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Update on calcined clay, January 2025
29 January 2025Northern-Ireland based cement producer Cemcor said this week that it has completed trials of a calcined clay cement product called CalcinX. The company started its trials in 2023 and it has been supported by Queen’s University Belfast and funding from Innovate UK. Work with commercial partners has involved precast concrete paving manufacturer Tobermore producing paviours made from 50% CalcinX as a CEM II replacement and Moore Concrete has also manufactured precast units using 50% CalcinX as a CEM I replacement. So far over 3000t of CalcinX has been produced in a number of industrial-scale trials.
David Millar, the managing director of Cemcor, mentioned his company’s plans for calcined clay in June 2022 when he was interviewed by Global Cement Magazine. The company that became Cemcor bought the Cookstown cement plant and a few other assets from Holcim at the start of 2022. It then changed its name to Cemcor in November 2022. At the time of the interview the company was looking to “...develop new value-added products, including low-CO2 options. This will allow us to use the same amount of clinker to produce more cement.” Millar couldn’t give away too many details at the time, however calcined clay was cited specifically. It was also noted that the company had the right material in its quarry and that it was already working with partners on it.
Amongst all the other decarbonisation options available for cement plants, a slow trickle of calcined clay projects keep being announced. In January 2025, for example, thyssenkrupp Polysius said it had secured a front-end engineering design contract from Circlua for the construction of the world’s largest activated clay plant in Brazil. This project in Para state will have a capacity of 3000t/day, will use renewable energy sources and will “improve the CO2 footprint in cement production.” CBMI Construction also officially launched a flash calcination clay project in Tangshan, Hebei province in China. In December 2024, Vicat signed an agreement with the US Department of Energy (DOE) Office of Clean Energy Demonstrations to develop the Lebec Net Zero (LNZ) project at its Lebec cement plant in California. This includes plans to produce calcined clay-based cement. Earlier in the autumn of 2024 Portugal-based Cimpor said it was preparing to convert a kiln at its Souselas plant to produce calcined clays, AVIC International Beijing and KHD said that they had secured a deal to build a 900t/day clay calcination plant for Ciments de l'Afrique (CIMAF) in Burkina Faso, and Holcim Česko said it was going to construct a calcined clay processing line at the Čížkovice cement plant in the Czech Republic.
One news story that stuck out in the autumn was the progress of a collaboration between Aumund and Holcim towards developing an electric linear calcination conveyor (eLCC). The two companies started work on the project in 2020 intending to look at the electrical calcination of clay using an Aumund pan conveyor. Initial tests of the eLCC reportedly demonstrated efficient thermal activation of clay through a combination of radiant heat and material circulation. The eLCC system is fully enclosed, insulated, has a compact design and can operate using electrical-powered renewable sources. The first industrial plant utilising this technology is scheduled for construction in 2025. Calcined clay technology and products by other industrial suppliers are available. The work by Aumund and its competitors show they are watching this market closely.
OneStone Consulting’s Joe Harder has found that only 14 clay calcination plants were operational worldwide in 2023 with a production capacity of just under 3.5Mt/yr. These are based in Latin America, Europe and Africa. In an article previewing a market report in the February 2025 issue of Global Cement Magazine, Harder predicts that by 2035 there will be 79 clay calcination plants with a capacity of just under 21Mt/yr. A steady growth of over 20 new plants annually is also expected subsequently from 2035 to 2050 as cement producers seek cost-effective ways to reduce their clinker factor. He identified installation costs, a lack of knowledge about clay-based cements, trouble obtaining mining rights and policy issues amongst other issues as holding back the use of clay calcination.
The current expectation is that calcined clay usage in the cement industry will be a minority option. Yet the size of global cement production can make a production share of, say, 3 - 8% a viable option for both cement manufacturers and equipment suppliers. The adoption of new cement products and standards can also take a long time and this clouds predictions of how far clay can go in the cement industry. At this point in the calcined clay story it is time to keep track of the new projects being set up.
Joe Harder will present a talk entitled ‘Calcined clay market trends by 2035’ at the Global FutureCem Conference taking place in Istanbul in early February 2025
Brazil: thyssenkrupp Polysius has secured a front-end engineering design contract from Circlua for the construction of the world’s largest activated clay plant, with a capacity of 0.96Mt/yr (3000t/day). The plant will be largely powered by renewable electricity, and will be located in Pará, utilising clay sourced from the Carajás iron ore complex. The clay contains up to 80% kaolinite content, and will be upcycled as supplementary cementitious material.
thyssenkrupp Polysius CEO Christian Myland said “We are honoured to partner on this landmark project. Leveraging high-quality local clay and our advanced activated clay technology, this plant will set a new benchmark for carbon-conscious cement production.”
