The Mevo A1 Production Facility has the capacity to produce up to 120,000 tonnes of ultra-low carbon cement
The UK’s largest ultra-low carbon cement factory is situated in Llay, Wrexham, on the same site as pre-cast concrete block manufacturer CCP Building Projects. It is hoped that placing both steps of the offsite concrete manufacturing process together will reduce transport requirements and ultimately reduce the carbon footprint of the end product.
Material Evolution raised the facility through a £15m Series A funding round last year and completed the build on schedule after just eight months of construction work.
What makes the cement ultra-low carbon?
The factory does not use heat or kilns to combine the cement ingredients- reducing the traditional production process, which contributes a vast amount of carbon to the atmosphere.
The cement industry currently contributes about 8% of global carbon emissions and 1.5% of emissions in the UK.
Instead, the production facility relies on Material Evolution’s patented alkali-fusion process to produce cement capable of undergoing geopolymerisation.
The facility can produce 120,000 tonnes of Material Evolution’s pioneering MevoCem product per year, which can reduce emissions by up to 85% compared to ordinary Portland cement.
The ultra-low carbon cement production facility is now operating on an industrial scale, making it the UK’s biggest producer of ultra-low carbon cement.
Lean and modular construction design have further reduced the factory’s carbon footprint
The design of the 120-square-metre plant was influenced by lean manufacturing techniques. Modern material handling processes allow materials to be transported around the site, reducing the factory’s carbon footprint compared to traditional methods.
The facility’s modular design will also easily adapt to new and developing technologies, ensuring the site’s longevity.
Making industrial ultra-low carbon cement a reality
Founded in 2020 by Dr Liz Gilligan and Sam Clark, Material Evolution aims to help revolutionise the £500bn concrete industry. Sam Clark commented: “This launch takes us one step closer to achieving our goal of removing one gigaton of CO2 by 2040.
“Constructing a first-of-a-kind facility in just eight months is a massive undertaking. But our modular construction and lean design principles not only allowed us to move rapidly, but also means our approach is highly scalable.
“We hope this facility proves that cement and concrete decarbonisation is not only a possibility in the future – it’s a reality on the ground today. We look forward to working with government agencies, trade bodies and concrete specifiers to join us on our mission to realise the green transition here in the UK.”
CCP Building Product’s parent company, SigmaRoc, was a strategic investor in Material Evolution’s 2023 round of funding.
Michael Roddy, RMD North West at SigmaRoc, added: “We are thrilled to see the Mevo A1 Production Facility up and running, marking a significant milestone in low-carbon cement production in the UK.
“This project aligns with SigmaRoc’s commitment to sustainable development, and we are proud to support Material Evolution in driving innovation that transforms the industry.”
