Nurhan Gürel
CemenTürk Editor-in-Chief
This article has been prepared by referencing the innovative perspectives, groundbreaking presentations, and the latest academic literature and industry reports presented at the Vision Zone sessions of the CUSCIT’25 Cement Olympics.
1. Introduction
The cement industry, which produces the fundamental structural materials of modern civilization, occupies a central position in combating climate change, as it accounts for approximately 7–8% of global CO2 emissions [1]. The commitment to achieving net-zero emissions by 2050, as set under the Paris Agreement, necessitates a radical technological and operational paradigm shift beyond marginal improvements for the sector. This creates a duality between the need to meet construction demand driven by global population growth and urbanization dynamics on one hand, and the pressure for decarbonization as a significant source of anthropogenic carbon emissions on the other.
The future of the cement sector depends on the steps toward carbon reduction and, ultimately, full decarbonization, while global infrastructure needs are expected to increase substantially by 2050. The GCCA roadmap requires a 40% reduction in clinker production and a transition to lower clinker ratios in cement through binder optimization. In the first phase, increasing supplementary materials such as calcined clay, raising alternative fuel usage, process optimization, and implementation of advanced control systems are targeted. Post-2030, it is expected that the “Cement Beyond Carbon” vision will be realized through oxy-fuel, CCUS, and next-generation low-carbon technologies [2].
The 2050 Roadmap published by the Global Cement and Concrete Association (GCCA) demonstrates that this target can only be achieved through a multi-faceted and integrated strategy [3]. In this context, pioneering symposiums such as CUSCIT’25 Cement Olympics have served as visionary platforms where industrial and academic leaders come together to discuss this new paradigm. This article aims to provide a comprehensive analysis of the holistic transformation strategy by presenting in-depth technical analyses and visionary approaches showcased at CUSCIT’25 Cement Olympics, supported by current scientific literature.
2. Stages of Transformation in the Cement Industry
The core consensus emerging from the sessions is that the path to net-zero requires the integration of three main, symbiotically related pillars: Green Transformation (sustainable materials and circular economy models), Digital Transformation (optimization through AI-driven efficiency and cyber-physical systems), and a supportive financial and policy framework enabling this transformation.
2.1. Green Transformation
The ultimate goal of green transformation is to radically reduce the environmental footprint of the sector, particularly its carbon intensity. The path to this goal consists of integrating a series of proven and scalable strategies based on thermodynamics, materials science, and ecological engineering principles.
2.1.1. Key to Decarbonization: Clinker Replacement and LC3 Technology
Since a significant portion (60–70%) of cement-related process emissions originates from clinker produced through high temperature calcination of calcium carbonate (CaCO3), the most effective strategy is to reduce the clinker factor. Reports from organizations such as the International Energy Agency (IEA) also highlight clinker replacement as one of the most effective decarbonization methods [4].
A paradigm-shifting solution in this field is ternary binder systems such as Limestone Calcined Clay Cement (LC3). Professor Karen Scrivener emphasizes that LC3 represents the most scalable and market-ready solution currently available [5]. This system relies on replacing up to 50% of Portland cement clinker with low-grade kaolinitic clays (metakaolin) calcined at 700–850°C, combined with micronized limestone [6]. The success of the technology stems from the synergy between the high pozzolanic reactivity of metakaolin and the limestone, which triggers the formation of calcium carboaluminate phases among hydration products, ensuring mechanical performance while enhancing chloride binding capacity and durability [7]. This technology has the potential to reduce CO2 emissions by up to 40%.
