Techno-economic feasibility of CO2 utilization for production of green urea by Indian cement industries

The cement industry contributes substantially to global carbon emissions, necessitating urgent adoption of mitigation pathways aligned with climate goals. This study investigates the technical and economic viability of capturing carbon dioxide (CO2) emissions from cement plants in India and using that captured CO2 to produce green urea. The research aims to determine the feasibility of the CCUS approach as a practical way to reduce CO2 emissions from cement production while also boosting India's self-sufficiency in producing urea, a crucial fertilizer. The research uses a multi-criteria analysis (MCA) framework to assess various factors, including the technological readiness of CCUS technologies, the capital and operating costs of setting up and running such a system, the market demand for green urea, and the potential reduction in CO2 emissions. The study focused on 32 major cement plants in India, using data from their annual reports to inform the MCA model with an assumption of a post-combustion Monoethanolamine (MEA) scrubbing capacity CO2 capture capacity of 0.5 million tonnes per year per plant and used existing data and modeling techniques to analyze the feasibility of converting the captured CO2 into urea. The key findings indicate that this approach is promising and projects a 12.4% reduction in CO2 emissions from the cement industry if these 32 plants implement the CCUS technology. Additionally, it highlights a favorable market for the green urea produced, with an estimated output of 21.82 million tonnes per year, enough to offset a significant portion of India's reliance on urea imports. Financially, the study projects a six-year payback period and a 16.7% return on investment. It concludes that implementing CCUS technology to create green urea in Indian cement plants is technically and economically feasible. The approach has the potential to significantly reduce CO2 emissions while also supporting India's goal of self-sufficiency in urea production. However, further investigation and pilot-scale projects are recommended to validate the model's findings and optimize various aspects, such as managing flue gas impurities and leveraging waste heat for energy efficiency. •Multi-criteria analysis evaluates technical, environmental, and financial viability.•Carbon capture with cement plants cuts emissions by 12.4%, aiding urea production.•Financials show a six-year payback and 16.7% return, proving economic feasibility.•Utility costs and hydrogen expe