Analysis

They’ve done it! Best wishes are due to the Heidelberg Materials Norcem Brevik cement plant and everyone else involved. Today it has officially inaugurated its carbon capture and storage unit. The world’s first full-scale carbon capture facility in the cement industry is live.

The launch of the Longship project has been a two-day affair in Norway hosted by the Norwegian Ministry of Energy, Heidelberg Materials, Northern Lights and other stakeholders. Tuesday 17 June 2025 saw assorted speakers across government and industry, including Heidelberg Materials’ CEO Dominik von Achten, talk about net zero, carbon capture, CO₂ markets and more at the Norwegian National Opera & Ballet in Oslo. Then the event moved to the Brevik cement plant, today on Wednesday 18 June 2025, to inaugurate the project led by HRH Crown Prince Haakon of Norway. Our editorial director Robert McCaffrey has been in attendance and a full write-up will be available in the September 2025 issue of Global Cement Magazine.

Completing the CCS project at Brevik is undeniably a major achievement. Heidelberg Materials in Norway started seriously thinking about carbon capture in the 2000s and then tested four different potential carbon capture technologies at Brevik in the 2010s. A feasibility study, concept study and a FEED study followed for the use of an amine technology approach. A full-scale capture unit on one of the plant’s two production lines was then approved for funding partly by the Norwegian government in late 2020. Technically this is a gross simplification because the project team at Brevik have worked through the technical challenges of connecting a cement production environment to a petrochemical one. 400,00t/yr of CO₂ has started to be captured at Brevik and transported by ship, as part of the Northern Lights project, for sequestration under the North Sea. Heidelberg Materials then intends to sell a net-zero cement product via carbon capture around Europe called EvoZero using a carbon accounting system to manage it. When Global Cement asked about plans for EvoZero, Von Achten said production of the product is fully sold-out for 2025. “Customers are not the issue,” said von Achten. “Property developers and architects are leading the discussion on the use of EvoZero.” The age of commercially-available cement made using carbon capture has begun.

The Norwegian government estimates that the entire Longship project will cost around Euro2.6bn with Euro1.8bn attributable to the state. The original white paper proposed to the Norwegian parliament estimated that the Norcem project would cost just under Euro400m for construction and 10-years of operation. 84% of this would be paid for by state aid. Northern Lights, the CO₂ transport and storage part of Longship, had an estimated cost of Euro1.2bn, with 73% of this funding attributable to the state. Heidelberg Materials acknowledged the scale of the government grant funding it received in its 2024 financial report. It received Euro110m in government grants in 2024 with Euro77m for the Brevik project and a further Euro21m for a carbon capture, utilisation and storage project in Edmonton, Canada.

As discussed recently in Global Cement Weekly in response to the US government cutting funding for cement carbon capture projects, net zero is a deeply political issue because governments either have to pay for it directly, set-up incentives such as carbon taxes to encourage society to pay for it or ignore it and cope with the consequences. European policy is encouraging these projects so far. However, this is not necessarily the case elsewhere in the world. And governments can change their minds. The rough figures shown above about the cost of Brevik’s carbon capture unit and the costs of moving the CO₂ onwards show how expensive this is.

From here it’s all about building experience on how running an industrial-scale carbon capture operation actually works in the cement sector year in, year out. This will be an exercise across multiple disciplines including engineering, the logistics of CO₂ transportation and sequestration, dealing with state-level partners on a long-term basis and more besides. Many more cement sector carbon capture projects are following in Europe. They will all be eager to learn from the first one in Norway, from both the good and the bad. We will leave the last word to Von Achten from today’s inauguration, "Personally I love the collaboration part of it because this is a masterpiece of national, European, in fact, global collaboration… These days this is important."

On 9 June 2025 the Nepalese government announced the shock closure of the state-owned Udayapur Cement Industry, which operates the 0.4Mt/yr Jaljale cement plant in the high-altitude Terhathum District.¹ No express reason for the closure has been forthcoming. A little digging is therefore required…

Nationally, Nepal is home to 13 integrated and 16 grinding plants,² which sounds like a lot. However, with a total capacity of 12.3Mt/yr between them, each plant – many of which are quite aged and in need of modernisation - has an average capacity of 0.4Mt/yr. Amid chronic low demand, the capacity utilisation rate in some regions is as low as 40-50%.³

The planned closure of the Udayapur Cement Industry is all the more surprising considering that it only resumed operations on 24 April 2025 following the suspension of operations at the end of November 2024. The plant resumed production at 400t/day, half of its capacity, despite a US$42m upgrade as recently as February 2022 that had expanded it from 0.3Mt/yr to 0.4Mt/yr!