Currently, there are 19 operational LC3 plants worldwide and 24 projects under development, with the goal of producing one-third of global cement with LC3 by 2040. Key factors in LC3 technology include clay selection and purity, calcination technology, color control, grinding strategy, and rheology, while optimizing kaolinite content, understanding the reactivity impact of iron oxide phases, co-grinding methods, and the use of grinding aids are also critical. Over the past decade, the technology has evolved from research studies into a competitive product in high demand within the industry, with a broad community of scientists and industrial stakeholders working to improve the entire production chain [8]. Recognized in international standards such as India, EN, and ASTM, this type of cement exhibits high durability and mechanical strength against chloride, sulfate, and alkali-silica reactions. Developed through extensive laboratory and field studies and tested in fullscale structural elements (beams, slabs), LC3 offers significant potential for sustainable development due to its lower clinker content and is increasingly adopted in industrial applications worldwide [9].
2.1.2. Application of Calcined Clay Technology
CIMPOR has taken a leading role in helping the global cement industry achieve decarbonization targets by successfully applying calcined clay technology, which it calls “deOHclay,” for clinker replacement. This technology reduces clinker usage, the largest source of carbon emissions in cement production, by up to 40%, achieving approximately a 90% reduction in CO2 footprint and significant energy savings. The company has commercialized this technology with industrial plants in Ivory Coast and Cameroon, proving that calcined clay provides a practical and scalable strategy to reduce the environmental impact of cement, particularly in regions facing SCM (supplementary cementitious material) shortages [10].
2.1.3. Process Innovation in the Production of Cementitious Materials
The widespread adoption of SCMs like LC3 has necessitated innovative technologies for efficient and sustainable production. Approaches presented by technology providers at CUSCIT’25 Cement Olympics include:
KHD Humboldt Wedag offers comprehensive solutions including both flash calciner and rotary kiln systems. Within these systems, the flash calciner process stands out, integrating essential operations such as drying, grinding, preheating, and decomposition. Implementing flash calcination technology enables the use of alternative fuels and significantly improves overall system performance. Rapid thermal treatment of particles in the hot gas stream over seconds provides higher efficiency and reaction rates compared to conventional rotary kilns. Additionally, KHD Humboldt Wedag’s Pyrorotor® technology allows broad utilization of low-quality waste fuels, while Simulex VR enables holistic digital optimization of the plant [2,11].
Advanced flash calcination systems, developed to replace conventional rotary kilns for thermal processing of industrial minerals, offer a revolutionary approach in terms of thermodynamic efficiency and reaction kinetics. The basic operational principle involves suspending micronized feed particles in a high-temperature gas stream for a very short residence time (typically a few seconds) to undergo dehydroxylation.
The large surface area of the particles maximizes heat and mass transfer coefficients with the hot gas. As a result, the removal of hydroxyl (-OH) groups as water vapor (H2O) from the crystal structure occurs at much lower temperatures and at exceptional speeds compared to conventional systems. Reducing the reaction time to the order of seconds not only minimizes energy consumption and operational costs but also prevents unwanted phase transformations such as overheating and sintering, improving product quality and reactivity. Therefore, flash calciners provide significant advantages over conventional rotary kilns in energy efficiency and product performance, particularly in processing industrial raw materials such as kaolin, talc, and aluminum hydroxide [12].
A radical alternative to thermal activation processes is the mechano-chemical activation method, which applies highpressure mechanical energy instead of thermal energy to activate the material. This approach holds notable potential for integration with renewable energy sources, particularly when using electricity, thus contributing significantly to reducing the carbon footprint of the production process [13].
Enhancing the performance characteristics of low-clinker cements is a key objective of modern cement technology. Accordingly, chemical companies such as Saint-Gobain have developed special chemical admixtures. These include polycarboxylate ether (PCE)-based superplasticizers to optimize rheology and workability, and alkanolamine-based set accelerators to regulate hydration kinetics and setting time. These chemicals improve the final product properties of lowclinker cements, such as mechanical strength and durability [14].
