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Valentine’s Day last week included some ‘hot’ news for the cement sector with the announcement that Electrified Thermal Solutions is preparing to build the first commercial-scale pilot of its Joule Hive thermal battery (JHTB) in San Antonio, Texas. The company is working with the Southwest Research Institute on the project along with Buzzi Unicem USA, 3M and Amy’s Kitchen as industrial partners. Advisors include Imerys. The project update follows the award of a US$5m grant from the US Department of Energy (DOE) in late January 2024.

The funding description from the DOE’s Industrial Efficiency & Decarbonization Office reports that the end goal is to “turn intermittent renewable electricity into constant industrial grade heat” that can replace fossil fuel usage. Electrified Thermal Solutions aims to test its JHTB thermal energy storage system, which uses electrically conductive refractory bricks, to convert and store electricity as heat at temperatures higher than 1700°C. The JHTB power ranges between 1 - 200MW of thermal output, with duration up to tens of hours, enabling ‘very affordable’ high temperature energy storage and on-demand heat. Notably, it can charge and discharge simultaneously, allowing a continuous heat supply.

Electrified Thermal Solutions is not alone in targeting the cement sector. As Global Cement Weekly has covered previously energy storage is a growing topic of interest with a few large-scale electrical battery units running at cement plants in Pakistan and Taiwan. The other big name in thermal batteries for cement production is Rondo Energy. Both Electrified Thermal Solutions and Rondo Energy are using modular three-dimensional arrays of refractory bricks to store thermal energy and then release it, although they are likely to have key proprietary differences. However, Rondo Energy appears to be further along the industrial adoption process so far. Titan Cement and Siam Cement Group (SCG) invested in Rondo Energy in 2022. Then in July 2023 SCG and Rondo Energy said that they were planning to expand the production capacity of a heat battery storage unit at an SCG plant from 2.4 GWh/yr in mid-2023 to 90GWh/yr. For more information on Rondo Energy read the feature by CEO John O’Donnell in the January 2023 issue of Global Cement Magazine.

The reason that this matters, as partly explained above, is that fossil fuels contribute about one third of the CO₂ emissions created by heating up the kiln in cement production to make clinker. This is dropping globally due to the uptake of alternative fuels, but burning alternative fuels emits gross CO₂, however you account for the emissions. Mass adoption of thermal batteries by the sector could potentially cut out this double-accounting and reduce that third down to the carbon footprint of the refractory bricks used. This would then create knock-on issues concerning what to do with the waste streams instead but that is not a problem for the cement sector. These are worries for another day, as we first need to see how thermal batteries work at scale at a cement plant.

A recent feature in the Economist considered whether the mass adoption of electrical power from renewable sources might be an increasingly viable path to decarbonising industry. Geopolitics, faster-than-expected growth in renewables and new technology are all doing their bit to make this possible. As with so much of the carbon agenda it may alter the very concept of the traditional cement production line or at least the speed of change. Just imagine how a future cement plant might look, decked out with a electrical micro-grid, a heat battery, an oxy-fuel kiln, a carbon capture unit and either a chemical plant or gas pipeline junction. Will it happen? Who knows… but it is an exciting time for the cement sector.

Denmark: Aalborg Portland has appointed Ignacio Arroyo as its plant director.

Arroyo started his career working for Holcim in 1998 as a project manager at the Carboneras Plant in Spain. Other roles in Spain followed before he became the Operation Manager at the Yeles plant in 2012. He then worked as Technical Director and Plant Manager at Holcim’s National Cement Factory in Abu Dhabi, UAE. Subsequent roles included Plant Manager positions in Holcim Romania and Lafarge Canada.

US: Aumund Group has appointed Wes Allen appointed as Vice President Operations and Scott Martin as Head of the Global Conversion Team.

Allen has worked for Aumund since 2007 first as Director of After Sales and Service, North & Central America, then Information Technology Operations Manager and then Vice President Sales and Marketing. Prior to his experience with Aumund, Allen worked for environmental services company WM.

Martin previously worked in technical retrofit roles at Aumund since starting at the company in 2019. Prior to this he worked for KettenWulf as a Technical Account Manager and Project Engineer from 2016. Martin is a graduate in mechanical engineering from Kennesaw State University.

Germany: Sweden-based CheckProof has appointed Peter Erbel as its Country Manager, Germany. Erbel previously worked for FLSmidth and associated companies from 2007 to 2023 in sales, product and project management roles.

