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.
- The process can run on biomethane, as well as natural gas and chemical plant flare gas.
- 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.
Jim Ratcliffe Mothballs UK Plants Over ‘Ridiculously High Gas Price’
The title of this post, is the same as that of this article in The Times.
These three paragraphs give more details.
Sir Jim Ratcliffe’s Ineos is mothballing three chemical plants in Hull in response to Britain’s “ridiculously high gas price”.
The plants directly employ 245 people producing acetyls, which are used as raw materials for everything from pharmaceuticals to food and military explosives. Ineos said the sites support almost 4,000 jobs in the wider supply chain across Humberside.
Ineos’s Hull acetyls plants “just cannot compete” as gas prices are now 12 times higher in Britain than in the United States, Ratcliffe said. The plants use gas as a feedstock and also burn hydrogen derived from gas as an energy source to power chemical production.
I don’t think, that this story, is as simple as it seems.
Consider.
- Sir Jim Ratcliffe graduated from the University of Birmingham in 1974 with a degree in chemical engineering.
- The plants in Hull make acetyls.
- The acetyl group has a Wikipedia entry.
- From my own experience, the 1970s was an exciting time for chemical engineering.
- ICI were trying to use a process purchased from BASF to make acetylene, which failed miserably, as all the process did was coat Runcorn in soot.
- Did ICI use the acetylene to make acetyls?
- Google AI says you can make acetyl-containing compounds, such as acetic acid and vinyl acetate, starting from acetylene.
- For a time, I shared an office, with a fellow Liverpool University graduate, who was helping to get the ICI plant working.
In the end the ICI plant was dismantled.
Has Sir Jim Ratcliffe A Connection To HiiROC?
I asked Google AI this question and received this reply.
Yes, Sir Jim Ratcliffe has an indirect financial and strategic connection to HiiROC through his petrochemical company, INEOS.
The INEOS Connection: INEOS backed HydrogenOne Capital Growth—a hydrogen-focused investment fund—which made a £10 million equity investment in HiiROC to develop affordable “turquoise hydrogen” (clean hydrogen produced via thermal plasma electrolysis).
Shared Industrial Projects: HiiROC has collaborated on low-carbon hydrogen projects in the Humberside region close to major INEOS operational footprints, connecting clean-tech hydrogen initiatives with heavy UK industrial chemical hubs.
Note.
- The last paragraph, I clipped from The Times mentioned hydrogen.
- The HiiROC process can use any hydrocarbon gas as feedstock and is five times more energy efficient than traditional electrolysis.
- HiiROC is backed technically by the University of Hull.
- The ICI plant produced loads of soot and HiiROC produces carbon black, so I wonder, if the two processes are by any chance related?
It strikes me that some of the various interests have come up with a route to creating acetyls, that is more efficient.
I suspect Sir Jim Ratcliffe will disclose a clever plan at some time.
What Is The Connection Between The University Of Hull And HiiROC?
I asked Google AI this question and received this reply.
The University of Hull and HiiROC have a collaborative partnership focused on developing clean energy technology.
Nature of the ConnectionTechnology
Collaboration: HiiROC worked collaboratively with the University of Hull (leveraging regional programs like those from the university’s Aura Innovation Centre) to help develop and test Thermal Plasma Electrolysis (TPE).
Clean Energy Innovation: This proprietary TPE technology converts biomethane, flare gas, or natural gas into clean “emerald” hydrogen and valuable solid carbon black without greenhouse gas emissions.
By-Product Research: The partnership includes joint efforts to research potential commercial uses for carbon black, the solid carbon by-product created during HiiROC’s hydrogen-generation process.
Regional Growth: HiiROC established its development and testing facilities in Hull to advance this technology, working alongside local academic and business innovation networks tied to the university.
From my experience in the 1960s at ICI Mond Division in Cheshire, I believe that this could be one of the most important research projects in the UK.
Could INEOS Be Going To Collect All Their Flare Gas In Hull?
Consider.
- The HiiROC process can use any hydrocarbon gas as feedstock.
- This would include chemical plant flare gas, biomethane and natural gas.
- The HiiROC process extracts the hydrogen as hydrogen gas.
- The HiiROC process extracts the carbon as carbon black.
I have seven questions.
- Suppose INEOS collected all the flare gas from their chemical plants in Hull, could they use this as feedstock in a HiiROC process to create hydrogen efficiently?
- Could they collect biomethane from Humberside and mix this with the flare gas?
- Could they bring in extra flare gas from chemical plants elsewhere in the UK and Europe using coastal gas tankers or rail tankers?
- Could INEOS use natural gas, if they were short of flare gas and biomethane?
- Could any excess hydrogen be stored in Aldbrough or Rough gas storage?
- Could any excess hydrogen be sold on to other companies?