2.1.4. Resource Optimization and Industrial Symbiosis
Green transformation focuses on the entire production chain. Professor Malcolm Powell emphasized that resource efficiency must be optimized from the very start of the production chain. One reason for the low energy efficiency (<1%) of comminution operations in mining and industrial production is that traditional theoretical calculations overlook practical application challenges and the complexities of rock mechanics. Measurements with new technologies such as the precision roller crusher (PRC) reveal that the commonly held belief that resistance increases with particle size reduction is actually due to increasing inefficiencies. These findings indicate that comminution circuits have the potential for up to 60% energy savings compared to traditional milling methods. Adopting this efficiency with a structured approach not only reduces energy costs but also lowers environmental impacts such as water consumption, waste generation, and dust emissions, contributing to sustainable resource use [15].
Similarly, Professor Aurbey Mainza demonstrated that correctly configuring grinding and classification circuits can significantly increase energy efficiency in the cement and mining sectors, reducing the carbon footprint. HPGR produces more fractured and easily grindable particles with lower specific energy consumption compared to cone crushers, while integrating classification with grinding reduces unnecessary over-grinding, improving both yield and energy savings. The presentation emphasized that optimizing mill fill, ball load, particle size, and energy–grinding relationships is critical, and modern technologies such as vertical roller mills and stirred mills enable finer products in a single stage with lower energy [16].
Similarly, Dr. Hakan Arden’s “Geocementing” concept introduces the notion of “geo-cementing,” inspired by the geo-metallurgical approach in the metal mining industry, tailored for the cement sector. This holistic approach, in contrast to traditional chemically-focused production, proposes the detailed characterization of raw material deposits (limestone, clay, etc.) from the outset—considering their geological, mineralogical, chemical, and physical properties—and their integration with 3D geological models. Geo-cementing aims to optimize quarry development, quality management, and process efficiency by anticipating the effects of raw material variability on the production process. In this way, it seeks to enhance consistency in the final product quality while reducing costs, minimizing environmental impacts, and ensuring more sustainable resource management in compliance with international standards such as CRIRSCO [17].
The final element of transformation is circular economy and industrial symbiosis. Initiatives like the “United Circles” project convert construction and demolition waste (CDW) into value-added building materials using advanced sensor-based sorting and accelerated carbonation technologies, realizing a cradle-to-cradle circular economy vision. The United Circles project is an industrial-urban symbiosis initiative involving 46 partners from 14 countries, aimed at upcycling urban food waste, municipal wastewater, and construction/demolition waste. The project’s main objective is to use resources more efficiently by creating zero-waste cities and decarbonized production processes, reduce freshwater use in arid regions by closing water cycles, and reintegrate waste into the economy. In Türkiye, the partners have focused particularly on recycling construction and demolition waste around the Hub for Circularity (H4C) established in Ankara. Within this scope, Baştaş Çimento produces next-generation cement using carbonate-based recycled cement blends; Tepe Betopan develops cement-bonded particleboards from these wastes; MINOVA implements smart waste sorting systems; and Türkiye İMSAD coordinates sectoral integration. Concrete outcomes of the project include constructing a two-story building with 3D printing using materials from demolition waste, converting wastewater facilities into resource recovery centers, and producing bioplastics from used cooking oils [18,19,20,21,22].
2.2. Digital Transformation
Digital transformation is not an end but a catalyst that enables and accelerates green targets. Industry 4.0 technologies play a critical role in enhancing operational efficiency, cyber-physical optimization, and transparency.
2.2.1. Predictive Analytics for Operational Excellence
Fizix and Innomotics’ AI-based platforms analyze data collected from Industrial Internet of Things (IIoT) sensors to enable the implementation of predictive maintenance strategies. These applications help minimize unplanned downtime and maintenance costs. Additionally, advanced control systems such as Model Predictive Control (MPC) dynamically optimize complex units like pyro-processing, reducing energy consumption and emissions.
