Displaying items by tag: Grant

Australia: Boral will receive US$15.4m in government funding for a kiln feed optimisation project at its Berrima Cement Works, with CO₂ emissions expected to reduce by up to 100,000t/yr, based on predicted production rates. The Powering the Regions grant will support the producer’s installation of a new specialised grinding circuit and supporting infrastructure, which will raise the use of alternative raw materials in kiln feed to 23% from 9%, lowering the amount of limestone used.

Boral will use steel manufacturing by-products and industrial waste, including granulated blast furnace slag, steel slag, cement fibre board, fly ash and recycled fine concrete aggregates. The project will be operational in 2028.

The head of innovation and sustainability at Boral, Ali Nezhad, said “In terms of the resulting emissions intensity of the manufactured clinker, the project will result in up to 11% reduction in clinker emission intensity, 9% attributable to a reduction in calcination emissions and 2% attributable to thermal efficiency gains.”

Europe: 77 decarbonisation projects (including 14 for the cement sector) have signed grant agreements under the Innovation Fund 2023 Call (IF23), following the announcement of results in October 2024. The cement projects, spanning nine European countries, will begin operations between 2025 and 2029.

The funding, sourced from the EU Emissions Trading System, provides grants ranging from €4.4m to €234m, supporting projects expected to avoid 118Mt of CO₂. The total 77 projects funded have the potential to reduce emissions by around 398Mt of CO₂ equivalent over their first 10 years of operation. The projects funded in the cement industry mostly involve carbon capture and storage (CCS). Among the selected CCS projects are Carbon2Business in Germany, Olympus in Greece, Go4Zero in Belgium and Cementir’s Accsion project in Denmark.

US: Terra CO₂ has raised US$82m in Series B funding from investors including Eagle Materials, GenZero and Just Climate. The company will build its first commercial facility in Dallas-Fort Worth, Texas, in partnership with Asher Materials.

With the help of Eagle Materials, the company will establish multiple 240,000t/yr plants across North America. The US Department of Energy has also awarded Terra CO₂ with a grant of US$52.6m for a second commercial facility. The producer has begun concrete trials of its Opus Zero cement-free product, designed to completely replace ordinary Portland cement in concrete. It will complete a second funding round in the first quarter of 2025.

“This strategic funding from the world’s leading climate funds and industry partners validates our approach to practical cement decarbonisation at commercial scale,” said Bill Yearsley, CEO of Terra. “As we break ground on our first full-scale plant in Texas, their support enables us to accelerate deployment across North America and establish an early footprint in Europe.”

US: Oakland, California-based cleantech startup Brimstone has received a US Department of Energy grant worth up to US$189m to establish a plant with a capacity of 80,000t/yr of ‘green’ cement and 20,000t/yr of smelter-grade alumina, according to the San Francisco Business Times. The grant will be paid out in instalments and requires matching funds from new investments, loans and other sources.

The US$378m facility, which is still in the site selection phase, will be located near an existing quarry in order to mine calcium silicate rocks.

CEO Cody Finke said “We’re exclusively looking at brownfield sites. The goal is to build our own plant while utilising existing quarries to ensure a sustainable and economically viable operation.”

Brimstone plans to begin pilot operations in 2025 and aims to have the plant fully operational by the end of the decade. The company is currently testing its decarbonised cement with potential customers from its Oakland research and development facility.

US: The US Department of Energy (DOE) has awarded funding for two Leilac projects to conduct preliminary front-end engineering design (pre-FEED) studies, subject to final negotiations.

A project at Roanoke Cement Company in Virginia, led by Titan Group in partnership with Leilac, Amazon and Virginia Tech, received US$1.49m. It aims to capture over 500,000t/yr of CO₂ from cement Scope 1 emissions using Leilac’s technology.

A project at Mississippi Lime Company in St Louis, Missouri, in partnership with Leilac, Industrial Ally and Nuada, received US$1.5m. It seeks to achieve net-zero lime manufacturing by integrating Leilac’s CO₂ capture technology with Nuada’s carbon capture system for combustion emissions.

