Displaying items by tag: LafargeHolcim US
Growing Portland limestone cement production in the US
16 February 2022Argos USA announced this week that its integrated Roberta plant in Alabama is set to produce 100% Portland limestone cement (PLC) by June 2022. As part of the transition three of its terminals in North Carolina will also switch over at the same time. The company also expects that all of its plants will convert to PLC in 2023. Cement sites including Newberry in Florida, Harleyville in South Carolina and Martinsburg in West Virginia are already producing PLC.
The change by Argos marks the latest example in an ongoing trend of US-based cement companies moving entire plants to PLC production. In September 2021 LafargeHolcim US said that its integrated Midlothian plant in Texas was preparing to convert to full PLC production and that it would be the first plant in the US to do so. It later confirmed that the plant had done so by the end of 2021. In October 2021 GCC said that its Trident Plant in Montana would fully move to PLC in early 2022. Then in November 2021 Titan America said that its Pennsuco cement plant in Florida would make the change possibly by 2023. Moving into 2022 brought the news that LafargeHolcim US’ Ste. Genevieve plant in Missouri and its Alpena plant in Michigan had each transitioned to PLC production. Lehigh Hanson then rounded up the bunch earlier this month, at the start of February 2022, when it announced that a PLC was the primary product now coming out of its Mason City plant in Iowa. It even invited a US Member of Congress to celebrate!
The current expansionist phase of PLC usage in the US dates back to late 2020 when the Portland Cement Association (PCA) launched a dedicated website to promote the use of the blended cement by discussing its applications and benefits. It then released a new environmental product declaration in March 2021 and PLC received a mention in the PCA’s Roadmap to Carbon Neutrality when it was released a year later in October 2021. Lots of work went into PLC prior to 2020 though, both by the PCA and others. The first commercial production of PLC in the US started in 2005 and PLC gained its own blended cement specification in 2012. Notably, the PCA has been tracking the state acceptance of PLC by the Department of Transportation and it grew markedly during the 2010s.
The US is playing catch-up with PLC. In Europe its usage dates back to the 1960s. Cembureau, the European Cement Association, reported usage of around 30% in 2004. More recently in 2020, the VDZ, the German Cement Association, reported a similar figure domestically with the proportion of blended cement shipments including limestone, shale and multiple additives at 31.6%. In the US it is hard to gauge the scale of the current move towards PLC by producers, due to limited publicly available data. A PCA survey reported PLC production of 0.89Mt in 2016. If all the plants mentioned above convert fully to PLC and maintain their rated production capacity that would be something like 14Mt/yr of PLC in 2023 or 11% of the US’s total cement capacity. For comparison, the United States Geological Survey (USGS) reported total shipments of all blended cements at 3.3Mt in 2020 and a total of 5.4Mt for the first 11 months of 2021. Plus, remember that PLC is just one blended cement among others, like those that use slag or fly ash.
Recent developments show that a large change is coming towards the US cement market in the update of blended cements. It’s been a long time coming but the last six months have seen brisk increases in PLC production at scale. The exact data is not available but one might expect something around triple the current number of production plants making PLC if the US market heads towards European levels. This rough estimate doesn’t take into account existing partial PLC production levels. At the same time the US cement sector should see a fall in its emissions due to PLC’s 10% reduction in CO2 emissions compared to ordinary Portland cement
LafargeHolcim US’ Ste. Genevieve and Alpena cement plants complete transition to Portland limestone cement production
13 January 2022US: LafargeHolcim US has announced the successful transition of two further plants to Portland limestone cement production. The company’s 4.5Mt/yr Ste. Genevieve, Missouri, cement plant and 2.4Mt/yr Alpena, Michigan, plant have begun exclusively producing its OneCem reduced-CO2 Portland limestone cement (PLC).
LafargeHolcim US’ manufacturing North vice president Michael Nixon said "LafargeHolcim is fully engaged in making carbon reduction an urgent priority and 100% dedicated to leading the market transformation needed for climate stability." He added "To achieve net-zero commitments by midcentury, we must start now in accelerating the adoption of low-carbon building solutions to mitigate the impacts of climate change."
LafargeHolcim US successfully transitioned its Midlothian, Texas, cement plant to PLC production in 2021.
LafargeHolcim US completes Marshall Concrete Products acquisition
14 December 2021US: LafargeHolcim has acquired Marshall Concrete Products. The newly acquired subsidiary supplies concrete products and services in the Minneapolis/St Paul metropolitan area in Minnesota.
Chief executive officer Jan Jenisch said “This acquisition is another step in our Strategy 2025 to become the global leader in innovative and sustainable building solutions. We welcome the employees of Marshall Concrete Products and look forward to building on their strong customer service focus, which made them a partner of choice in the Twin Cities area for decades. This acquisition strengthens our presence in this strong growth market while contributing to Holcim’s overall strategy to expand our range of low-carbon products and solutions.”
LafargeHolcim US launches TerCem blended cement
02 December 2021US: LafargeHolcim US has announced the launch of TerCem, a blended cement which offers 65% reduced CO2 emissions compared to ordinary Portland cement (OPC), according to the company. LafargeHolcim US will produce TerCem at its Whitehall, Pennsylvania, cement plant. The product joins its ECOPlanet low-carbon cement range.
Senior vice president sales Patrick Cleary said "We are leading a market transformation and taking a step towards a net-zero future. Our cement organisation has invested heavily in broadening the industry's range of superior sustainable products designed to lower our carbon footprint with no compromise in quality and long-term durability."