Fizix’s solution primarily focuses on Model Predictive Control (MPC) and digital twin technologies. The platform creates a virtual replica of complex and hard-to-control units in cement plants, such as rotary kilns. This digital twin processes thousands of real-time data points from Industrial Internet of Things (IIoT) sensors—covering parameters such as temperature, pressure, gas composition, and raw material quality—to analyze the current state of the process and predict its future behavior with high accuracy. The AI algorithm continuously optimizes the kiln’s operational parameters (e.g., fuel and raw material feed, fan speeds) based on these predictions. Through this dynamic optimization, Fizix aims to reduce energy consumption by 5–10%, increase production by 3–7%, and significantly lower emissions such as carbon dioxide (CO2) without requiring operator intervention. In this way, it directly contributes to both cost efficiency and sustainability objectives [23].
Innomotics’ AI-based solutions are specifically designed to monitor the health of rotating equipment such as motors, drives, and generators, and to implement predictive maintenance strategies. Their platforms continuously collect data—such as vibration, temperature, current, and voltage—from IoT sensors integrated into these critical assets and analyze it using cloud-based AI algorithms. These algorithms learn the normal operational “fingerprint” of the equipment and can detect even the smallest deviations over time as anomalies. For instance, microscopic bearing wear or weakening in bearings can be identified months before a failure occurs. These early warnings enable maintenance teams to know precisely when a failure might happen and which component needs replacement. This approach virtually eliminates unexpected production stoppages, reduces maintenance costs, and, most importantly, maximizes the operational efficiency and reliability of industrial facilities [24].
2.2.2. Virtual Optimization and Digital Twins
Digital twins, which represent a revolutionary approach to industrial process optimization, are dynamic, living virtual replicas of physical assets or processes. The foundation of these virtual models is built on highly advanced numerical modelling techniques such as the Discrete Element Method (DEM). DEM simulates, individually, the interactions of millions of discrete particles (e.g., cement raw materials, sand grains, pharmaceutical powders) with each other and with equipment surfaces. This allows engineers to observe and understand material flow, mixing behavior, wear effects, and energy transfer at a microscopic level.
The greatest advantage of this technology is that it creates a “virtual laboratory” environment for engineers. In traditional methods, even the smallest modification in a process (e.g., increasing the mill speed or testing a different raw material) would require halting production, conducting costly physical trials, and accepting potential risk of failure. With digital twins, all these trials can be performed in a virtual environment, with zero risk and significantly lower cost. Engineers can simulate hundreds of different scenarios (varying particle sizes, moisture levels, equipment geometries, etc.) to scientifically determine the optimal process conditions that maximize energy efficiency and improve product quality. In particular, for challenging processes such as handling recycled aggregates or biomass and other new sustainable materials, these virtual experiments become invaluable tools for predicting how these materials can be integrated into existing systems and identifying the most efficient operating windows [25].
2.2.3. Technology Transfer
Technology transfer and knowledge sharing are at the heart of the green and digital transformation paradigm in the cement industry. The success of this transformation depends on suppliers evolving from traditional, passive product providers into strategic partners actively participating in innovation and implementation processes. Such strategic partnerships first require establishing a shared vision and roadmap with the participation of all stakeholders. Subsequently, supply strategies should be developed to support this vision, targeting specific goals such as decarbonization and efficiency. Suppliers must redefine their roles in the value chain by offering integrated digital solutions that enrich their product portfolios rather than focusing solely on individual products. To effectively manage the transformation process, a controlled implementation methodology should be adopted: starting with pilot projects, measuring results, and gradually expanding rather than pursuing large-scale, high-risk initiatives.
Within this collaboration framework, the main technological and operational areas where suppliers can create value include systems that enhance energy efficiency, digital twin and AI platforms for process optimization, alternative fuel solutions that replace fossil fuels, and circular economy applications that convert waste back into resources. The sustainability of this complex transformation process relies on rigorously monitoring Key Performance Indicators (KPIs), proactively managing potential operational and financial risks, and establishing longterm strategic partnerships beyond short-term commercial relationships. Ultimately, in the cement industry’s journey toward net-zero emissions, this deep, technology-focused partnership between producers and suppliers constitutes a fundamental determinant of success [26].