Upon re-opening in April 2025, the plant said that it had sufficient coal to maintain operations for at least 12 days and that it had a secure supply of electricity from the state-owned Nepal Electricity Authority (although it did also have unpaid electricity bills…). It has since been able to secure more coal, which must be imported through tortuously narrow passes from India. As well as securing coal, the plant’s altitude, some 1800m above sea level, complicates electrical infrastructure supplies. Back in 2019, the pre-expansion Jaljale cement plant was reduced to periods of just 13% capacity utilisation, with power cuts occurring at a rate of more than 60 in a single year, with six once hitting in a single day.

Back to the current year, Nepali cement producers faced an additional challenge on 15 February 2025, when a court issued a ‘show cause’ notice over seasonal price rises that had taken effect in December 2024. Bizpati News reported producers’ explanations that they were not in a cartel, including the admission that they were already operating at a loss.⁴ The situation got worse on 4 June 2025, when the government raised sales taxes from US$0.08/bag to 5% of the sales’ value.⁵ In order to protect their margins, producers raised prices by US$0.15-0.18/bag. According to Ravi Singh, president of the Federation of Contractors’ Associations of Nepal, this has meant that contractors are now struggling to purchase cement. He accused manufacturers of cutting production by up to 40% to create an artificial shortage, calling it ‘a tactic to manufacture scarcity and exploit the situation.’ Producers defended the price rise, claiming it corrects previous underpricing caused by ‘unhealthy competition.’

Regardless of who can shout the loudest, it is clear that there is just too much cement capacity in Nepal. While exports to India, itself not completely lacking in cement, have helped, more plants are likely to close. Back in Jaljale, Udaypur Cement Industry’s workers, their families, other local stakeholders and political parties have united in signing a memorandum of understanding in opposition to the closure. They too are asking: Why call time on a plant that was recently upgraded… and how can we keep the gates open?

References

1. https://www.globalcement.com/news/item/18859-nepali-government-announces-shock-closure-of-udayapur-cement-industry
2. Global Cement Directory 2025, Pro Global Media Ltd., Epsom, UK, 2025.
3. https://www.globalcement.com/news/item/17800-nepal-exports-us-3-81m-worth-of-cement-to-india-via-kakarvitta-crossing-in-2024-financial-year
4. https://bizpati.com/industry/88192
5. New Business Age News, ‘Cement price rises to Rs. 22 per bag,’ 4 June 2025, https://abhiyandaily.com/article/simenttko-muuly-boraamai-22-rupaiyaansmm-bddhyo

A week ago, there were two fully-financed cement plant carbon capture, utilisation and storage (CCUS) projects underway in the US.¹ Now, there aren’t.

Projects to decarbonise National Cement Company’s Lebec, California, plant and Heidelberg Materials North America’s Mitchell, Indiana, plant were each set to receive up to US$500m in US Department of Energy (DoE) funding on a one-for-one basis with private investments. The projects were to include eventual 950,000t/yr (Lebec) and 2Mt/yr (Mitchell) carbon capture installations. Additionally, the Lebec plant was to transition to limestone calcined clay cement (LC3) production and the use of alternative fuels (AF), including pistachio shells. Both were beneficiaries of the DoE’s US$6bn Industrial Demonstrations Program (IDP), touted by former US Secretary of Energy Jennifer Granholm as ‘Spurring on the next generation of decarbonisation technologies in key industries [to] keep America the most competitive nation on Earth.’ Disbursement of funding under the programme was frozen by executive order of President Trump in January 2025.^{2, 3}

On 30 May 2025, Trump’s Secretary of Energy announced that the government in which Granholm served had approved spending on industrial decarbonisation without a ‘thorough financial review.’ He cancelled remaining project funding in signature Trumpian style, in list form.⁴ Among 24 de-funded projects, Lebec and Mitchell accounted for US$1bn (27%) of a total US$3.73bn in allocated funds that have now been withdrawn.

It's hard not to feel sorry for the management of the Lebec and Mitchell plant and the teams that had been working to deliver these projects. Heidelberg Materials has yet to comment, though CEO Dominik von Achten was in North America in late May 2025. National Cement Company parent Vicat, meanwhile, conceded the setback with a strong statement of its commitment to CO₂ reduction, to 497kg/t of cementitious product globally.⁵ There was a diplomatic edge to the statement too, however. Echoing the Secretary of Energy, Vicat said that its target remains ‘solely based on existing proven technologies, including energy efficiency, AF substitution and clinker rate reduction’ – as opposed to ‘any technological breakthroughs’ like carbon capture. There are currently no public details of possible back-up financing arrangements for these projects; for now, the best guess at their status is ‘uncertain.’

