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New developments in alternative cement
16 October 2024One 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!
Belarusian Cement to build Moscow logistics facility
10 June 2024Russia: Belarusian Cement has concluded a deal with the Moscow regional government to build a logistics facility in the region at Naro-Fominsk. Prime Press News has reported that the facility will cost US$22.5m. It will be equipped with ready-mix concrete, precast concrete and dry mix plants, as well as a rail terminal, storage areas and loading zones for despatches by road.
Director General Alexander Dovgalo said "This investment will not only bolster our logistics capabilities but also enhance our service quality for Russian partners and extend our market reach within Russia and the CIS member states."
Cem’in’log expands operations at Sète
06 June 2024France: Cem’in’log has surpassed 1Mt of clinker processed at the Sète site since its inception over four years ago, encouraging parent company Cem’in’EU to continue investments there. Since 2019, the Port of Sète has served as a key entry point for Cem’in’EU’s clinker imports, mainly from North Africa. The site's storage capacity was expanded to 300,000t/yr in 2023. A new warehouse set to increase capacity to 500,000t/yr will begin construction in summer 2024 with a €5m budget. Cem’in’log will also boost its equipment, expecting to operate six rail services weekly by the end of 2024, supporting future expansion.
General manager Jean-Yves Apard said "We are currently dispatching four to five trains per week from Sète, loaded with 1850t of clinker. By the end of 2024, with a second locomotive provided by Regiorail and handled at the port by Viia, we will increase to six trains per week."
Belarus Cement Group to export cement to Russia
29 May 2024Belarus: Belarus Cement Group (BCG) will export 67,000t of cement to Russia by rail in May 2024, using its own train, which will complete 18 runs. So far, the BCG train has completed 9 runs to the Central Federal District of Russia, delivering 37,000t of cement.
The Ministry of Architecture and Construction of Belarus said "This month, the BCG has launched a fixed-route train of its own hopper wagons to deliver cement to Russia. The first train was dispatched from the Belarusian cement plant (Kostyukovichi, Mogilev Oblast) to Moscow Oblast.”
Swiss cement shipments drop in 2023
18 January 2024Switzerland: Swiss cement shipments dropped by 10% year-on-year to 3.7Mt in 2023, from 4.1Mt in 2022. Shipments declined across all quarters, including by 10% quarter-on-quarter in the third quarter. Cement with a reduced clinker factor grew to account for 96% of shipments from 95%, and rail shipments rose to 38%. Ready-mixed concrete plants received 73% of shipments, and building sites 21%.
The Swiss cement association, Cemsuisse, said that it anticipates continued uncertainties and high import pressures in 2024.
Tarmac digitises its rail logistics with Everysens
15 January 2024UK: CRH subsidiary Tarmac has successfully deployed France-based software developer Everysens’ Transport Visibility & Management System (TVMS) in its total operations processing system (TOPS) for rail transport. The TVMS digitally tracks trains, enabling the customer to measure performance, analyse patterns and ensure smooth anticipation and collaboration between stakeholders. Tarmac expects the upgrade to streamline its delivery monitoring and also allow for proactive decision-making.
Tarmac head of rail Chris Swan said "Everysens' integration with TOPS has significantly supported Tarmac to digitise its rail freight operations. Tracking our freight trains has become a lot easier and more precise through digital solutions. With real-time ETA data, we can optimise routes, manage resources, and provide an even higher level of service to our customers. This integration underscores our commitment to staying ahead in technology and embracing digitisation for more efficient and streamlined operations."
Heidelberg Materials secures funding for Geseke cement plant GeZero carbon capture project
18 December 2023Germany: The European Union Innovation Fund has awarded Heidelberg Materials Euro191m in funding to support its development of a carbon capture and storage (CCS) value chain at Geseke cement plant in North Rhine-Westphalia. The planned project, called GeZero, involves the construction of an oxyfuel kiln, capture system and train transport infrastructure. Having received the funding, Heidelberg Materials and its partners will commence work in January 2024. They will subsequently scale the capture system to 700,000t/yr and build pipelines to transport CO2. Energy provider Wintershall Dea will receive the CO2 at its upcoming coastal hub for processing and storage below the North Sea.
Heidelberg Materials Germany general manager Christian Knell said “Together with our partners, we walk the talk and pave the way for CCS in Germany. GeZero will complement our global project portfolio with a truly unique approach. We are developing a promising novel solution for inland cement sites, with the intention to inspire industry peers and other emission-intensive sectors to follow.”
Global chief custainability officer Nicola Kimm said “The successful grant agreement demonstrates the relevance of GeZero for the decarbonisation of our sector, and the trust that European authorities place in our approach.”
Tanzania Railways Corporation plans US$5.6bn railway line
05 December 2023Tanzania: Tanzania Railways Corporation has announced plans to build a 1000km railway across the south of the country, between Lake Nyasa and the Indian Ocean. Business News Africa has reported that the railway will serve Dangote Cement’s local operations, as well as businesses in other industries. The project will cost US$5.6bn, of which Tanzania Railways Corporation has already secured US$2.2bn in potential private investments.
Planned railway to support Kazakh cement exports to Kyrgyzstan
21 November 2023Kazakhstan/Kyrgyzstan: The government of Kazakhstan’s Jambyl Region says that investors have come forward to support construction of a proposed railway between the region and Kyrgyzstan. Central Asia News has reported that a major cement plant construction project is underway in Jambyl Region. Regional governor Yerbol Karashukeyev said that Kyrgyzstan is undergoing a ‘building boom,’ including in the major market of Bishkek, 20km from the border with Jambyl Region.
Karashukeyev said “In view of the rapid development of the market in Kyrgyzstan and the production of large volumes of construction materials in Kazakhstan, it is worth developing cooperation.”
US: Holcim US will invest US$100m in an expansion to raise its Ste. Genevieve cement plant’s capacity by 15% to 4.6Mt/yr. The expansion will involve the installation of a fifth vertical roller mill (VRM) for cement grinding and a new mineral component addition system, alongside a rail-loadout expansion. The producer says that the expanded plant will have lower net CO2 emissions than before. Construction is set to commence in 2024.
Toufic Tabbara, head of Holcim’s North America region, said “With an emphasis on achieving the highest levels of environmental performance and operational efficiency, Ste. Genevieve has been the leader in US cement manufacturing since it was built in 2009. This investment will ensure we maintain that leadership in supporting the sustainable growth of our nation’s infrastructure and residential construction while accelerating net carbon reduction across the built environment.”