Calix CEO Phil Hodgson said “We look forward to concluding the grant agreements and developing these exciting projects that have the potential to demonstrate industry-leading solutions to produce both low-carbon cement and lime at commercial scale.”

US: Cemex has obtained US$13m through the Texas Emissions Reduction Plan (TERP) to deploy four lower-emission locomotives and two haul trucks at its cement and aggregate sites in New Braunfels and Katy, both in Texas. TERP provides financial incentives to businesses and governments to reduce emissions from vehicles and equipment. Three of the four locomotives and both trucks began operations in late 2023 and mid-2024 in New Braunfels, respectively, according to Energy Tech news. Cemex reportedly intends to deploy additional equipment in 2025.

A US$2m grant from the Environmental Protection Agency’s (EPA) Diesel Emissions Reduction Act (DERA) will fund two additional locomotives for Cemex’s Florida operations in Jacksonville and Miami in the summer of 2025. Cemex plans to decommission the vehicles that are replaced and expand its low-emission fleet for its operations in Victorville, California.

US: Sublime Systems has completed negotiations with the US Department of Energy for a US$87m grant to build a ‘clean’ cement manufacturing plant in Holyoke, Massachusetts. The company will now commence site engineering, design and permitting. The Holyoke plant will demonstrate full-scale operations of its cement manufacturing process when production begins in 2026. Sublime Systems expects to create 70 - 90 jobs once its new plant is operational.

US: Terra CO₂ has received a US$52.6m federal grant from the US Department of Energy to support the construction of a new plant in Magna, Utah, that will produce up to 240,000t/yr of supplementary cementitious materials using mining waste from the nearby Kennecott copper mine. This method reportedly aims to cut CO₂ emissions by 70% per tonne of traditional cement replaced, according to the company’s CEO Bill Yearsley. The project is expected to create 61 jobs.

France: Holcim has been awarded a new grant from the EU Innovation Fund for its ‘CarboClearTech’ carbon capture, utilisation and storage (CCUS) project in Martres-Tolosane, France. This support marks Holcim's seventh large-scale EU-backed CCUS project. The value of the funding was not disclosed by the company.

One unusual thing about coverage of cement in the media is the way that discussions often centre precisely on its absence – that is, on alternatives to cement. These alternatives boast unique chemistries and performance characteristics, but are all produced without Portland cement clinker. They are generally called ‘alternative cements,’ perhaps because ‘cement-free cement’ does not have such a commercially viable ring to it. This contradictory tendency reached a new high in the past week, with developments in alternative cement across Asia, Europe, the Middle East and North America. Together, they hint at a more diverse future for the ‘cement’ industry than the one we know today.

Asia

In Indonesia, Suvo Strategic Minerals has concluded tests with Makassar State University of a novel nickel-slag-based cement. Huadi Nickel-Alloy Indonesia supplied raw materials, and tests showed a seven-day compressive strength of 37.5MPa. Suvo Strategic Minerals says that a partnership with Huadi Nickel-Alloy Indonesia for commercial production is a likely next step.

Europe

Cement producer Mannok and minerals company Boliden partnered with the South Eastern Applied Materials (SEAM) research centre in Ireland to launch a project to develop supplementary cementitious materials (SCMs) from shale on 7 October 2024. The project will additionally investigate CO₂-curing of cement paste backfill for use in mines. Irish state-owned global commerce agency Enterprise Ireland has contributed €700,000 in funding.

UK-based SCM developer Karbonite expects to launch trial production of its olivine-based SCM with a concrete company in 2025. The start-up launched Karbonite Group Holding BV, with offices in the Netherlands, to facilitate this new phase. Karbonite’s SCM is activated at 750 – 850°C and sequesters CO₂ in the activation process, resulting in over 56% lower CO₂ emissions than ordinary Portland cement (OPC). Managing director Rajeev Sood told Global Cement that talks are already underway for subsequent expansions into the UAE and India.

Back in the UK, contractor John Sisk & Son has received €597,000 from national innovation agency Innovate UK. John Sisk & Son is testing fellow Ireland-based company Ecocem’s <25% clinker cement technology in concrete for use in its on-going construction of the Wembley Park mixed development in London.

