns fuel in oxygen-rich conditions instead, so less nitrogen enters the exhaust and the resulting gas is richer in CO₂. Water can be removed to produce a CO₂ stream for further processing. The plant needs an air separation unit to supply oxygen and changes to heat recovery and flue-gas recirculation; air leakage and burner and cooler design also affect how the system integrates.
GCCA distinguishes full oxy-fuel, applied across the pyroprocess, from partial oxy-fuel, applied only to calcination. Its overview gives indicative capture ranges of 90–99% for full and 55–75% for partial oxy-fuel. These are technology ranges, not guaranteed plant outcomes. GCCA also reports that full oxy-fuel entails greater production-line adaptation, while partial oxy-fuel may allow staged implementation. For the integrated equipment described in that overview, it reports more than doubling electricity use per tonne of clinker and a 40–50% increase in production cost; neither figure is a project-specific estimate. GCCA’s oxy-fuel overview.
Calcium looping
Calcium looping uses calcium oxide (CaO) as a reusable sorbent. In a carbonator, CaO reacts with CO₂ and becomes calcium carbonate (CaCO₃). A second reactor, the calciner, heats the carbonate to release concentrated CO₂ and regenerate CaO for another cycle. GCCA gives a calcination temperature of about 850–950°C.
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Heat can be supplied directly or indirectly. Direct heating often uses oxygen-rich combustion to avoid diluting the CO₂ with nitrogen, adding the energy burden of oxygen supply. The sorbent also loses performance over repeated cycles, so some material needs replacement and spent material must be managed. GCCA’s calcium-looping overview.
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Direct separation changes the calciner so limestone is heated indirectly. This keeps the CO₂ released by limestone decomposition apart from combustion gases, potentially reducing the separation work needed compared with treating a mixed flue-gas stream. The IEA cites the LEILAC pilot at HeidelbergCement’s Lixhe plant in Belgium as an example of the technology being tested; that reference does not establish its current operating status. IEA’s CCUS overview.
Emerging approaches
Membranes can selectively pass CO₂ while retaining other gases, but the IEA describes flue-gas membrane treatment as under development. Commercial membranes used for syngas or biogas do not, by themselves, establish equivalent maturity for cement-kiln exhaust. Ammonia-based post-combustion capture has been piloted in other industrial and power settings, but GCCA says commercial-scale use under cement-flue-gas conditions remains unproven. IEA; GCCA.
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What happens to captured CO₂
Capture is one stage in a chain, not the final destination. The CO₂ stream needs purification and conditioning for its intended use, then transport. Pipelines and ships are large-volume transport options; trucks and rail can move smaller volumes at higher cost per tonne. The availability of safe, reliable transport infrastructure is therefore a practical requirement, not an optional add-on. IEA’s CCUS overview.
What happens after transport affects the climate outcome. Some CO₂ may be used in products, while other captured CO₂ may be sent to geological storage. “Utilization” does not necessarily mean permanent storage: the outcome depends on the product and what eventually happens to its carbon. A capture rate also is not the same as a whole-plant emissions reduction. Residual emissions can remain in untreated streams or arise elsewhere in production, and captured CO₂ is not permanently kept out of the atmosphere unless its destination and fate support that conclusion.
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A capture percentage describes a particular system boundary; it should not be treated as the percentage reduction in all emissions from a cement plant. Comparisons are useful only when they clarify which streams are covered, the plant configuration, and whether the figure is a technology range, an estimate, a trial result or a project target. Energy demand, integration work, gas cleanup, sorbent or solvent management, and access to transport and storage all affect the real-world choice.
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For cost context, the IEA’s 2025 estimate says early commercial near-zero-emissions cement plants using CCS could have production costs 75–150% higher than conventional plants, with the premium varying by region. This is a production-cost estimate for plants using CCS—not the cost of capture alone or a quote for a particular facility. The analysis uses 2024 energy prices, energy intensities and fuel mixes, and excludes explicit policy support. IEA, “Cement and concrete – Breakthrough Agenda Report 2025”.
No single capture configuration is a universal fit. The relevant decision depends on which emissions stream a plant targets, its existing equipment, available heat and electricity, and whether a route to CO₂ use or storage exists. The cited technology overviews do not establish a universal engineering design or current site-by-site cost.
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