Carbon Upcycling’s Cost-Effective Approach to Low-Carbon Concrete

Carbon Upcycling is leading a pioneering effort to reduce the significant carbon footprint associated with concrete production by utilizing industrial waste and recycled carbon dioxide. In Canada, the steel industry generates vast quantities of by-products, specifically basic oxygen furnace slag, which typically ends up in landfills, despite the steel mills producing around half a million tonnes per year. The need to utilize these by-products is critical as industries like steelmaking, coal-fired power, and cement production contribute profoundly to greenhouse gas emissions.

Apoorv Sinha, CEO of Carbon Upcycling based in Calgary, emphasizes the challenge of developing effective recycling methods that can integrate seamlessly into existing industrial processes. The company aims to transform low-value industrial waste and carbon emissions into a sustainable low-carbon cement additive. With plans to construct a facility in Mississauga at Ash Grove Cement, the company seeks to upcycle carbon dioxide captured from flue gases alongside slag from local steel plants, proposing a viable circular economy model. The facility is expected to produce 100 tonnes of low-carbon cement daily, effectively utilizing nearby waste resources.

Carbon Upcycling is part of a broader movement involving numerous startups intent on decarbonizing cement production, which globally accounts for around 8% of greenhouse gas emissions. The challenge is multifaceted, particularly because traditional Portland cement—which is crucial for making concrete—releases substantial carbon dioxide during its production due to the heating of limestone. Although Canada’s emissions from cement production are lower than the global average, cement still accounted for approximately 1.5% of national emissions in 2019.

Experts like R. Douglas Hooton note that decarbonization efforts in the cement industry are primarily focused on reducing reliance on coal and exploring alternative raw materials to limestone. Some companies are investigating the use of biofuels, waste fuels, and materials like ground-up glass and various slags to reduce their carbon footprints. Many innovative solutions are still in the pilot phase, but show promise in transitioning the industry toward low-carbon options.

The partnership with Ash Grove places Carbon Upcycling in a favorable position. Their new facility is anticipated to lower the plant's carbon intensity by approximately 12,000 tonnes annually and produce commercially viable quantities of low-carbon cement that may be competitive with traditional products. This operational site is set to be one of the first commercial-scale carbon capture and utilization facilities in the world, supporting significant infrastructure projects while also reducing overall carbon emissions.

Despite the optimism, challenges remain, particularly regarding resource availability and energy sourcing. As fewer coal plants operate, the accessibility of fly ash decreases, and variations in local materials can complicate cement production. However, Carbon Upcycling’s technology allows for the use of various slag types, potentially offering an advantage as the industry shifts towards electric arc furnaces, which produce different by-products.

Ultimately, the movement towards local solutions is emphasized, as transportation logistics and global supply chains can exacerbate environmental impacts. By harnessing local resources and emissions, companies like Carbon Upcycling highlight the potential for impactful change in the cement industry, aligning with broader net-zero goals and the push towards sustainable construction practices. This initiative is part of a larger mission to accelerate Canada’s transition to a sustainable carbon management framework.