Displaying items by tag: Australia

From the Nordics to the Mediterranean, European countries lead the field in reduced-clinker cement production using supplementary cementitious materials (SCMs). While consumers, faced with ever-greater choice, continue to opt for sustainability, projects to improve existing SCMs and develop new ones have won government backing and have become a matter of serious investment for other heavy industries beside cement. European cement producers’ decisions are steering the course to a world beyond CEM I. Yet, even in Europe, great untapped potential remains.

Companies generated a good deal of marketing buzz around their latest reduced-CO₂ cement ranges in 2021 and the first quarter of 2022: Buzzi Unicem’s CGreen in Germany and Italy, Holcim’s EcoPlanet in six markets from Romania to Spain, Cementir Holding’s Futurecem in Denmark and Benelux, and Cemex’s Vertua in Spain and several other countries. All boast reduced clinker factors through the use of alternative raw materials. This, however, is really a rebranding of a long-established norm in Europe.

Since 2010, cements other than CEM I have constituted over 75% of average annual cement deliveries across Cembureau member countries (all cement-producing EU member states, plus Norway, Serbia, Switzerland, Turkey, the UK and Ukraine). This statistic breaks down differently from country to country. CEM II is the norm in Austria, Finland, Portugal and Switzerland, with deliveries in the region of 90%. Portland limestone cement (PLC) makes up a majority of deliveries in all four. It has been central to Switzerland’s transition to 89% (3.72Mt) of CEM II deliveries out of a total 4.18Mt of cement despatched in 2021. There, the main types of cement were CEM II/B-M (T-LL) Portland composite cement, with 1.38Mt (33%), and two different classifications of PLC: CEM II/A-LL PLC, with 1.28Mt (31%), and CEM II/B-LL PLC, with 888,000t (21%).

A second approach is that of the Netherlands, where CEM III blast furnace slag cement with a clinker factor below 65% predominates, favoured for its sulphate resistance and the protection it offers against chloride-initiated corrosion of steel reinforcement in marine settings. By contrast, the UK has traditionally maintained a higher reliance on CEM I cement. This can be partly explained by the preference of builders there for adding fly ash or ground granulated blast furnace slag (GGBFS) at the mixing stage. Nonetheless, CEM II Portland fly ash cement held a 14% (1.43Mt) market share in the UK’s 10.2Mt of cement consumption in 2021.

The UK Mineral Products Association (MPA) has identified limestone as an underutilised resource in the country’s cement production. Together with HeidelbergCement subsidiary Hanson Cement, it has applied for a change to National Application standards to allow the production of Portland composite cement from fly ash and limestone or GGBFS and limestone. The association has forecast that Portland composite cement could easily rise to 30 – 40% of UK cement consumption, and that this has the potential to eliminate 8% of the sector’s 7.8Mt/yr-worth of CO₂ emissions.

Metallurgical waste streams have long flowed into European cement production, primarily as GGBFS, but also as bauxite residue. In 2021, alumina production in the EU alone generated 7Mt of bauxite residue, of which the bloc recycled just 100,000t (1.4%) that year. Two projects – the Holcim Innovation Center-led ReActiv project and Titan Cement and others’ REDMUD project – aim to produce new alternative cementitious materials from bauxite residue.

By collaborating with other industries, cement producers’ investments can most effectively reduce the overall cost of using these materials in cement production. In Germany, HeidelbergCement and ThyssenKrupp’s Save CO₂ project aims to develop new improved latent hydraulic binders or alternative pozzolan from GGBFS by producing slag from directly reduced iron (DRI). The Save CO₂ team believes that GGBFS substitution for clinker has the capacity to eliminite 200Mt/yr of CO₂ emissions from global cement production.

Meanwhile in the world of mining, ThyssenKrupp and others’ NEMO project is investigating the recovery of a useable mineral fraction for cement production from the extractive waste of the Luikonlahti and Sotkamo mines in Finland and the Tara mine in Ireland, through bioleaching and cleaned mineral residue upcycling. This may give cement producers full access to Europe’s 28Bnt stockpiles of sulphidic mining waste, of which mines generate an additional 600Mt each year.

Denmark-based CemGreen, which produces the calcined clay supplementary cementitious material CemShale, is developing a shale granule heat-treating technology called CemTower. This consists of three pieces of equipment vertically integrated into cement plants’ preheaters, kilns and coolers, and brings the processing of waste materials – here oil shale – to the cement plant.

