Displaying items by tag: Trial

US: Ash Grove Cement and the Nebraska Department of Transportation have tested a  calcined clay blended cement product on a 4km stretch of road in the state. The product, Duracem N, was manufactured at the company’s Louisville Plant. It uses clay sourced locally in the region. The Louisville Plant was reportedly upgraded recently to convert a clinker kiln into a clay calciner. Improvements were also made to the milling process.

Full-scale production of Duracem N will begin early in 2026, with customer deliveries expected in mid-2026. The product has been approved for use by the Nebraska Department of Transportation, with further approvals forthcoming.

UK: First Graphene has announced the successful large-scale production of around 600t of graphene-enhanced cement at Breedon’s Hope Cement Works in Derbyshire ahead of new trial projects rolling out across the UK. The batch contains 3t of First Graphene’s PureGRAPH-CEM® additive, and was produced in a single day. The product is now in storage ahead of despatch for use in three concrete projects across the UK. The University of Manchester will conduct compressive strength testing and analysis of the concrete’s performance.  The additive is introduced during the final milling stage, and is designed to reduce CO₂ emissions by up to 16% by lowering the clinker content in the cement.

The first trial involves using 30-40t of the graphene-enhanced cement to produce thousands of roof tiles at FP McCann’s Cadeby plant in Leicestershire. The five-month study is part of an Innovate UK-funded initiative aiming to improve resource efficiency and reduce construction waste in response to the UK government’s housing targets. First Graphene has also reportedly received further interest from organisations in both the UK and Australia for testing the material in various applications.

First Graphene CEO Michael Bell said “Adding graphene into cement has proven to deliver performance benefits for a wide range of applications, and multiple end uses of this cement batch reinforces PureGRAPH®'s versatility. We look forward to working closely with our strategic commercial partner Breedon, Morgan Sindall, FP McCann and the University of Manchester as application trials roll out over the coming months."

France/Syria: The former Lafarge CEO Bruno Lafont has taken the witness stand at the start of a hearing that will focus on the alleged financing of the Islamic State in Syria in the early 2010s. Lafont took the stand on 19 November 2025 to face questions from the 16th Criminal Chamber of the Paris Judicial Court, according to the Libération newspaper. He is on trial, along with several former senior executives, for financing terrorism in Syria.

At the heart of the trial is the continued operation of the former French multinational’s assets within Syria, a country embroiled in civil war between 2011 and 2014. Lafarge has since been absorbed into Switzerland’s Holcim.

Bruno Lafont joined Lafarge in 1983 and served as its CEO from 2007 to 2015. He maintains that, on a multinational scale, the Syrian plant, located in the city of Jalabiya, north of Raqqa, was not one of the group's most strategic assets. Lafarge nevertheless aimed to supply 30% of the country's cement needs and employ 1000 people, which Lafont conceded was a ‘significant investment.’ The plant only opened shortly before the onset of hostilities.

Explaining the decision to keep the plant running, Lafont asserted that Lafarge keeping the plant open was “a form of commitment to the local communities.” Lafont said that he and his subordinates were bound by a ‘moral obligation,’ stating “These assets were ours, but they also belong to the country, to the region.”

Questioned by the presiding judge, Isabelle Prévost-Desprez, and pressed further by representatives of the National Anti-Terrorist Prosecutor's Office, Aurélie Valente and Olga Martin-Belliard, the former CEO mostly claimed he hadn't been informed about the situation at the Syrian factory. Prosecutors pointed out that Lafarge had received numerous warnings before the plant was invaded by Islamic State on 19 September 2014. They also pointed out the embassy closures, the mass departure of international companies and the removal of country directors from Syria, asking why these events did not attract the ‘curiosity’ of Lafarge’s CEO. In reply Lafont stated "Before Syria, we had experienced several Arab Springs… and they all stopped.” He also drew parallels to the situation in Egypt, which he described as ‘practically an insurrection.’

In a separate case in the US, Lafarge admitted in 2022 that its Syrian subsidiary paid US$6m to Islamic State and the Nusra Front to allow employees, customers and suppliers to pass through checkpoints after the civil conflict broke out in Syria. The group paid US$778m in forfeiture and fines as part of its plea agreement. Lafarge faces much lower fines in France if it is found guilty, but eight of the 10 individuals on trial face up to 10 years in prison if found guilty.

The trial in Paris continues.

France: The Lafarge group and several former senior officials will stand trial in Paris from 4 November 2025, accused of historically financing terrorist organisations, including Islamic State (IS). The aim of the alleged payments was to maintain operations at a cement plant in Jalabiya, northern Syria. The defendants include former CEO Bruno Lafont, five former managers and two Syrian intermediaries. They face charges of financing a terrorist enterprise and, for some, breaching international financial sanctions.

Lafarge Cement Syria (LCS), the group’s Syrian subsidiary, is suspected of paying several million Euros between 2013 and 2014 to jihadi groups IS and Jabhat al-Nusra to secure raw materials and allow the movement of employees and goods. The €680m Jalabiya plant, completed in 2010, continued operating until IS took control in September 2014, two years after most other multinationals had left Syria.

An internal investigation in 2017 found ‘violations of Lafarge’s business code of conduct.’ Lafarge, which merged with Holcim in 2015, has said the events predated the merger.  In October 2022, Lafarge pleaded guilty in the US to paying IS and Jabhat al-Nusra nearly US$6m and agreed to pay a US$778m penalty.