2.2.4. Digital Product Passports for Transparency and Traceability
For the circular economy to function effectively, it is essential to track materials transparently throughout their lifecycle. Digital Product Passports (DPPs), developed to meet this need, serve as a digital identity that records a product’s journey from cradle to grave. These passports are typically built on “Distributed Ledger Technologies (DLT)”, such as blockchain, to ensure reliability and immutability. Blockchain technology allows data to be recorded and verified by all participants in the network without a central authority, making it nearly impossible to alter or delete information later.
A DPP for a construction material contains critical data such as the carbon footprint of the material, all chemical components, recycled content ratio, and deconstruction and reuse instructions. When these digital identities are integrated with Digital Building Logs (DBLs), which contain all structural and material information of buildings, the system’s power multiplies. At the end of a building’s lifecycle, demolition companies can refer to these logs to know precisely which materials (e.g., steel beams, glass panels, wooden floors) are located where and how they can be safely dismantled. By scanning the material’s DPP, its quality, history, and potential for reuse can be instantly verified. This integration transforms debris that would traditionally end up in landfills into proven “urban mines,” allowing materials previously considered waste to re-enter the value chain as resources through a transparent and reliable data infrastructure, making the circular economy a tangible reality [27].
2.3. Financial Framework: Economic Dynamics and Policies of Transformation
The technological revolution to be undertaken can only be sustainable with a robust financial and political framework. The multi-billion-dollar investments required for green and digital transformation can only be realized with a solid financial strategy and supportive regulatory environment.
2.3.1. The Role of Carbon Pricing
The strongest financial driver for green transformation is the fact that carbon emissions are no longer an abstract environmental concern but a tangible cost element. As highlighted in Neslihan Ergüven’s presentation, central to this transformation are pioneering regulations such as the European Union Emissions Trading System (ETS) and the Carbon Border Adjustment Mechanism (CBAM). ETS sets specific emission quotas for industrial facilities within Europe, and companies exceeding these limits must purchase carbon certificates from the market, incurring additional costs. This system ensures that carbon emissions create a direct “invoice,” incentivizing companies to reduce their emissions.
CBAM, the global extension of this mechanism, requires that carbon emissions associated with products imported from outside the EU (initially carbon-intensive products such as cement, iron & steel, and aluminum) be accounted for. Its main purpose is to prevent “carbon leakage” caused by companies seeking cost advantages by relocating production to countries with looser environmental standards. Therefore, for export-oriented economies like Türkiye, CBAM makes decarbonization—not just as an environmental policy choice but as a necessity for international competitiveness and economic sustainability. With these regulations, investments in low-carbon technologies and processes are no longer just an environmental responsibility but a smart business strategy grounded in direct economic rationale [28].
2.3.2. Global and National Support Mechanisms
In light of the multi-billion-dollar investment needs of green transformation, multilateral development banks such as the European Bank for Reconstruction and Development (EBRD) and international collaboration platforms play a critical role. These institutions go beyond traditional project financing to provide innovative financial instruments that accelerate green transformation. For example, sustainability-linked loans and bonds, which reduce interest rates based on a company’s ESG (environmental, social, and governance) performance, incentivize concrete actions. These financial supports often include grants for technical consultancy, feasibility studies, and capacity building, ensuring that projects succeed not only financially but also technologically and operationally.
When these global support mechanisms are combined with national incentives, such as Türkiye’s Digital Transformation Program or KOSGEB’s green industry support programs, companies benefit from a multi-layered and robust financial support network. A company may secure a favorable EBRD loan for establishing a waste heat recovery facility while simultaneously benefiting from national incentives for its digital automation infrastructure. This synergy enhances the feasibility of decarbonization projects that would otherwise be postponed or deemed risky due to high upfront costs. In conclusion, the integration of capital from international financial institutions and global standards with local national incentives transforms the green transition journey for Turkish industrial companies into a financeable, manageable, and profitable process [29].