At the same time, Innovate UK granted a further €3.23m to other companies for concrete decarbonisation. Recipients included a calcined clay being developed by Cemcor, an SCM being developed from electric arc furnace byproducts by Cocoon, a geopolymer cement technology being developed by EFC Green Concrete Technology UK and an initiative to develop alternative cement from recycled concrete fines at the Materials Processing Institute in Middlesbrough. Also included was the Skanska Costain Strabag joint venture, which is working on the London stretch of the upcoming HS2 railway. The joint venture, along with partners including cement producer Tarmac and construction chemicals company Sika UK, will test low-kaolinite London clay as a raw material with which to produce calcined clay as a cement substitute in concrete structures in HS2’s rail tunnels.

Middle East

Talks are underway between UK-based calcined clay producer Next Generation SCM and City Cement subsidiary Nizak Mining Company over the possible launch of a joint venture in Riyadh, Saudi Arabia. The joint venture would build a 350,000t/yr reduced-CO₂ concrete plant, which would use alternative cement based on Next Generation SCM’s calcined clay.

North America

Texas-based SCM developer Solidia Technologies recently patented its carbonatable calcium silicate-based alternative cement, which sequesters CO₂ as it cures.

Meanwhile, C-Crete Technologies made its first commercial pour of its granite-based cement-free concrete in New York, US. C-Crete Technologies says that the product offers cost and performance parity with conventional cement, with net zero CO₂ emissions. Its raw material is globally more abundant than the limestone used as a raw material for clinker. Other abundantly available feedstocks successfully deployed within C-Crete Technologies’ repertoire include basalt and zeolite.

Across New York State, in Binghamton, KLAW Industries has succeeded in replacing 20% of concrete’s cement content with its powdered glass-based SCM, Pantheon. KLAW Industries has delivered samples to local municipalities and the New York State Department of Transportation. Its success expands the discussion of possible circular cement ingredients from the industrial sphere into post-consumer resources.

In Calgary, Canada, a novel SCM has drawn attention from one of the major cement incumbents: Germany-based Heidelberg Materials. It invested in local construction and demolition materials (CDM)-based SCM developer EnviCore on 9 October 2024. The companies plan to build a pilot plant at an existing Heidelberg Materials CDM recycling centre.

Conclusion

Alternative cement developers are still finding the words to talk about their products. They may be more than ‘supplementary’ up to the point of entirely supplanting 100% of clinker. Product webpages offer ‘hydraulic binder,’ ‘pozzolan’ and even ‘cement.’ As alternative ‘cements’ are developed, they build on the work of pioneers like Joseph Aspdin and Louis Vicat. Start-ups and their backers are now reaching commercial offerings, on a similar-but-different footing to cement itself. None of these novel materials positions itself as the sole, last-minute ‘super sub’ in the construction sector’s confrontation with climate change. Rather, they are a package of solutions which can combine into a net zero-emissions heavy building materials offering, hopefully before 2050.

Related to this is the need for ‘technology neutral’ standards, as championed this week by the Alliance for Low-Carbon Cement and Concrete (ALCCC), along with 23 other European industry associations, civil society organisations and think tanks. The term may sound new, but the concept is critical to the eventual uptake of alternative cements: standards, the ALCCC says, should be purely performance-based. They ought not attempt to define what technology, for example cement clinker, makes a suitable building material. According to the ALCCC, Europe’s building materials standards are not technology neutral, but instead ‘gatekeep’ market access, to the benefit of conventional cement and the exclusion of ‘proven and scalable low-carbon products.’

At the same time, cement itself is changing. Market research from USD Analytics showed an anticipated 5% composite annual growth rate in blended cement sales between 2024 and 2032, more than doubling throughout the period from US$253bn to US$369bn. If you can’t beat it, blend with it!

For a further discussion of alternative cement and binders in Europe, see Global Cement’s interview with ALCCC co-ordinator Joren Verschaeve in the forthcoming November issue of Global Cement Magazine on 17 October 2024.