Mannok – World’s First to Implement FUELFLEX®, Pioneering Co-Processing in Ireland
Mannok, a subsidiary of global building materials company Çimsa, has achieved major advancements in co-processing, reaching a thermal substitution rate (TSR) of up to 75% in grey cement production.
In partnership with FLS Cement, Mannok co-developed and became the world’s first to implement the FUELFLEX® solution in 2024. Installed at the calciner, this system enabled the full replacement of coal with Solid Recovered Fuel (SRF), addressing the short calciner residence time challenge in the plant, originally built in 2000.
By integrating satellite and multi-channel main burner systems at the kiln, Mannok optimized fuel efficiency using only standard SRF—a resource abundantly available in Ireland. This streamlined approach has reduced operational complexity, simplified licensing, and improved profitability. Moreover, focusing on a single alternative fuel has allowed continuous refinement, boosting TSR and significantly reducing CO₂ emissions.
To date, Mannok has eliminated over 104,000 tonnes of coal annually, replacing it with low-carbon SRF, reducing emissions by approximately 98,000 tonnes of CO₂ (Scope 1) each year.
Mannok’s position as one of Ireland’s leading cement producers under the EU-ETS, combined with Çimsa’s proven expertise in renewable and alternative fuel technologies, forms a strong platform for advancing innovation and sustainability in the years ahead.