Researchers at Stanford University have developed an electrically-powered plasma heating process that could significantly reduce fossil fuel use in clinker production.
The technology uses electricity to generate ionised gas at temperatures above 2400°C, directly heating cement raw materials. Researchers reported that clinker formation occurred within seconds – nearly 100 times faster than conventional production – while around 80 per cent of the generated heat was used in cement production, compared with typical thermal efficiencies of 30-40 per cent.
Tests found that cement produced using the process had comparable mechanical properties to conventional cement, while nanoscale defects created during plasma treatment accelerated hydration and improved strength.
The process can also use recovered cement waste as a feedstock, potentially combining kiln electrification with material recycling. If powered by renewable electricity, it could eliminate fuel-related CO2 emissions, although process emissions associated with carbonate raw materials would remain.
The research team, plans to work with cement industry partners to test and scale the technology for industrial production.
