H₂News: Mr Kocakerim, could you introduce our readers to your company, Limak Cement?
Erkam Kocakerim: Limak Cement is the second largest cement producer in Turkey and is one of the top 50 in the global cement industry. We operate a total of 11 cement plants in Turkey, Ivory Coast and Mozambique with a total production capacity of 18 million tonnes. We also have 30 ready-mix concrete plants and several waste-to-fuel plants. Limak exports to 15 countries on four continents. I would particularly like to highlight our innovation centres, which we are also using to drive forward our sustainable transformation: an R&D and innovation centre, a competence centre, a climate change and sustainability centre and the Limak Cement Academy. Incidentally, Turkey is an important location in the global cement market: it is Europe's largest producer and the country ranks fifth worldwide. In terms of exports, we are even the leading cement nation with a 15% share of global trade.
H₂News: Which fuels do you currently use for your production?
Kocakerim: We are currently using coal. Natural gas is only economically viable for cement production in countries with their own natural gas reserves. However, it could become more interesting in the future as it reduces CO2 emissions by 40 % compared to coal and also releases fewer pollutants such as SO₂ and NOx. However, the technical changeover would be challenging, as natural gas flames have different properties to solid fuels and this would require adjustments in production. Developments in European emissions trading and CO2 taxation are important factors in the decision in favour of or against natural gas.
H₂News: How did you become aware of hydrogen as a fuel?
Kocakerim: We recognised the potential of hydrogen back in 2021 when we developed our first decarbonisation plans. As almost 40% of Limak's CO2 emissions come from combustion, the search for alternative fuels is of strategic importance to us. We currently see the use of green hydrogen as one of the most important levers for reducing CO2. This is because hydrogen is particularly well suited to replacing fossil fuels due to its high calorific value and ignition properties.
In preparation for this transformation, we are already pushing ahead with the switch to alternative fuels (AF). While the global cement sector and Turkey currently only achieve utilisation rates of 10-15%, Limak is at 30-50% in the plants that have already converted. By 2026, all our plants should be using AF. The goal is to increase the average to 60% and the maximum utilisation per plant to 70% by 2030 - which would put Limak well above the current EU average of 53%. This gradual transformation of the fuel supply also paves the way for the future use of green hydrogen.
H₂News: What specific advantages does hydrogen offer in cement production compared to other AF?
Kocakerim: Hydrogen can replace virtually all fossil fuels and only produces water vapour instead of CO₂. The use of hydrogen also makes cement plants less dependent on fossil fuels and their price fluctuations. This not only increases competitiveness in a market that is increasingly geared towards sustainability, but also helps to fulfil stricter environmental regulations. In the long term, we want to use a mixture of hydrogen and alternative fuels with a high biogenic content in all plants. This could result in annual CO2 savings of up to 700,000 tonnes.
H₂News: When did you start your first hydrogen project?
Kocakerim: At the end of 2022, we started planning studies on the use of green hydrogen, initially in small quantities. We then found a strong global partner for supply, transport and technology in Air Liquide. After completing the project studies, we were able to carry out the hydrogen combustion tests first in June 2024 to determine the optimum feed-in rate. The initial project objectives were clearly defined: safe use of green hydrogen in cement rotary kilns, development of transport solutions, investigation of the effects on AF use and quality assurance of the intermediate products.
H₂News: What experience have you had with hydrogen so far?
Kocakerim: The first trials were very promising: we were able to achieve 100 per cent thermal substitution in the clinker production calciner with a mixture of AF with a high biogenic content and hydrogen. In the region, we have increased our AF utilisation rate by up to 20 %, while at the same time substituting 3 % with hydrogen. This shows the potential to reduce CO2 emissions at each of our medium-sized cement plants by 180,000 tonnes per year. The next six months have already been planned: Following successful tests on the rotary kiln calciner, we will test both the calciner and the main burner with oxygen-rich combustion in phases 2 and 3.
H₂News: What alternative fuels do you use besides hydrogen?
Kocakerim: In our tests, we used a mixture of biomass (chicken waste), processed municipal waste (Refuse Derived Fuel, RDF) and used tyres (Tire Derived Fuel, TDF). By adding 3 % hydrogen, we were able to completely replace fossil fuels in the calciner, which corresponds to 50 % of the total heat.