2.3.3. Global and National Policies
International collaborations conducted in the context of global climate negotiations for decarbonizing the cement sector, particularly initiatives such as the Cement and Concrete Breakthrough and the Climate Club, are of great importance for Türkiye. The cement industry’s 8% share of global industrial emissions underscores the goal of making near-zero emission cement the preferred choice in the global market by 2030. Harmonizing standards, creating demand for low-carbon cement, accelerating innovation, aligning international trade with new carbon rules, and providing finance–technical support to developing countries are priority action areas. The Climate Club aims to reach the net-zero target by 2050 through ambitious policies, industrial (steel–cement–chemical) transformation, and strong international partnerships. Türkiye has actively participated in these initiatives by applying to the Global Matching Platform for CCUS technologies, as well as developing a low-carbon roadmap, technology needs analyses, and large-scale financing mechanisms for the cement sector through TIDIP [30].
The current state of Türkiye’s cement industry in digital transformation, its priority needs, and how the Digital Transformation Program designed by the Ministry of Industry and Technology supports this process have been described. The sector’s most critical objectives include increasing energy and auxiliary plant efficiency, reducing unplanned downtime, extending equipment lifespan, improving labor productivity, minimizing quality issues, and digitally monitoring safety. Analyses indicate that Türkiye’s cement industry surpasses the global average in production automation and connectivity maturity; however, opportunities remain in corporate intelligence, data analytics, and integrated decisionmaking systems. The Digital Transformation Program supports digital investments in manufacturing industries by integrating technology, software, sensors, automation, cyber systems, and quality–safety solutions into enterprises, while strategic incentives, expert training, maturity assessments, and investment planning processes strengthen the sector’s transformation capacity [31].
The Netherlands-based Sustainable Process Technology Institute (ISPT) is an independent, collaboration-focused innovation platform with a mission to transform process industries into fully circular and carbon-neutral structures by 2050. Conducting over a hundred projects with a broad stakeholder network across key sectors such as energy, materials, and agri-food, the institute promotes cross-sector synergy and knowledge sharing, developing long-term transformation models.
Within this scope, a strategic roadmap has been set to reach the 2050 net-zero goal. According to this plan, key technologies are to be identified by 2030, commercially implemented by 2040, and fully scaled by 2050. Concrete projects illustrating this vision include producing valuable chemicals such as methanol from captured CO2, converting by-products from the steel industry into raw materials for the chemical sector, and circular carbon initiatives that turn various waste streams into valuable inputs. ISPT’s effectiveness in this field stems from its impartial stance toward all stakeholders, its holistic system approach covering the entire value chain rather than limiting problems to a single sector, and its ability to manage numerous diverse stakeholders toward a common goal [32].
3. Conclusion
The cement industry’s net-zero emission target can only be achieved through a holistic approach in which green, digital, and financial strategies are deeply integrated, rather than through isolated technological solutions. The vision presented at the CUSCIT’25 Cement Olympics Vision Zone clearly demonstrated the inevitability and potential of this integration. The green revolution defines the “what” of decarbonization (sustainable technologies and materials), while the digital revolution illustrates the “how” it can be implemented most efficiently (smart and optimized processes). The financial framework constitutes the “economic engine” that drives and sustains this transformation.
Clinker replacement technologies such as LC3 reduce emissions at the source, while AI maximizes the efficiency of these new processes. Circular economy models convert waste into resources, and digital product passports ensure the transparency and reliability of this cycle. Carbon pricing turns the transformation into an economic imperative, while green financing mechanisms make this imperative an investable reality.
Ultimately, the future of the cement industry depends on adopting this integrated vision, where sustainability and profitability are not conflicting objectives but two sides of the same coin. Only by implementing such an integrated strategy can the sector fulfill its responsibilities to the planet while building a competitive, resilient, and profitable future in a net-zero world.
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*A book incorporating all the topics presented within the scope of CUSCIT’25 Cement Olympics and listed in the references section of this article is currently in the publication phase.