Huaxin Cement to buy aggregates producer Embu
24 December 2024Brazil: China-based Huaxin Cement has signed a deal worth US$187m to buy aggregates producer Embu. Embu owns four quarries in the metropolitan region of São Paulo with a production capacity of nearly 9Mt/yr, according to the Rio Times newspaper. In 2023 it produced 6.3Mt and reported a net profit of around US$3.2m.
Brazil: InterCement, the indirect controlling shareholder of Loma Negra, has extended its exclusivity agreement with Companhia Siderúrgica Nacional for a potential acquisition of its entire share capital until 16 December 2024. This extension is part of a broader non-judicial collection process and does not impose any binding obligations on InterCement or its shareholders. This follows a previous extension of the exclusivity period in July 2024.
Votorantim Cimentos reports 2024 third quarter financial results
13 November 2024Brazil: Votorantim Cimentos has reported that its net profit surged by 24% in the third quarter of 2024 compared to the same period of 2024, to reach US$179m. Its net revenue increased by 6% year-on-year to reach US$1.33bn.
However, when excluding currency fluctuations, revenue decreased by 1%. This highlights the significant impact of foreign exchange rates on Votorantim's global operations. Adjusted earnings before interest, tax, depreciation and amortisation (EBITDA) rose by 20% to US386m. Cement sales volume increased by 3% to 10Mt during the quarter.
The company said that these figures indicate resilient demand across Votorantim's markets, despite challenging economic conditions in some regions. The company's diversified geographical presence has helped balance market fluctuations.
In the sustainability arena, Votorantim Cimentos also says that it has made significant progress. The company reduced its specific embodied CO2 emissions by 4% to 556kg/t of cement in 2023. It has also increased its alternative fuel thermal substitution rate (TSR) from 26.5% in 2022 to 30.9% in 2023.
Buzzi acquires full ownership of Companhia Nacional de Cimentos
07 October 2024Brazil: Buzzi has finalised the acquisition of the remaining 50% stake in Companhia Nacional de Cimentos (CNC) from Brennand Cimentos, securing full control over the joint venture. The deal, valued at US$311m, was approved by Brazil's Administrative Council for Economic Defense (CADE), according to Movimento Econômico. CNC has been operational since 2018 and has five integrated cement plants and two grinding plants in Brazil, with a total production capacity of 7.2Mt/yr. This acquisition follows initial transactions that began in June 2024.
Brazil: Votorantim Cimentos has launched Blenture, a new brand of cement and concrete designed to reduce CO₂ emissions and promote sustainable construction practices. Blenture products, developed through significant investment in research and development, align with the company’s decarbonisation strategy to utilise recycled materials and non-fossil fuels. Blenture cements and concretes, certified with environmental product declarations by AENOR, reportedly offer a 30% lower carbon footprint while maintaining quality, strength and performance.
Brazil: China-based Sinoma Overseas has signed an engineering and supply contract for the Z02 cement grinding plant and a technical cooperation framework agreement with Votorantim Cimentos. The agreements were signed by Sinoma chair Zhu Linhe and Votorantim’s global projects director Alvaro Lorenz. This collaboration marks the third cement grinding plant project between the two companies and is part of Votorantim's ‘2028 Development Strategy.’ The contract encompasses the design, equipment supply, and technical services for a 150t/hr cement grinding plant.
Zhu Linhe said "Votorantim is the most valuable client for Sinoma Overseas, this contract and agreement strengthens the strategic partnership between the two companies. It is the strong commitment of Sinoma Overseas to support Votorantim in achieving its '2028 Development Strategy' with Sinoma’s extensive industry expertise, advanced technology and mature localised operations.”
InterCement submits restructuring plan
17 September 2024Brazil: InterCement has presented a restructuring plan to local courts. The plan is aimed at reprofiling the capital structure of the company, and has gained approval from creditors representing over one third of its debt. The plan depends on a possible merger and acquisition transaction that is still under negotiation, according to a statement by the company. This plan comes a few months after the company announced it had entered talks to sell to Companhia Siderurgica Nacional.
Brazilian cement sales reach record high
10 September 2024Brazil: Cement sales increased to 6.2Mt in August 2024, marking the highest monthly sales since October 2014, when sales reached 6.7Mt. This 10-year peak reflects a 5% month-on-month and 3% year-on-year increase, spurred by dry weather and a robust real estate sector, according to data released by the National Union of the Cement Industry (SNIC).
All regions in Brazil reported sales growth, with the highest sales in the north and northeast and a recovery in the south after the floods in Rio Grande do Sul. Year-to-date sales reached 43Mt, up by 3% from 2023.
However, concerns about prolonged dry spells potentially affecting electricity prices and logistics are emerging, with SNIC stating in a press release "The announcement of the increase in the red flag energy bill in Brazil due to the lack of rainfall is already causing concern for the cement sector, both in terms of production costs and logistics. Brazil is facing the worst drought in history in 2024 and this could have an impact on cement sales, especially in the north."