LafargeHolcim US and Geocycle receive first delivery of coal ash under 6Mt recycling contract with CenterPoint Energy
17 November 2021US: LafargeHolcimUS and its subsidiary Geocycle have successfully completed a barge shipment of 2000t of reclaimed bottom ash and fly ash from a pond at CenterPoint Energy’s AB Brown coal-fired power plant at Evansville in Indiana. The delivery is the first under a new 6Mt multi-year coal ash recycling contract with the energy provider.
LafargeHolcim US will use the coal ash to replace clay and sand in cement production at its Ste. Genevieve cement plant in Missouri. The producer says that this will help to reduce the plant's consumption of raw materials. LafargeHolcim US and Geocycle have invested US$80m in infrastructure to extract, process, transport, store and recycle ash from the power plant. Geocycle has managed the on-going joint recycling initiative between LafargeHolcim and CenterPoint Energy since 2009.
LafargeHolcim US's chief executive officer Toufic Tabbara said “This milestone is a tangible example of how industry participants together can develop creative and efficient solutions that contribute to the circular economy. Together, LafargeHolcim, Geocycle and CenterPoint Energy will avoid landfilling for power plants and reduce the consumption of non-renewable raw materials. This is a clear win-win for people and our planet.”
LafargeHolcim US reveals more detail on carbon capture study at Ste. Genevieve cement plant
03 November 2021US: LafargeHolcim US has revealed more information about a commercial-scale carbon-capture study based at its integrated Ste. Genevieve cement plant in Missouri. The project aims to deliver a front-end engineering design (FEED) study for a carbon capture retrofit that can separate up to 95% of CO2 emissions at the plant. The captured CO2 will be ‘pipeline ready’ for geological storage and analysis of the project socio-economic impact will also be part of the study. The US Department of Energy’s National Energy Technology Laboratory awarded US$4m to the Prairie Research Institute at the University of Illinois to work on the project in early October 2021. LafargeHolcim and Air Liquide are also making cost share contributions.
The design will use Air Liquide’s Crycocap FG system at the cement plant. LafargeHolcim US says that it combines pressure swing adsorption capabilities with cryogenic refrigeration technologies to achieve high CO2 capture rates with high CO2 purity rates. Notably, for a carbon capture project, the Ste. Genevieve plant has one of the largest single clinker kilns in the world.
LafargeHolcim US collaborates with ECOncrete Tech on offshore wind turbine foundation scour protection unit development
15 October 2021US: LafargeHolcim US and ECOncrete Tech have launched a research and development collaboration to design and manufacture a fully structural concrete scour protection unit for offshore wind turbines. The unit’s specifications include seabed stabilisation and promotion of the growth of marine organisms. The collaboration includes a large-scale pilot project to evaluate the ecological performance of units in an offshore environment. The US/Canada Binational Industrial Research and Development (BIRD) Energy programme are funding the project, which will conclude in May 2024.
LafargeHolcim US commercial excellence vice president Josep Maset said “There are many paths to achieving our net zero commitment, and most require innovative partnerships and out-of-the-box thinking. The work we’re doing with ECOncrete Tech is a notable example of searching for solutions that enable increased use of renewable energy in an environmentally responsible way.”
LafargeHolcim US to convert Midlothian plant to Portland Limestone Cement production
15 September 2021US: LafargeHolcim US says that the integrated 2Mt/yr Midlothian plant in Texas will become the first cement plant in the country to fully convert to Portland Limestone Cement (PLC) production. The unit will switch to producing the company’s OneCem product, a blended cement manufactured with up to 15% of finely ground limestone. The move is intended to help LafargeHolcim US and its customers meet sustainable construction goals and lower carbon emissions.
“This is an important, but not unique, step for us. We were the first to produce OneCem, a PLC product, in one of the fastest-growing metro areas in the country, and fuel our industry’s step towards a zero carbon future,” said Patrick Cleary, senior vice president of sales, LafargeHolcim US Cement.
The company is promoting OneCem as an alternative to Ordinary Portland Cement in terms of concrete workability, set time, durability and strength development. It can be incorporated into a broad spectrum of applications that will support foundational structures. The product is available in the Western and Southern regions of the US and the company plans to ‘rapidly’ expand production.
LafargeHolcim US launches CementDirect
26 August 2021US: LafargeHolcim US, part of Switzerland-based Holcim, has launched its CementDirect ready-mix concrete delivery mobile and web application (app) on the US market. The app consolidates ordering, tracking and shipping records for customers. Plant operators will be able to sign-off on deliveries and access bills of lading remotely.
Supply chain senior vice president Kristin Beck said “More than ever, ready-mix producers are operating under significant constraints. CementDirect allows for easier access to delivery information and removes the daily burden of managing and storing paper.”
US: LafargeHolcim subsidiary LafargeHolcim US has adopted Environmental Product Declarations (EPD) to designate products’ Global Warming Potential (GWP) for easy consumer use, with third-party verification from ASTM International or the National Ready Mixed Concrete Association (NRMCA). Aggregates and construction materials chief executive officer (CEO) Jay Moreau said, “The growth in sustainable construction is driving demand for low-carbon building products that can transparently demonstrate a decrease in our environmental footprint. These new EPDs also push us to continue innovating as we consider the next generation of building materials.”