Alongside these group’s local subsidiaries, another organisation that has to do business daily with the DoE is the American Cement Association (ACA). President and CEO Mike Ireland has continually acknowledged the complex needs of the government, while stating the association’s case for keeping support in place. With regard to these funding cuts, Ireland’s emphasis fell on the latter side: “Today’s announcement is candidly a missed opportunity for both America’s cement manufacturers and this administration, as CCS projects have long been supported by bipartisan members in Congress and bipartisan administrations.”⁶ He reasserted the ACA’s understanding that carbon capture aligns with the administration’s strategy to bolster domestic manufacturing and innovation.

The early 2020s heyday of US carbon capture was founded on gradual, consensus-based politics – unlike its demise. Table 1 (below) gives a non-exhaustive account of recent and on-going front-end engineering design (FEED) studies and the funding they received:

Additionally, MTR Carbon Capture, which is executing a carbon capture pilot at St Marys Cement’s Charlevoix plant in Michigan, previously received US$1.5m in Fossil Energy Research and Development funding towards a total US$3.7m for an unspecified cement plant carbon capture study.¹⁰

Market researcher Greenlight Insights valued industrial decarbonisation initiatives under the Office of Clean Energy Demonstrations (ODEC – the now defunct DoE office responsible, among other things, for the IDP) at US$65.9bn in cumulative returns in April 2025.¹¹ The government has yet to publish any account of how it might replace this growth, or the 291,000 anticipated new jobs that would have come with it. Given all this (along with the extensive financial and technical submissions that accompanied each project), the issues raised by the DoE are presumably budgetary, or else founded in a perception of CCUS as essentially uneconomical.

Carbon capture is very, very expensive. A fatuous reply is that so is climate change, just with a few more ‘verys.’ Hurricane Ian in September 2022 cost US$120bn, more than enough to fund carbon capture installations at all 91 US cement plants, along the lines of the former Lebac and Mitchell agreements.¹² Unlike climate change, however, carbon capture remains unproven. Advocates need to continually justify taxpayer involvement in such a high-risk venture.

At its Redding cement plant in California, Lehigh Hanson successfully delivered a funding-free FEED study, with its partner Fortera raising US$85m in a Series C funding. This presents an alternative vision of innovation as fully-privatised, in which the government might still have the role of shaping demand. This is borne out in the IMPACT Act, a bill which ‘sailed through’ the lower legislature in March 2025.¹³ If enacted, it will empower state and municipal transport departments to pledge to buy future outputs of nascent reduced-CO₂ cements and concretes.

A separate aspect of the funding cancellation that appears decidedly cruel is the targeted removal of grants to start-ups. Two alternative building materials developers – Brimstone and Sublime Systems – were listed for a combined US$276m of now vapourised liquidity. Both are commercially viable without the funding, but the effect of this reversal – including on the next generation of US innovators who hoped to follow in their footsteps – can only be chilling. As non-governmental organisation Industrious Labs said of the anticipated closure of the ODEC in April 2025: “We may see companies based in other geographies start to pull ahead.”

Heidelberg Materials’s Brevik carbon capture plant came online in June 2025, 54 months after the producer secured approval for the project. The term of a presidency is 48 months. This probably means that producers in the US will no longer see CCUS as a viable investment, even under sympathetic administrations.

Even as government funding for CCS flickers from ‘dormant’ to ‘extinct,’ the sun is rising on other US projects. Monarch Cement Company commissioned a 20MW solar power plant at its Humboldt cement plant in Kansas on 27 May 2025. The global momentum is behind decarbonisation, even if economics determines that it will only take the form of smaller-scale mitigation measures at US cement plants into the medium-term future. We can hope that these, at least, might include the AF and LC3 aspects of National Cement Company’s plans at Lebec.

References

1. Clean Air Task Force, ‘Global Carbon Capture Activity and Project Map,’ accessed 3 June 2025, www.catf.us/ccsmapglobal/

2. Democrats Appropriations, ‘Issue 5: Freezing the Industrial Demonstrations Program Undermines U.S. Manufacturing Competitiveness and Strands Private Investment,’ January 2025, www.democrats-appropriations.house.gov/sites/evo-subsites/democrats-appropriations.house.gov/files/evo-media-document/5%20DOE%20Frozen%20Funding%20-%20Industrial%20Demos.pdf

3. Colorado Attorney General, ‘Attorney General Phil Weiser secures court order blocking Trump administration’s illegal federal funding freeze,’ 6 March 2025, www.coag.gov/press-releases/weiser-court-order-trump-federal-funding-freeze-3-6-25/

