Cement plant in a green landscape, water in front of it

GeZero

Paving the way for a decarbonised cement industry 

Please feel free to contact us at gezero@heidelbergmaterials.com

Heidelberg Materials is leading the way in decarbonising the building materials industry and is pioneering industrial-scale carbon capture and storage in Germany. With GeZero, Germany's first inland cement plant will be established to fully utilise carbon capture technology in a scalable manner.

This technology has the potential to transform cement production fundamentally, thus setting an entirely new benchmark for CO₂ reduction. CCS (Carbon Capture and Storage) prevents unavoidable CO₂ emissions from being released into the atmosphere. This makes a fundamental contribution to achieving the climate targets to which we are also committed.

In Geseke, North Rhine-Westphalia, a large-scale carbon capture facility and a solution for transport and storage are being developed. The project relies a second generation advanced oxyfuel technology and aims to capture 700,000 tonnes of unavoidable CO₂ per year, storing it safely and permanently. The total investment sum exceeds half a billion euros and is being subsidised by around 191 million euros from the EU Innovation Fund. 

Geseke site as a pioneer for CCS

GeZero will be implemented at our cement plant in Geseke, in the district of Soest. The region has a long tradition of cement production and meets key requirements for investments of this kind. By implementing a complete CCS value chain, we are not only investing in the future of the Geseke site, but also bringing innovative cutting-edge technology to the region. In this way, we aim to pave the way for other players and accelerate the transition to climate-neutral industry in North Rhine-Westphalia. To ensure that as many people and companies as possible benefit from this initiative, important connection points to the emerging CO₂ infrastructure are also being created for other industrial players in the region.

With around a third of the nation's cement production, North Rhine-Westphalia is a key location for the industry. We are therefore delighted that the first carbon-free cement plant in Geseke, in the district of Soest, serves as a flagship project for a sustainable and climate-neutral future in the cement sector. GeZero demonstrates how climate protection can also be achieved in energy-intensive industries through new technologies and processes. This is an important step towards sustainable cement production and a net-zero industry in North Rhine-Westphalia, Germany and beyond.

Mona Neubaur

Mona Neubaur is Minister for Economic Affairs, Industry, Climate Action, and Energy and Deputy Prime Minister of the State of North Rhine-Westphalia.

Mona Neubaur, dressed in black in front of an exposed concrete wall

The CO₂ separation and purification process

Illustration shows industrial plant with highlighted light green towers

Air separation unit. A separate air separation unit (ASU) will be integrated into the plant, as oxyfuel technology requires a high volume of pure oxygen. In cryogenic air separation, ambient air is drawn in and purified to remove impurities. The cleaned air is then compressed and cooled in a heat exchanger. Next, the air is brought to extremely low temperatures (between –185 °C and –196 °C) and liquefied in a cooling circuit. The liquefied air mainly comprises nitrogen and oxygen, which are separated in a condensation process. The result is high-purity oxygen that can be fed directly into the kiln system.

Illustration of an industrial plant, highlighted in light green is a flat part of a building connected to a tower via a pipe

Second generation advanced oxyfuel kiln. In conventional rotary clinker kilns, limestone is heated to high temperatures and processed using fuel and ambient air. The resulting process gas consists mainly of atmospheric nitrogen and around 20% CO₂. This gas, including the climate-damaging CO₂, is typically released directly into the environment as flue gas. The new kiln system does not change the firing process, but there are two major differences: instead of ambient air, pure oxygen is used in the firing process, which reduces the flue gas flow and achieves CO₂ concentrations of over 90%. Furthermore, the flue gas is not discharged into the atmosphere. Instead, it is directed into downstream systems where the CO₂ is cleaned and processed for further use or storage.

Illustration of an industrial plant with numerous larger and smaller towers highlighted in light green

CO₂ purification system and condensing unit (CPU). In the upstream flue gas purification systems, the exhaust gas stream is first cleaned of impurities such as nitrogen and sulphur oxides. It is then cooled to approximately –35 °C in the Cryogenic Processing Unit (CPU) as a "process gas", using a multi-stage compression process to liquefy it. In the next step, any remaining components are removed from the flue gas in a distillation process, resulting in high-purity, liquid CO₂.

