Conventional cement production is responsible for nearly 8% of global CO₂ emissions, making it one of the construction industry’s most urgent environmental challenges. This research explores how sustainable engineering solutions can transform cement manufacturing into a cleaner, more resource-efficient process while maintaining industrial and economic viability.
The study examines the full cement production process, comparing dry and wet manufacturing techniques and evaluating opportunities to reduce emissions through energy-efficient practices and advanced carbon capture technologies. It also investigates hazard and operability considerations, equipment design and sizing, and environmental and economic factors influencing plant location selection, identifying Alexandria, Egypt as the proposed site for the sustainable plant.
A key innovation within the project is the development of a closed-loop CO₂ capture and regeneration system capable of extracting NH₄Cl while reusing raw materials, supporting a circular economy approach through the use of industrial by-products and waste reduction strategies.
By integrating sustainability, process engineering, and environmental responsibility, the research demonstrates how the cement industry can reduce toxic emissions, lower raw material consumption, and contribute to a greener future. The findings also highlight future opportunities for improving carbon capture systems, developing alternative cement materials, and strengthening industry collaboration to support long-term sustainable industrial development.
