Terra closes in on first commercial-scale plant to decarbonise cement production

Concrete Plants, Equipment & Applications / September 13, 2023
By Guy Woodford
Terra's scalable low-carbon alternative for cement production will be used in a new landmark commercial plant supplying customers in the Dallas-Fort Worth, Texas, market. Pic: Terra
Terra's scalable low-carbon alternative for cement production will be used in a new landmark commercial plant supplying customers in the Dallas-Fort Worth, Texas, market. Pic: Terra

Terra CO2 Technology (Terra), the scalable low-carbon alternative for cement production, has entered into a definitive agreement with Asher Materials for an exclusive market license of Terra's first commercial-scale advanced processing facility. Under the agreement, Asher Materials will acquire the plant, based in the Dallas-Fort Worth, Texas market, after construction and commissioning are complete.


This first plant will be capable of producing up to 240,000 tons per year of Terra's OPUS Supplementary Cementitious Material (SCM), which can substitute up to 40% of Portland cement in common concrete mixes and significantly reduce CO2 and NOX pollution in the cement industry.


Unlike other sustainable cement solutions, many of which are still in the lab phase, Terra's OPUS SCM can scale to meet the immense market demand, making decarbonised concrete a viable, affordable alternative for the industry.


The news comes after Terra recently showcased its real-world performance during a demonstration pour in Houston. The company's OPUS Supplementary Cementitious Material (SCM) was successfully used in constructing the Porsche Sugar Land dealership, owned by the Indigo Auto Group. The pour marked a pivotal moment, proving that Terra's innovative solutions are field-ready and can seamlessly integrate into practical construction applications.

Terra CO2
Terra's OPUS SCM can scale to meet big market demand, making decarbonised concrete a great alternative for the industry. Pic: Terra CO2 Technology


"The entire Terra team has worked tirelessly to achieve this major milestone – both for Terra and the industry at large as we move toward our collective goal of decarbonising cement. We are delighted to have Asher Materials as a valued customer partner, and we look forward to expanding our close relationship to license additional Terra facilities across Texas," said Bill Yearsley, CEO of Terra CO2.


Terra's SCM is a 1:1 replacement of traditional SCMs that does not require any additional RMC infrastructure or cement design investments, creating a win-win for both the environment and the economy. Terra's core technology is a production process that converts inexpensive, abundant, and local silicate rock feedstocks from existing aggregate mines to high-performing, climate-friendly, and cost-competitive cementitious materials. Unlike existing SCMs, OPUS products are precisely engineered and can be manufactured locally in large quantities, minimising transportation costs and allowing reliable supply with strict quality control.


Having successfully moved through research and development, piloting, rigorous third-party testing, and now to commercial deployment, Terra's approach is designed to unlock construction decarbonisation without impacting existing mix designs, cost, protocol, or procedures.


"From start to finish, we've designed a system to create large-scale impact in the real world. Our game-changing production process converts affordable, abundant, and local raw materials to cementitious material that meets rigorous performance standards," said DJ Lake, Chief Science Officer of Terra CO2. "At Terra, we know that true sustainability will come from deep innovations in materials and technology and not from incremental improvements to the existing cement supply chain."


Terra's partner, Asher Materials, has been working for over a decade, constructing first-of-its-kind industrial facilities focused on sustainability and efficiency. Asher is committed to making the Lone Star State the leader in low-carbon building solutions in the US through their partnership with Terra CO2.


"We're proud to partner with Terra for our first environmentally friendly plant, making it possible to start building a progressive network of these advanced processing facilities across Texas," said Jonathan Green from Asher Materials. "Our vision aligns with Terra's — making low-carbon cement the industry standard, one region at a time. In the coming years, we're committed to transforming Texas into a sustainable, cost-competitive construction leader and establishing a blueprint for other regions."


To ensure the success of this transformative project, Terra has engaged Christensen Building Group's industrial division out of Houston, Texas, to construct the first facility. Construction is expected to start in the second quarter of 2024. The first facility will sit on an established NSG Logistics transload property, underscoring both organisations' commitment to seamless integration and efficient operations.


"The marketplace can expect additional exciting announcements in different geographies over the next few months," continued Yearsley. "The future of sustainable cement is here, and Terra is excited to be leading the charge to market."


To learn more about Terra CO2, please visit: https://terraco2.com/