Illustration of a low building with four large spherical containers next to it, two wind turbines and clouds in the background

Solar plant. Cement production, along with the separation and purification of CO₂, is highly energy-intensive. To reduce reliance on fossil fuels, renewable energy sources are being introduced. A new solar plant, currently under construction for the GeZero project, will contribute to this transition in future.

Illustration shows light green tank wagons in front of trees and a wind turbine

Rail loading and local carbon hub. The CO₂ is first transported to the storage site by rail. A loading station with a connection to the rail infrastructure is being built on the factory premises for this purpose. A CO₂ hub for short-term interim storage is also being established. The hub is also intended to offer smaller local CO₂ emitters in the region a connection to the emerging CO₂ transport infrastructure.

Illustration of an industrial plant directly by the sea, clouds in the background

Transport. Tank wagons specially developed for CO₂ transport are used for this purpose. CO₂ has been transported in this way on a smaller scale for many years in the chemical industry. This rail transport solution is intended as an interim measure until a comprehensive pipeline network is in place, enabling CO₂ to be transported as efficiently and safely as possible.

Illustration of an artificial island floating on the sea with three towers, the centre of which is connected to the seabed

Offshore storage facility. The CO₂ captured in Geseke is expected to be stored offshore, in deep geological layers beneath the seabed of the North Sea. From land, the CO₂ is transported either by ship or pipeline to offshore platforms.

Illustration shows cross-section through different soil layers. Liquid is transported through a pipe via a tower on the surface into one of the deep rock layers.

Injection. The CO₂ is stored at depths of between 1,000 and 3,000 metres below the seabed. Storage sites include former gas and oil fields as well as saline aquifers. These are saltwater-bearing porous rock layers that are particularly well suited to storing gas. Once the storage capacity of a site is reached, the borehole is securely sealed to prevent any release of CO₂. All boreholes are continuously monitored to detect and prevent leaks.

Our project partners

For complex, large-scale projects such as GeZero, working with the right partners is essential. We depend on collaborations that bring a high level of expertise and many years of experience. 

Within the value chain, we are responsible for cement production, the operation of the separation plant and the loading of CO. Our project partners are responsible for developing and operating the transport and storage infrastructure. 

Transport

Companies across the rail, inland and maritime shipping, port terminal and pipeline sectors are preparing for a growing market and the development of a logistics chain to support high-volume CO₂ transport. Transporting CO₂ is not a new concept – it has long been part of chemical production processes. Rail transport offers a better carbon footprint and greater efficiency than road haulage. GeZero will initially use specially developed tank wagons to transport the captured CO₂ by rail. A dedicated pipeline network is planned for a later phase.

Storage

CO₂ storage in deep geological formations is being delivered by a GeZero project partner with specialist expertise in this field. Research in this area has been ongoing for many years. Organisations within the oil and gas industry are pioneers in this field as they have in-depth knowledge of suitable storage formations.

In addition, the professional exchange is an important element of our work. This is why we are involved with GeZero in the think tank IN4climate.NRW, NRW.Energy4Climate and the model region for climate-neutral cement production Erwitte/Geseke. 
 

IN4climate.NRW

IN4climate.NRW sees itself as a platform on which industry, research and politics work together to develop innovative strategies for a climate-neutral industry. You can find more information on the IN4climate website.

The model region for climate-neutral cement production in Erwitte/Geseke

The aim of the model region for climate-neutral cement production, Erwitte/Geseke, was to investigate whether and how cement production in the region can be made climate-neutral. An initial study was presented at the beginning of 2024. The full report is available for download on the Erwitte website.

Questions and answers

What does GeZero have to do with climate protection?

Committed to climate protection. The Paris Agreement, adopted in December 2015, sets out the goal of limiting global warming to well below 2 °C – ideally to 1.5 °C – compared to pre-industrial levels. This is both a global aspiration and a shared responsibility, for Germany and for Heidelberg Materials as an international company. Achieving this requires immediate and decisive action. Germany’s Federal Climate Change Act makes this clear, setting a target for the country to become greenhouse gas neutral by 2045. Industry, particularly energy- and CO₂-intensive sectors such as the basic materials industry, must play a key role in this transformation. At Heidelberg Materials, we are reducing our carbon footprint in line with the 1.5 °C pathway set out by the Science Based Targets initiative (SBTi). The climate protection goals of Heidelberg Materials.