H₂News: Does the use of hydrogen also have an effect on the product?
Kocakerim: Our experience to date has been positive here too. Thanks to its high calorific value and fast ignition, hydrogen helps to maintain the same thermal profile in the clinker production process. This is an important advantage over alternative fuels with a low calorific value, high moisture content and large grain size, which can affect the production process and the product itself due to longer ignition times. When mixing with hydrogen, the operating conditions remain the same as with fossil fuels - there is no impact on the end product. However, the optimum hydrogen substitution rate must be determined individually, based on the site specifications, the properties of the alternative fuels and the process layout. To find this optimum, we are conducting further tests with our partner to evaluate different scenarios and fuel specifications.
H₂News: Do you source your hydrogen exclusively from Air Liquide?
Kocakerim: Our hydrogen strategy is based on two pillars: Firstly, we are currently carrying out projects with our partner Air Liquide, which supplies us with green hydrogen in liquid or gaseous form. Secondly, we are planning to set up our own hydrogen production using electrolysers directly at our sites. We are pursuing this dual strategy for economic reasons: While in-house production should reduce operating costs in the long term, new political instruments such as the carbon border adjustment mechanism (CBAM) and the emissions trading system (ETS) will create additional incentives for low-CO2 fuels. We are working with Air Liquide not only on transport and delivery, but also on the technical development and planning of our first smaller electrolyser plants.
H₂News: Do you use low-CO2 or renewable (blue/green) hydrogen?
Kocakerim: Our roadmap envisages the installation of electrolysers for the production of green hydrogen directly at our sites. By 2050, hydrogen should account for around 8% of thermal substitution in order to completely replace fossil fuels together with alternative fuels with a high biogenic content. To this end, we are planning additional renewable energy plants with a capacity of around 400 MW.
H₂News: What are your next steps?
Kocakerim: Tests are currently underway to improve combustion by adding pure oxygen. We are using this to simulate how the entire output of an electrolyser could be utilised efficiently. We expect the results in the first quarter of 2025. We are also planning to install the first demonstration-scale electrolyser at one of our plants in early 2026. With this, we not only want to demonstrate the continuous use of hydrogen and oxygen in cement production, but also contribute to the development of the hydrogen ecosystem in Turkey.
H₂News: What infrastructure adjustments are necessary for the use of H2?
Kocakerim: First of all, the supply must be ensured - either through on-site electrolysis or through external supply. In the case of on-site production, an appropriate infrastructure for renewable energies is also required. Storage and transport require special tanks or pipelines due to the special properties of hydrogen - keyword: flammability. The cement kilns themselves also need to be modified, as hydrogen has different combustion properties to fossil fuels. This primarily concerns the burners, temperature controls and kiln design. Robust safety measures such as hydrogen detection systems, pressure relief valves and flame arresters are particularly important. Staff must also be trained in the safe handling of hydrogen. Although the investments are extensive, they are essential for reducing the CO2 footprint.
H₂News: How is Turkey actually positioned when it comes to hydrogen?
Kocakerim: The Turkish government has presented comprehensive roadmap for green hydrogen a in 2023. The country has great potential to become a major hydrogen exporter - thanks to its abundant renewable energy sources (wind, solar, hydropower and geothermal) and its strategic location between the EU, the Middle East and North Asia. The specific expansion targets are ambitious: Electrolysers with a capacity of 2 GW are to be installed by 2030, 5 GW by 2035 and as much as 70 GW by 2053. While the basic political direction has thus been set, the regulatory framework for safety, transport and grid integration still needs to be developed further. A particular focus is on the development of regional hydrogen hubs in metropolitan regions. These should utilise the existing infrastructure for natural gas and oil and enable nationwide access to the hydrogen value chain through networking.
H₂News: As a final question: Where do you see the opportunities and challenges for hydrogen in cement production in the future?
Kocakerim: As I said, our experience with hydrogen so far has been very encouraging. The successful tests show that the technology is suitable for practical use. It will be crucial that the entire hydrogen ecosystem develops in parallel with the cement industry - from production and infrastructure to the legal framework. We see ourselves in the role of a pioneer here, actively contributing to the development of this ecosystem in Turkey. We are convinced that those who invest in a future technology such as hydrogen today will be among the winners of the industrial transformation tomorrow.
H₂News: Mr Kocakerim, thank you very much for the interview!
