Sustainable development is a non-negotiable principle for Semapa. In its ambition to create long-term value, the Group has invested on the creation of innovative solutions, which allow the defined requirements and environmental goals to be met. These solutions not only imply developing new products, but also the introduction of changes in the manufacturing process itself, as in the “Clean Cement Line” (CCL) project.
The stage for this change was the Outão factory of Secil Portugal, which became one of the most advanced cement factories in Europe and in the world. This came about thanks to an original process of integrating mature and recent technologies (which had never been combined), which were also innovative and generated intellectual property rights.
In this way, by adopting a new cement production technology, the Outão factory, in Setúbal, has become one of the most efficient and sustainable factories in the world.
Technologies interlinked in an innovative manner
In practice, the CCL project involved four subprojects combining current cutting-edge technology (precalcinators and grid coolers) with innovative technologies.
- Zero Fossil Fuels: exclusive use of alternative fuels, whose adoption increased to 70% during the precalcination phase. The remaining 30% derive from a new fuel, Energreen. This is a biofuel created from the liquefaction of refuse-derived fuel (RDF), the object of a Secil patent.
- Waste Heat Recover: use of equipment associated to solar farms, which enables the recovery of the heat wasted in the oven in order to generate electric energy and the drying of alternative fuels.
- Combustion Boost: implementation of a fuel cell system, with pulsed injection of Brown gas (hydrogen and oxygen), which enables the acceleration and optimisation of fuel burning conditions, thus improving the energy efficiency of the process.
- Sun2Dry: installation of a solar thermal plant in the factory, which allows renewable photovoltaic energy to be generated and an increase in energy efficiency in drying alternative fuels.
In this way, these subprojects enable the production of low-carbon clinker and, consequently, the creation of a range of cements with a low ecological footprint.
Clear and ambitious goals
Overall, an investment of 86 million EUR was made, rendering the CCL project simultaneously a PIN project (National Interest Project), a R&D project and the largest project of Portugal 2020. From the outset, the goals were clear:
- Eliminating fossil fuels;
- Reducing the factory’s CO₂ emissions by at least 20%;
- Increasing energy efficiency by 20%;
- Generating 30% of electricity via a hybrid generation system, through the recovery of heat from the process itself and from concentrated solar thermal energy.
In this way, Secil positions itself as a key provider of low-carbon cement for the public works and civil construction cycle that is linked with the Portuguese Recovery and Resilience Plan and Portugal 2030, in which green procurement criteria will already be applied.
With the CCL project, Semapa fulfils its mission to create future-proof solutions, thus demonstrating its purpose: “Making it Better”.