Lastly, cement producers are exploring the possible uses of waste made of cement itself. In Wallonia, HeidelbergCement subsidiary CBR’s CosmoCem project is investigating the production of alternative cement additives from large available flows of local demolition, soil remediation and industrial waste. Similarly, the Greece-based C2inCO₂ project seeks to mineralise fines from concrete recycling for HeidelbergCement to use in the production of novel cements in its Greek operations.

In Switzerland, ZND Portland composite cement (produced using fine mixed granulate from building demolitions) is the third largest cement type, with 178,000t (4.3%) of total deliveries – narrowly behind CEM I with 239,000t (5.7%).Holcim Schweiz developed its Susteno 4 ZND Portland composite cement with Switzerland’s lack of any ash or slag supply in mind, demonstrating the potential flexibility of a circular economic approach to cement production.

On 21 March 2022, the University of Trier reported that it is in the process of mapping mineral resources, waste deposits and usable residues ‘on a cross-border scale,’ in an effort to produce new materials for use in cement production. Industry participants include France-based Vicat, CBR, Buzzi Unicem subsidiary Cimalux and CRH subsidiary Eqiom. Vicat is preparing a kiln at its 1Mt/yr Xeuilley cement plant in Meurthe-et-Moselle to use in testing new alternative raw materials developed under the project.

For Cembureau and its members, work continues, with the goal of Net Zero by 2050 constantly in sight. This goal includes a reduction in members’ clinker-to-cement ratios to well below 65%. In this, the association and its members are working towards a world not just beyond CEM I, but beyond CEM II, too. What exactly this will mean remains to be seen.

Sources

CemSuisse, ‘Lieferstatistik,’ 11 January 2022, https://www.cemsuisse.ch/app/uploads/2022/01/Lieferstatistik-4.-Quartal-2021.pdf

WSA, ‘December 2021 crude steel production and 2021 global crude steel production totals,’ 25 January 2022, https://worldsteel.org/media-centre/press-releases/2022/december-2021-crude-steel-production-and-2021-global-totals/

MPA, ‘Low carbon multi-component cements for UK concrete applications,’ July 2018, https://prod-drupal-files.storage.googleapis.com/documents/resource/public/Low%20carbon%20multi-component%20cements%20for%20UK%20concrete%20applications%20PDF.pdf

European Commission, ‘European Training Network for Zero-waste Valorisation of Bauxite Residue (Red Mud),’ 16 July 2020, https://cordis.europa.eu/project/id/636876

European Commission, ‘Industrial Residue Activation for sustainable cement production,’ 16 February 2022, https://cordis.europa.eu/project/id/958208

Recycling Portal, Zement der Zukunft – Forschungsprojekt „SAVE CO₂“ gestartet, 28 May 2021, https://recyclingportal.eu/Archive/65677

h2020-NEMO, ‘Project,’ https://h2020-nemo.eu/project-2/

European Commission, ‘Green cement of the future: CemShale + CemTower,’ 14 April 2021, https://cordis.europa.eu/project/id/101009382

CosmoCem, ‘Communiqué de Presse,’ https://cosmocem.org/

CO₂ Win, ‘C²inCO₂: Calcium Carbonation for industrial use of CO₂,’ https://co2-utilization.net/en/projects/co2-mineralization/c2inco2/

Les Echos, ‘Rendre le ciment moins gourmand en CO₂,’ 21 March 2022, https://www.lesechos.fr/pme-regions/innovateurs/des-substituts-au-clinker-rendent-le-ciment-moins-gourmand-en-co2-1395002

Germany: Australia-based Calix says that its LEILAC-2 carbon capture retrofit of HeidelbergCement's Hanover cement plant has passed its financial investment decision. The company is accordingly proceeding with detailed design and long-lead item purchasing. It will launch construction in 2023. Calix added that, due to a number of project risk flag points given the 'market situation,' it will not buy major components until closer to that time.

When commissioned, the installation will capture 0.1Mt/yr of CO₂ and cost an estimated Euro20 - 25/t of CO₂ captured.

Australia: Boral has updated the market that ‘exceptional’ wet weather on the East coast of Australia ‘significantly’ disrupted its New South Wales and South East Queensland operations in February and early March 2022. The Australian newspaper has reported that CEO Zlatko Todorcevski has forecast that the disruption to cement production and deliveries will have a negative impact of US$17.1m on the producer’s earnings in the first quarter of 2022. Coal and diesel costs have also risen ‘sharply’ so far in the quarter, to partly offset which the company has raised its cement prices. It now forecasts full-year earnings from continuing operations, excluding property, of US$108 – 115m.