Learn more under Sustainability
 

Why are CCUS technologies an indispensable building block for climate protection?

At Heidelberg Materials, we are committed to continuously reducing our CO₂ emissions following the principle of avoidance before capture. We do this by maximising the use of alternative fuels, particularly biomass, reducing the share of CO₂-intensive clinker in cement by incorporating alternative materials, optimising our product mix and increasing the efficiency of our plants. However, only about one third of emissions from cement production can be reduced through these measures. The remaining two thirds are process-related and stem from the deacidification of limestone and currently unavoidable from a technical perspective. The only viable solution for these emissions – which also occur in other industrial sectors – is to capture the CO₂ for subsequent use or storage. This is known as Carbon Capture, Utilisation, and Storage (CCUS). There is broad scientific consensus that CCUS is essential for dealing with emissions that are unavoidable or difficult to avoid. They complement the expansion of renewable energies, the circular and hydrogen economy, the increase in energy and resource efficiency and the potential of natural CO₂ sinks.

CCUS in policy: the path ahead for Germany and the EU

Germany and the European Union are now laying the political and legal foundations for the rollout of CCUS. Carbon management strategies at both national and European levels will form the basis for this. Crucial decisions will be made in the coming years – particularly around the creation of a CO₂ infrastructure that links all parts of the value chain: capture, transport, utilisation and storage. Success will depend on the active participation of many partners. GeZero and other pioneering industrial projects are already rising to this challenge by driving practical implementation. To enable broader progress, it is essential that policymakers in Germany establish a clear legal framework – providing the regulatory certainty and investment security needed.

How does the carbon capture technology work?

Carbon capture is the process of removing CO₂ from large emission sources. The aim of carbon capture is to prevent the release of CO₂ emissions into the atmosphere and to either process the captured CO₂ further or store it safely. Carbon capture and storage (CCS) refers to the process of capturing, transporting and storing CO₂ in suitable geological formations.

Heidelberg Materials has already initiated around a dozen CCUS projects worldwide. As a result, some cement plants will be fully decarbonised before 2030 – such as the plants in Edmonton/Canada, Padeswood/UK, Geseke/Germany and Mitchell/USA.

What is the aim of carbon capture and storage?

The concept of carbon capture and storage (CCS) provides for the capture of CO₂ emissions resulting from the use of fossil fuels in electricity generation and industrial processes. This prevents the carbon dioxide from being released into the atmosphere. Instead, it is stored permanently in suitable underground geological formations. 

Why are net-zero cement products only possible with CCS?

The production of cement, the "glue" in concrete, is very CO₂-intensive. Around two thirds of direct CO₂ emissions in cement production are generated during the calcination process – the chemical transformation of limestone into cement clinker in the kiln. As this reaction is a fundamental property of limestone, these emissions are technically unavoidable. This is why the cement industry is one of the largest emitters of carbon dioxide globally. Today, CCS is one of the most effective solutions for preventing these process-related emissions from entering the atmosphere. 

Carbon capture, utilisation or storage (CCUS) is a vital prerequisite for achieving net-zero emissions in our sector – and for enabling the production of net-zero cement products.
 

Is it really necessary to store the captured CO₂ under the North Sea? Why is it not used for other purposes?

In addition to our CCS projects aimed at the capture and storage of CO₂, we are also investigating, testing and scaling up a number of promising opportunities for the use of captured CO₂ – in the food industry, for the production of synthetic fuels, in the cultivation of microalgae or for the recarbonation of recycled concrete.

What is the EU Innovation Fund?

The EU Innovation Fund is an EU instrument to support the transformation of European industry towards climate neutrality. It focuses on highly innovative technologies and flagship projects that enable substantial reductions in greenhouse gas emissions across Europe. Funded projects commit to sharing their insights and taking part in activities that support scaling, accelerate the adoption of breakthrough technologies and drive their commercialisation. The EU Innovation Fund is financed by trading CO₂ certificates within the framework of the EU ETS. More information can be found on the website of the European commission.

Press enquiries

You are a journalist and would like to receive further information? Please contact Feline Strassburger.

Feline Strassburger

Stakeholder Engagement & Communication Manager GeZero