Balcones Cement

The FEED study evaluated deployment of RTI International’s non-aqueous solvent (NAS) carbon capture technology at the CEMEX Balcones cement plant, targeting 95% CO₂ capture and a nominal capacity of approximately 2.4 Mtpa. The project was led by RTI International as technology developer, with CEMEX as host site partner, KBR serving as EPC engineering contractor, and SLB Capturi acting as owner’s engineer and technology licensor, supported by funding from the U.S. Department of Energy. The study developed an AACE Class 3 design and cost estimate to support commercial-scale deployment and investment decisions, capturing emissions from cement kiln flue gas and a natural gas-fired steam boiler and producing compressed CO₂ ready for transport and storage. Total estimated CAPEX is approximately $849 million, with annual operating costs of about $109 million, resulting in a base capture cost of roughly $101.6/tCO₂ excluding transport and storage. The facility requires about 46 MW of power and 610 MMBtu/hr of natural gas for solvent regeneration. An acid wash emissions control system is included, while a future amine recovery upgrade could reduce capture costs by roughly 9%. No major technical risks were identified during FEED. Site constraints, particularly limited water availability, led to selection of a hybrid air- and water-cooling design that increases energy use and capital costs compared with water-cooled systems; sites with sufficient cooling water could reduce capture costs by roughly 13%. The study provides a detailed engineering basis for future detailed design and potential project execution.