4. US Department of Energy, ‘Secretary Wright Announces Termination of 24 Projects, Generating Over $3 Billion in Taxpayer Savings,’ 30 May 2025, www.energy.gov/articles/secretary-wright-announces-termination-24-projects-generating-over-3-billion-taxpayer

5. Vicat, ‘Cancellation of funding agreement for the Lebec Net Zero project by the US Department of Energy,’ 3 June 2025, www.vicat.com/news/cancellation-funding-agreement-lebec-net-zero-project-us-department-energy

6. American Cement Association, ‘Statement from the American Cement Association on Department of Energy’s Cancellation of Clean Energy Grants,’ 30 May 2025, www.cement.org/2025/05/30/statement-from-the-american-cement-association-on-department-of-energys-cancellation-of-clean-energy-grants/

7. Gov Tribe, ‘Cooperative Agreement DEFE0031942,’ 30 September 2022, www.govtribe.com/award/federal-grant-award/cooperative-agreement-defe0031942

8. Higher Gov, ‘DECD0000010 Cooperative Agreement,’ 13 May 2024, www.highergov.com/grant/DECD0000010/

9. Gov Tribe, ‘Cooperative Agreement DEFE0032222,’ 7 February 2025, www.govtribe.com/award/federal-grant-award/cooperative-agreement-defe0032222

10. Higher Gov, ‘DEFE0031949 Cooperative Agreement,’ 1 May 2023, www.highergov.com/grant/DEFE0031949/

11. Center for Climate and Energy Solutions, ‘Jobs, Economic Impact of OCED Closure,’ 11 April 2025, www.c2es.org/press-release/oced-closure-could-cost-65-billion-290000-jobs/

12. National Centers for Environmental Information, ‘Events,’ accessed 4 June 2025, www.ncei.noaa.gov/access/billions/events/US/2022?disasters%5B%5D=tropical-cyclone

13. US Congress, ‘H.R.1534 - IMPACT Act,’ 26 March 2025, www.congress.gov/bill/119th-congress/house-bill/1534

The Polish Cement Association (SPC) has taken a swing at mounting cement imports from outside of the European Union (EU) in recent weeks. Its ‘apocalyptic’ message was underlined by the name of a seminar it participated in at the European Parliament: “Is the end of cement production in the EU approaching?” The SPC’s primary target appeared to be imports from Ukraine. It said that, “...cement imports from Ukraine - only to Poland - have increased by almost 3000% over five years (2019 - 2024). (In 2024) it amounted to more than 650,000t, and forecasts for 2025 already indicate more than 1Mt.” However, it detailed other issues affecting the sector including high energy prices, the EU Emissions Trading Scheme (ETS) and decarbonisation costs such as carbon capture.

The SPC is clearly keen to find cross-country support in the EU. In its accompanying statement it said "The uncontrolled increase in imports - from Ukraine to Poland or Romania, and from Türkiye and Africa to Italy or Spain - is already directly threatening cement producers, and will only continue to rise until the full implementation of the CBAM. It shows that imports from outside the EU are not just a problem for Poland.” Representatives from the cement associations in the later countries - CIROM, AITEC and Oficemen - all added comments to the SPC statement.

The SPC has called for a customs quota on cement imports from Ukraine to Poland to be introduced. It also asked for the European Commission to extend the EU ETS indirect cost compensation scheme to include the cement sector in order to further hedge against rising energy bills. It argues that this measure is essential to keep the cement industry competitive both now and in the future. Future electricity consumption is expected to double as cement plants start to install carbon capture technology.

Graph 1: Domestic cement sales and imports in Poland, 2019 - 2024. Source: SPC, Eurostat. Note: 2024 sales estimated.

Data from the SPC suggests that domestic cement sales in Poland peaked at 19.4Mt in 2022. They fell by 12% year-on-year to 16.6Mt in 2023 and then appear to have grown to 17.1Mt in 2024 based on estimated data. It is hard to replicate the SPC’s methodology for determining cement imports into Poland based on Eurostat data. However, data in its Economic Impact Report published at the end of 2024 suggests that imports from Ukraine grew from 79,000t in 2019 to 332,000t in 2023. Any significant rise in imports of cement in 2024, as the local industry recovered from the decline in 2023, seems likely to have caused concern.