- Could hydrogen be used to make the acetyls?
I suspect that all questions have an answer in the affirmative.
Conclusion
I feel that Sir Jim Ratcliffe made a very shrewd investment in HiiROC.
Is Sumitomo Heavy Industries Highview Power Energy Storage System On Line At Hiroshima?
From some work I did at ICI in the 1970s on a PACE231R analog computer, I believe that Highview Power may have an extremely promising way of storing energy.
The Highview Power web site talks of Sumitomo Heavy Industries, who are building one of Highview’s batteries at Hiroshima in Japan.
So I asked Google AI the question in the title of this post and received this comprehensive answer.
Yes, the Sumitomo Heavy Industries (SHI) Highview Power liquid air energy storage (LAES) commercial demonstration plant in Hatsukaichi, Hiroshima, is operational, having commenced operations on December 1, 2025.
Key details about the plant:Location: Within the Hiroshima Gas Hatsukaichi LNG Terminal.Capacity: 5 MW output with 4-hour storage (4 MW charging).Technology: Uses Highview Power’s CRYOBattery™ technology, specifically utilizing waste cold from the adjacent LNG terminal to improve efficiency.Role: The facility is designed to support grid stability and enhance renewable energy integration.A completion ceremony for the project was held on December 9, 2025. This news item from Sumitomo Heavy Industries gives more details.This paragraph describes Liquid Air Energy Storage or (LAES).
- It looks like the battery has a capacity of 5 MW/20 MWh.
- As it talks about using waste cold, this looks to be a very professionally-designed specialist application.
- But surely, that would be expected from a company like Sumitomo Heavy Industries.
There are hundreds of LNG terminals globally, with significant growth driven by over 300 projects (roughly 177 import/regasification and 124 export/liquefaction) expected between 2025 and 2030. In 2023, there were 22 countries with active liquefaction (export) capacity, while Europe alone operates roughly 28 large-scale terminals, supplemented by a rapidly expanding fleet of FSRUs.Export Capacity: In 2023, global liquefaction capacity was 472 million tonnes per annum (mtpa), with top exporters being Australia, the U.S., and Qatar.Expansion: By 2027, 52 new liquefaction terminals are expected to commence operations.Import Growth: European regasification capacity is expanding, with major terminals in Spain, France, Italy, and new additions in Germany and other nations.U.S. Infrastructure: The U.S. alone has more than 170 LNG facilities performing various services.
- They are listed in this Wikipedia entry.
- There are around thirty in Japan alone.
- Will Centrica add a 5 MW /20 MWh Highview Power battery to their Grain LNG Terminal?
- Each facility installed is claimed to be designed to support grid stability and enhance renewable energy integration, so the last part must cut carbon emissions.
Yes, several major chemical engineering and industrial processes generate significant amounts of “waste cold” (low-grade thermal energy or cryogenic energy) that is often discarded. While the chemical industry conventionally focuses on recovering waste heat, recovering waste cold is becoming increasingly popular for improving energy efficiency, particularly in cryogenic processes.
- Liquefied Natural Gas (LNG) Regasification
- Cryogenic Air Separation Units (ASUs)
- Dry Ice and CO2 Liquefaction
-
Liquid Nitrogen Vaporization
-
Emerging: Cryogenic Carbon Capture
- Creation of this page was not difficult, but you have to get the tricks right.
- I used Google Chrome and Google AI.
- My blog is hosted in WordPress.
- All pages on this blog, where I have had help in their creation from Google AI are tagged as such.
I would be happy to help anybody, who wanted to use Artificial Intelligence to create blog pages.
The Chemical Engineer Magazine On Highview Power
This is said in the Wikipedia entry for The Chemical Engineer Magazine.
The Chemical Engineer is a monthly chemical engineering technical and news magazine published by the Institution of Chemical Engineers (IChemE).
I first read the magazine perhaps fifty years ago, when it explained a chemical process, I was working on at ICI.
It is one of several well-respected magazines published by UK scientific, medical and engineering institutions.
This article in the magazine is entitled Energy Stored As Liquefied Air: £300m Investment Triggers Construction Of UK’s First Commercial-Scale Plant.
These three paragraphs introduce the investment.
HIGHVIEW POWER has received £300m (US$379m) in funding to build the UK’s first commercial-scale liquid air energy storage plant (LAES), designed to balance peaks and troughs in power demand as more renewable energy sources are brought online.
Construction of the facility is now underway in Carrington near Manchester. It is scheduled to begin operations in early 2026 and the company predicts it will provide more than 700 jobs in construction and the supply chain.
The plant will have a storage capacity of 300 MWh and an output of 50 MW per hour for six hours.
The rest of the article is just two sections.
- How Will Highview’s New Plant Work?
- Why Is The Technology Needed?
This article in the magazine is an absolute must read.
