The Anonymous Widower

Cemex To Install World-First Hydrogen Process At UK Cement Plant

The title of this post, is the same as that of this article on The Chemical Engineer from 2024.

These two paragraphs introduce the article.

CEMEX is set to trial a process developed by Hiiroc that uses plasma to produce hydrogen for greener industrial heat at its cement plant in Rugby, UK.

Cemex is finalising contract details now with UK-based process developer Hiiroc and expects to start engineering studies early next year with hydrogen production set for a “hard deadline” of January 2026. The cement major thinks the process is a better bet for producing hydrogen than water electrolysis because it requires 80% less electricity and wins out over steam methane reforming because it doesn’t produce CO2.

I believe that this process, which has its origins in Hull University, could revolutionise the manufacture of zero-carbon hydrogen.

The article describes its first big application at Cemex’s Rugby cement plant.

There are obviously issues to be solved and the article is mainly an interview with Alfredo Carrato, who is innovation advisor at Cemex Ventures.

These are some thoughts.

HiiROC Is Containerised

The article says this.

Carrato expects the changes required to integrate the process at the Rugby plant to be minimal. One or two of Hiiroc’s containerised process units will be plugged into the grid and pipes installed to carry hydrogen to the existing kiln where a new burner will be installed to combust the hydrogen producing heat to convert limestone to clinker.

It also says this.

If successful, the Rugby plant could see eight or nine of Hiiroc’s modules installed at the site, Carrato said.

There could be a lot of low-carbon cement coming out of Rugby.

But containerisation also means that any factory using natural gas for a lot of heat, can plug in a number of Hiiroc’s containerised process units and decarbonise.

Worldwide Expansion

The article says this.

“We do have plans to expand this across our operations worldwide for a number of reasons. Hydrogen certainly is a relevant vector that we are considering to decarbonise our operations. And second, the modularity of the solution allows for a quick deployment.”

Cemex Aim To Be Net Zero By 2050

The article says this.

Cemex has set itself a target of becoming net zero by 2050. The Hiiroc process can make use of biomethane so could allow Cemex to replace its use of fossil fuel natural gas. It could also use renewable electricity to power its plasma burners. In terms of output, the process produces carbon black which can be used as an additive in its cement-making operations or sold for use in tyres, rubbers, plastics, inks, and toners.

“Because of the stoichiometry, the volume of carbon black is pretty significant, meaning we are not able to take the entirety of what is produced. So, we need to figure out how to also monetise it.”

Hiiroc is searching for alternative markets too. It has partnered with researchers in Europe and the US to investigate how the carbon black from its process could be used in other applications including filters, soil enhancers, and animal feed.

Note.

1. The process can run on biomethane, as well as natural gas and chemical plant flare gas.
2. The carbon black could be a long-term problem, but I suspect a use will be found.

Having worked in integrated chemical plants, I believe innovative uses for both feedstocks and what to do with the carbon black will be found.

Water Stress

The article says this.

Carrato said: “We’re looking at not only the carbon footprint, but also the stress on water. Water electrolysis has a lot of water demand, whereas technology such as Hiiroc has none. In regions where there’s a lot of water scarcity, we believe that Hiiroc can move the needle [for industrial decarbonisation] way better than water electrolysis.”

Any water problems seem soluble.

Conclusion

Alfredo Carrato of Cemex Ventures seems to be enthusiastic about his charge.

September 23, 2026 - Posted by AnonW | Energy, Hydrogen, Uncategorized | Biomethane, Cement, Cemex, Chemical Engineering, HiiROC, Rugby, Water