CheckProof is a software-as-a-service company supplying heavy industry markets including aggregate, asphalt, cement, ready mix concrete and heavy machinery. The company says it has seen strong, continual growth in Germany and appointing Erbel is planned to support existing clients and grow the business in Germany, Switzerland and Austria. CheckProof has clients in 38 countries.

US: Vulcan Materials raised its sales by 6.4% year-on-year in 2023, from US$7.32bn to US$7.78bn. Its adjusted earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 24% to US$2bn, while its profit grew by 25% to US$1.95bn. Vulcan Materials’ full-year concrete volumes dropped, during which time it also divested some concrete operations. Altogether, the producer plans to invest US$625 – 675m in maintenance and growth projects in 2024.

Chair and CEO Tom Hill said "We carry momentum into 2024, and our focus is the same - compounding unit margins through all parts of the cycle and creating value for our shareholders through improving returns on capital."

UK: The Global Cement and Concrete Association (GCCA) has launched the 3rd Innovandi Open Challenge 2024, with a focus on the deployment of carbon capture, use and storage (CCUS) for the decarbonisation of cement and concrete. Possible fields of study include process-integrated and end-of-pipe capture. The 1st Innovandi Open Challenge 2024 previously focused on CCUS, and has now produced two projects at pilot stage.

Cement, innovation and environmental, social and governance (ESG) director Claude Loréa said "Our industry is committed to achieving net zero and the development of carbon capture technology is a key part of that work. Our world-leading Innovandi Open Challenge programme has already seen remarkable progress in just two years, with start-ups and our member companies working together. We're looking forward to seeing what this year's applicants can bring, to build on the extensive work that is already underway across the world."

India: Germany-based ThyssenKrupp has agreed to sell its 55% stake in ThyssenKrupp Industries India to local joint venture partners. VCCircle News has reported that the move is part of on-going strategic cost-saving measures. The supplier expects to complete the sale in mid-late 2024. As a result, its total global employees will drop by over 2300. Protos Engineering and Paharpur Cooling Towers will reportedly acquire the stake. The companies hold existing stakes of 16% and 11% respectively.

Czech Republic: The Czech Cement Association (SVC ČR) says that it is “firmly” committed to decarbonise the cement industry and has agreed a clear roadmap explaining how to reach net zero by 2050. It added that it was also backing the strategy outlined in the European Commission’s (EC) industrial deal. In a statement the association said, “The position of SVC ČR regarding the proposal of the decarbonising targets by 2040 is that the Czech government has to prepare in cooperation with the individual industries a deep analysis of the opportunities and the risks arising from the new proposal and prepare a long-term strategy to support the competitiveness of Czech energy-intensive industries.”

SVC ČR distanced itself from comments published in ČTK Business News reporting that a group of energy-intensive industry associations in the country had challenged the EC's proposal to aim to reduce CO₂ emissions by 90% by 2040. The associations argue that the target will harm the competitiveness of Czech industries. They say that it is based on unrealistic assumptions and overlooks the absence of necessary conditions for major investment in the EU’s green industry transformation.

This story was updated on 29 February 2024 with comments from SVC ČR

France: Calderys Group says that it has successfully implemented technology sharing between US-based HWI and Calderys, following their integration in February 2023. In the past 12 months, the group has transferred select Calderys products to HWI in the Americas and introduced HWI products in Europe, the Middle East and Africa and Asia-Pacific. The refractories supplier says that the collaboration offers customers an enhanced product range.

Calderys Group president and CEO Michel Cornelissen said "The past 12 months have been exciting, demanding and very productive for our newly-formed group. The combination brought together two dynamic businesses with complimentary product ranges and created the opportunity for technology sharing and cooperation for the benefit of the world's high temperature manufacturing sectors. I am delighted that we are already seeing great results. Throughout 2024, we will continue to add to, and update, our product portfolios.”

India: Ambuja Cements is planning to build a 4Mt/yr cement grinding plant at Motia Village, Godda District in Jharkhand. The project has a budget of US$120m. The proposed plant will use fly ash supplied from the nearby Andani Power Godda thermal power plant.

Ajay Kapur, CEO – Cement Business at Adani Group, said “We believe that Jharkhand holds immense potential in terms of resources, infrastructure and skilled manpower, making it an ideal location for this project.”

Ambuja Cements operates two cement plant in Jharkhand with a combined production capacity of 6Mt/yr.