Displaying items by tag: Aggregate Industries

UK: Aggregate Industries has rebranded as Holcim UK. The company operates over 200 sites across the UK with 4000 employees. Following 20 years as a UK-based subsidiary of Holcim Group, the new direction sees the business align more closely with its Swiss-based parent company, which operates across 70 countries and employs over 60,000 people worldwide.

Holcim UK CEO Lee Sleight said “Our evolution from Aggregate Industries to Holcim UK is much more than a rebrand. It represents a commitment to leading the sector towards a more sustainable future through a commitment to innovation and collaboration.”

UK: The first shipment of bulk cementitious materials has arrived at Aggregate Industries’ new deep-sea cement terminal in Southampton.

Cementitious materials are conveyed pneumatically into the terminal’s new warehouse. The facility, developed under a €7.2m investment, is reportedly the UK’s fastest cement discharging terminal, unloading 1t of cement every five seconds. The project began in March 2024 and was completed with the arrival of the Nacc Indian Cement Carrier, marking the terminal’s operational launch.

UK: Aggregate Industries has built a 45m high and 32m diameter airform dome silo at the Port of Tilbury in Essex. The silo is part of its new cement import, manufacturing and distribution facility, which is under construction. The inflatable structure will store up to 30,000t of cement to support demand for construction materials in the region. Aggregate Industries worked with US-based Dome Technology to inflate the dome. Contractor Dome Technology will now apply nearly 4500m³ of sprayed and wet mix concrete to form the dome silo.

The cement facility is expected to be operational in 2026.

UK: Aggregate Industries has appointed Tom Murphy as Carbon Capture Utilisation and Storage (CCUS) Project Manager at the Cauldon Cement Plant in Staffordshire. He will play a leading role in managing the introduction of a carbon capture unit at the site.

Murphy joins the subsidiary of Holcim from Tata Chemical Europe where he was the Plant Manager for a first-of-a-kind post combustion carbon capture plant. Prior to that, he worked as an Energy Chemical Engineer for Tata and as a Research Engineer for the Materials Processing Institute. He holds an undergraduate degree in chemical engineering from the University of Manchester.

The CCUS project at the Cauldon Cement Plant is part of the wider Peak Cluster partnership, which was formed by cement and lime producers around the Derbyshire Peak District region and aims to cut collective annual carbon emissions by 3Mt/yr by 2030. More than 0.6t/yr is targeted to be cut at Cauldon. The project is being led by Progressive Energy. It aims to capture and transport CO₂ emissions from Cauldon and other partner plants before sequestering them beneath the eastern Irish Sea in one of the storage options which the project has access to, including the Liverpool Bay CCS or the Morecambe Net Zero project.

UK: Loesche has won a contract from Aggregate Industries UK, part of the Holcim Group, to design, manufacture and deliver a grinding plant for a new production and distribution facility at the Port of Tilbury, set to open in 2025. The new plant will feature a Loesche vertical roller mill of the LM 30.2 CS type, complete with a dynamic classifier, process and nuisance filters, a hot gas generator and mill fan. This facility will allow Aggregate Industries UK to supply its customers with a range of conventional, low carbon and circular cementitious materials 24 hours a day from five loading heads.

UK: Aggregate Industries has commenced civil construction at its new manufacturing facility and import terminal at the Port of Tilbury. This new grinding station and storage facility aims to be fully operational by 2026.

The project will allow the company to supply conventional, low-carbon and circular cementitious materials 24 hours a day from five loading heads, meeting growing demands for sustainable building materials. It includes investments in new plant equipment for manufacturing blended cements and lower carbon cement components, such as ground granulated blast furnace slag and materials from construction demolition.

The Hillhead Quarrying, Construction and Recycling Show is in full flow this week, taking place near Buxton in Derbyshire. As one delegate marvelled on the panoramic minibus journey down to the quarry, “It’s like a music festival without the music and… other stuff.” Indeed. Of course what one doesn’t find at Glastonbury and the like is a near comprehensive range of suppliers, over 600 of them, to the industry all in one place… in a quarry! Where else can one get up close and see the new hydrogen-powered generators and excavating vehicles that are being piloted? The official attendance figures don’t get released until after the event but on the ground it looks as busy as ever. It’s truly the place to be this week.

The show gives us a reason to take a look at the UK cement sector. Like many other countries around the world it is an election year in the UK, with a General Election scheduled for 4 July 2024. The result of this should determine the next Prime Minister and the ruling party. So, naturally, the MPA, the trade association for the aggregates, asphalt, cement, concrete, dimension stone, lime, mortar and industrial sand industries, is taking the opportunity to remind the political parties what its priorities are. The quick version is: support for decarbonisation; a streamlined planning system; and better delivery of projects. This sounds familiar to priorities in other countries but one British spin on this includes the UK’s carbon border adjustment mechanism (CBAM).

Graph 1: Domestic cement sales and imports in the UK, 2017 – 2022. Source: MPA.