Polish concern at growing imports from Ukraine started to be expressed in the press from early 2024 onwards when the 2023 data became apparent. Germany had been the biggest source of imports from the mid-2010s. Yet Germany and Ukraine both supplied about 30% of total imports each in 2023. For example, SPC head Zbigniew Pilch noted in April 2024 that imports from Ukraine were growing steadily each month and represented nearly half of total imports in January 2024. He described these volumes as “deeply concerning.” The Association of Cement Producers in Ukraine (Ukrcement) later attempted to soothe Polish concerns in late 2024 looking at longer import trends and bringing up the challenges facing Ukraine-based producers operating in a warzone.

Concerns about imports from Ukraine in eastern countries in the EU go back decades but have been clouded by the war with Russia. This is now reasserting itself as import levels grow, the cost of decarbonising heavy industry becomes more urgent and the CBAM comes into force. That said , cement plants in Ukraine look unlikely to cope with the CBAM that well due to their relatively high emissions intensity. Yet, other exporting countries outside the EU with lower cement sector emissions intensities may simply displace their competitors. Hence, the SPC’s call for a quota. The kinds of arguments that the SPC is making about carbon leakage are likely to grow fiercer across the EU as the definitive stage of the CBAM, due to start in 2026, draws nearer. Will the current situation lead to ‘the end of cement production in the EU?’ Time will tell…

Najmat Al Samawa Cement (NAS Cement) in Iraq announced this week that its second production line was successfully fired up on 13 May 2025. The new 5500t/day line was formally announced in May 2023. It joins the existing line at the site and should bring the plant’s total production capacity to around 3Mt/yr. The plant is a joint-venture between Pakistan-based Lucky Cement Limited and the Al Shumookh Company in Dubai and its representatives in Iraq.

Global Cement Magazine interviewed Intezar Ahmad, the Director of Operations at NAS Cement, in the November 2024 issue. He explained that China-based TCDRI was the main contractor for both the original and new lines. Equipment for Line 2 was also supplied by Fives Pillard, Loesche and IKN. Commissioning was scheduled for the second quarter of 2025. This, nicely, appears to be spot on. Lucky Cement added in its statement about the new line this week that it is also building a new 0.65Mt/yr cement grinding mill at the plant. This addition is expected to be commissioned during the second half of the 2025 calendar year. Lucky Cement also operates a cement grinding plant, under a joint-venture, in Basra.

The expansion at NAS Cement is by no means the only one as there have been a number of project announcements over the last three months. Germany-based Gebr. Pfeiffer revealed in late-March 2025 that it had won an order to supply a vertical roller mill for the Al Amir cement plant in Najaf. This contract was awarded through the China-based contractor Sinoma Suzhou. Commissioning is planned for the second half of 2026. Then, one month later in April 2025, Prime Minister Mohammed Shia Al-Sudani made a statement launching ‘implementation works’ at four cement plants in Al-Muthanna Province. This included the 6000t/day Al-Arabi Cement Plant, the 6000t/day Al-Khairat Al-Muthanna Cement Plant, the 6600t/day Al-Samawa Cement Plant and the 6000t/day Al-Etihad Cement Plant. Al-Sudani also mentioned the start of commercial operations at NAS Cement’s second line. Subsequently, IVI Holding signed a US$240m deal with Sinoma Overseas in mid-May 2025 to build a 6000t/day plant in Al-Muthanna Province. Presumably, this is one of the projects that the government highlighted. Finally, the Kurdistan Region prime minister Masrour Barzani inaugurated the 6300t/day Dabin cement plant at around the same time. This last project was built by PowerChina together with a power station.

The Iraqi economy has been doing well in recent years. The International Monetary Fund (IMF) reported in May 2025 that the non-oil sector experienced “very strong growth” of 13.8% in 2023. This slowed down to 2.5% in 2024 due to a slowdown in public investment and in the services sector, and a weaker trade balance. However, the IMF noted that the agriculture, manufacturing, and construction sectors had remained resilient. Non-oil sector growth is forecast to remain subdued in 2025 amid a “...challenging global environment and financing constraints.” In its coverage of the new line at NAS Cement, Pakistan Today reported that the country has a notional cement production capacity of around 40Mt/yr but that many of the older plants have suffered from under-investment. Accordingly, the domestic market is around 25Mt/yr supported by state-funded housing projects, oil-field infrastructure schemes and reconstruction in Mosul. 3 - 4Mt of this is supplied via imports from Iran and Türkiye. The newspaper also noted the risk that all these new cement plant projects may face from variable gas supplies from the government. NAS Cement, for example, switched from heavy fuel oil (HFO) to gas in 2022.

Cement sector capacity expansion is coming in Iraq following a revived local economy. Risks abound though due to the country’s economic outlook, its dependence on oil and an geopolitical uncertainty. Yet money is being spent and new projects are starting to be commissioned. Onwards!