Pakistan: Cement plants in North Pakistan are using 70% Afghan coal in their fuel mix, and may increase the figure to 90%. Afghan coal costs US$170 – 200/t, in line with local Pakistani coal prices. The News International has reported that fossil fuel supply disruptions ensuing from the on-going war in Ukraine have increased global coal prices. Additionally, Indonesian coal is subject to a ban on exports, while bad rains have disturbed Australian coal production. On 14 March 2022, the price of South African coal exported from Richard Bay, Umhlathuze Municipality, was US$460/t, up by 95% month-on-month from US$236/t on 10 February 2022. South Africa has previously been a major source of coal for Northern Pakistani cement production. Cement producers in the region have on average 4 – 5 months’ supply of coal in inventory.

US: Solidia Technologies has appointed Padmaja Parakala as its director of research and development.

She holds 20 years of experience working in corporate material science, most recently working for Innovantage, a professional services firm she founded that has worked with Solidia Technologies and the Boral Innovation Factory. Prior to this she worked as the principal scientist and product performance leader at James Hardie Building Products in Australia. Earlier in her career she also worked for GE at the John F Welch Technology Center.

Parakala holds s PhD in material engineering from the Queensland University of Technology and master’s degrees from the Indian Institute of Technology in Kharagpur and the Indian Institute of Technology in Varanasi.

Australia: AdBri’s consolidated revenues reached US$1.13bn in 2021, corresponding to a 7.6% year-on-year rise from US$1.05bn. Cement sales constituted 39% of the group’s revenues and rose by 12% year-on-year. Earnings before interest and tax (EBIT) were US$128m, down by 0.4% from US$129m. The company recorded a net profit after tax of US$85.7m, up by 3.1% from US$83.2m in 2020.

Chair Raymond Barro said “The many challenges of 2021 revealed the strength of our people and the depth of their skills, capabilities and experience. On behalf of the board, I would like to commend (managing director and CEO) Nick Miller, his executive leadership team and all our people for their commitment, dedication and resolve as they have continued to deliver for our stakeholders.”

Papua New Guinea: Mayur Resources has signed a collaboration agreement with First Graphene Limited for the production of low-carbon cement using the latter’s PureGraph graphene-based grinding aids and performance improvers. Mayur Resources operates a 0.9Mt/yr cement plant, where it also produces a further 0.75Mt/yr of clinker and 0.2Mt/yr of lime, near Port Moresby in National Capital District. The Australia-based partners hope to export their cement across Melanesia and to Polynesia and Australia.

Australia: Boral’s earnings in the first half of its financial year have fallen as it has completed the sales of its North American fly ash business. Its revenue from continuing operations fell slightly to US$1.08bn in the six months to 31 December 2021. However, its earnings before interest, taxation, depreciation and amortisation (EBITDA) for continuing operations dropped by 16% to US$138m from US$164m in the same period in 2020. Cement and concrete sales volumes remained stable and rose slightly respectively.

“With the completion of the divestment of our North American Fly Ash business on 11 February 2022, we have now finalised the strategic realignment of our portfolio to focus on our Australian construction materials business,” said Boral’s chief executive officer Zlatko Todorcevski. “We are focused on building a more competitive and profitable business that is positioned for success and delivers increased returns to shareholders.” He blamed falling earnings on construction shutdowns and growing energy prices despite changes to the business.

Australia: Boral has selected Earlytrade to digitise its supplier payment and progress claim processes. The supplier says that it will help protect Boral's supply chain against inflation and insolvency trends. It will roll out its early payment technology for 5000 suppliers of Boral products, as well as subcontractors, across Australia.

Australia: In the third quarter of the 2022 financial year, James Hardie’s net sales rose by 22% year-on-year to US$900m. Its Asia Pacific fibre cement business recorded sales of US$140m, up by 20% and adjusted earnings before interest, taxation, depreciation and amortisation (EBIT) of US$38.2m, up by 17%. James Hardie’s North America fibre cement business’ sales also rose, by 24% to US$645m, while its adjusted EBIT rose by 18% to US$183m. Following the results, James Hardie raised its 2022 net income guidance to US$620 – 630m from US$605 – 625m.

Interim chief executive officer Harold Wiens said, "I am pleased to report the James Hardie team has continued to execute well on our stated global strategy.” He attributed the successes to “Firstly, enabling our customers to make more money by selling more James Hardie products and, secondly, marketing directly to the homeowners to create demand of our high value products through our customers."

Wiens also announced the launch of the company’s new Architectural cement boards collection.