Edwin Trout’s feature on the UK cement sector in the June 2024 issue of Global Cement Magazine presents a good overview of the last 12 months. The general UK economy has faced shocks in recent years such as Brexit, Covid-19 and the war in Ukraine. However, this has been further compounded by a downturn and high interest rates since late 2022 when the then Prime Minister Liz Truss caused market turbulence in the wake of a badly received government financial statement. As Trout relates, sales of heavy building materials have been in relative decline since mid-2022 with more of the same expected in 2024. Production of cement in 2023 is currently uncertain given the reporting time lag from the MPA but up until 2022 domestic cement sales fell somewhat but imports grew. This has created a situation where overall cement sales in 2022 were 12Mt, not far behind the annual level in the early 2000s. However, the share of imports has nearly doubled since then. More recent MPA data on mortar and ready-mixed concrete sales throughout the first nine months of 2023 suggest that market activity has decreased and poor weather at the start of 2024 looks set to have made this worse.

Despite the apparent slowdown in building materials sales the cement companies have been conducting smaller-scale maintenance and upgrade projects at their facilities and supply chain schemes such as the cement storage unit for deep sea shipping lines that Aggregate Industries said in February 2024 it was going to build at the Port of Southampton. The news the cement companies want to show off has been a steady stream of information about ongoing decarbonisation projects in the cement sector. C-Capture started a carbon capture trial at Heidelberg Materials’ Ketton cement works in Rutland in May 2024, Capsol Technologies said in March 2024 that it had been selected to conduct a study on its carbon capture technology at Aggregate Industries Cauldon cement plant in Staffordshire, Heidelberg Materials' Ribblesdale cement plant in Lancashire announced in March 2024 that it was taking part in a study to assess the use of ammonia as a hydrogen source for fuelling cement kilns and Heidelberg Materials awarded Japan-based Mitsubishi Heavy Industries (MHI) a front end engineering design contract for a carbon capture installation at its Padeswood cement plant in Flintshire in February 2024. Finally, on the divestment front, CRH completed the sale of its UK-based lime business to SigmaRoc for €155m in March 2024. The business operates from sites in Tunstead and Hindlow with five permitted lime kilns.

That’s it for this short recap on the UK for now. For a longer look at the UK cement sector read Edwin Trout’s feature in June 2024 issue of Global Cement Magazine.

Hillhead 2024 runs until 27 June 2024

UK: Capsol Technologies has been selected to conduct a study on its carbon capture technology at Aggregate Industries Cauldon cement plant in Staffordshire. Owned by the Holcim Group, the company’s plant will undergo a feasibility study by Capsol Technologies for its CapsolEoP® carbon capture system. The potential for carbon capture at this plant is 600,000t/yr of CO₂. The CO₂ captured will be stored geologically through the nearby MNZ Cluster or HyNet North West.

CCO Johan Jungholm said “CapsolEoP® provides a cost-efficient carbon capture solution for cement, and our solution can be run on electricity alone without expensive heat integration or external steam supply. It offers flexibility in the optimisation of the designs, allowing for high capture rates, high reliability and low energy consumption."

The contract includes supplier input for the feasibility study, and further pre-FEED engineering if Capsol's technology is selected. The UK Government's Industrial Energy Transformation Fund (IETF) is funding the study, with Petrofac as Aggregate Industries engineer. This study is part of Peak Cluster's objective to reduce over 3Mt/yr of CO₂ from cement, lime, and refuse facilities by 2030. Capsol Technologies is focusing on the cement industry, which accounts for about 8% of global CO₂ emissions.

UK: Aggregate Industries is preparing to build a new cement storage unit for deep sea shipping lines at the Port of Southampton. As part of a 20-year agreement, Aggregate Industries will be working with port owner Associated British Ports and industry-leading cargo handler Solent Stevedores, which will operate the new cement import unit. The site is intended to help the business maintain a continuous supply of lower CO₂ cementitious products in the south and south west of England.

Matt Owen, Head of Supply Chain at Aggregate Industries Cement Division said “This is a significant project for us. It constitutes the first stage in a wider programme of planned investments over the short to medium term in deep sea imports designed to enable us to serve growing demand.” He continued, “The southern construction market remains buoyant with lots of major projects in the pipeline this year and beyond. Constituting one of the few deep-sea vessel facilities of its kind in the region, this facility will enable us to remain primed and ready to meet our customers rising demand for lower carbon solutions.”

UK: Aggregate Industries has successfully removed gas duct sections from the electrostatic precipitation filter at its Cauldon cement plant in Staffordshire. This will make way for the installation of a new CTP Team process kiln bag filter, following an annual shutdown.

Cauldon plant capital expenditure manager Mark Powling said “The new bag filter not only provides the best available technology, but will enable the Cauldon plant to optimise its plant performance, driving its decarbonisation and alternative fuel strategies. Thanks to the project team for their efforts and hard work to date.”