Former CEO Lafont has denied knowledge of the payments. His lawyers argue that the US plea “is a blatant attack on the presumption of innocence” and aimed to “preserve the economic interests of a large group.”

So far, 241 civil parties have joined the case. “More than ten years after the events, the former Syrian employees will finally be able to testify about what they endured: the checkpoint crossings, the kidnappings and the constant threat hanging over their lives,” said Sherpa legal officer Anna Kiefer. Lafarge faces a fine of up to €1.125m for financing terrorism, while penalties for violating the embargo could reach ten times the value of the offence. A separate investigation into alleged complicity in crimes against humanity in Syria and Iraq remains ongoing.

There have been a few burner and related stories to note in the cement industry news this week. Firstly, Canada-based PyroGenesis announced that it had signed a deal with an unnamed-European cement company to supply a plasma torch system for a ‘calcination furnace.’ Around the same time UBE Mitsubishi Cement (MUCC) revealed that it had successfully tested natural gas co-firing at MUCC’s Kyushu Plant using a newly developed burner.

The PyroGenesis project is a potential game-changer for the sector because it alters the way cement production lines are heated. Roughly one third of CO₂ emissions associated with cement manufacture arise from the fossil fuels used to heat the kiln and the pre-calcination system. Cut out some of that and the specific CO₂ emissions of cement production drop. PyroGenesis’ approach uses electricity to generate high-temperature plasma. This then gives the cement plant the option of obtaining its electricity from renewable sources. PyroGenesis signed a memorandum of understanding with the power conversion division of GE Vernova in March 2025. This had the aim of targeting high temperature processes, such as cement production, with electric plasma torches. The current deal with a cement producer has been valued at US$871,000 with delivery to the client scheduled for the first quarter of 2026.

We don’t know who the mystery client might be. However, Heidelberg Materials reportedly operated a 300kW plasma-heated cement kiln at its Slite cement plant in February 2025 as part of the ELECTRA project. The producer said it had achieved 54 hours of continuous operation, with 60% CO₂ concentration in the flue gas. The aim was to reach 99%. It then said that it was planning to build a larger 1MWel furnace at its Skövde cement plant in 2026 with tests to continue in 2027. In an interview with Global Cement Magazine in May 2025, Heidelberg Materials said that it was using commercially supplied CO₂ as the ionising gas in the plasma generator but that it was considering using captured CO₂ from the production process in the future. It also mentioned issues from its trials such as the effective ‘flame’ being hotter than the conventional process but not as long. This increased the reactivity of the resulting clinker. Finally, Heidelberg Materials noted from a feasibility study that a 1Mt/yr cement plant would need around 170MW of plasma generation, but that typical plasma generators topped out at around 8MW. Hence, any full set-up would likely require multiple plasma generators. For more on non-combustion style kilns see GCW561.

UBE Mitsubishi Cement’s burner installation is more conventional but again it is concerned about sustainability. In this case the line has tested burning natural gas. The cement producer says it is the first such installation at a cement plant in Japan to do so commercially. The burner was jointly developed by UBE Mitsubishi Cement, Osaka Gas and Daigas Energy. Firstly, the plant will consider switching to natural gas. This will reduce the unit’s CO₂ emissions from fuel combustion. However, a later step being considered is to move on to e-methane. This is a synthetic methane made from CO₂ and hydrogen using renewable energy.

Finally, another recent story on this theme is the installation of a new satellite burner by Northern Ireland-based Mannok at its Derrylin cement plant in August 2025. This is Phase One of a two-part project to upgrade the pyro kiln system at the site. The cement company worked with FLSmidth on the €2.5m upgrade. The new burner has now allowed the plant to burn solid recovered fuel (SRF) by up to a 30% substitution rate in the kiln. This followed a project, also with FLSmidth, to install a FuelFlex Pyrolyzer in 2022. This is used to replace coal with SRF in the pre-calcination stage of cement production. Phase two will be an upgrade of the main burner to a new Jetflex burner. Once this part is completed, Mannok is aiming for an overall substitution rate of 65 - 70% on the whole pyro-processing system.

Burners at cement plants are replaced fairly commonly. However, the supplier companies don’t advertise every installation due to the commercial relationships with their clients and other factors. Hence the more interesting upgrades tend to get the publicity. Typically this means if a burner uses new technology, meets sustainability goals and so on, we find out about it. It’s a similar situation when a new heating technology such as plasma is trialled. Changing trends in fuel types for cement plants suggest different types of conventional burners. Some of this can be seen in the burner stories above with the trend moving towards ever higher rates of alternative fuels usage. Combustion in cement kilns is here to stay for the time being but plasma trials will be watched carefully.

The 18th Global CemFuels Conference & Exhibition on alternative fuels for cement and lime 2025 will take place in Milan on 17 - 18 September 2025

Japan: Mitsubishi UBE Cement Corporation (MUCC), Osaka Gas, Daigas Energy and Saibu Gas have successfully tested natural gas co-firing at MUCC’s Kyushu Plant in the Kurosaki area. Using a newly developed burner, the companies replaced 40% of coal with natural gas at commercial scale without affecting kiln stability, product quality or environmental performance.

The burner was developed using MUCC’s coal combustion expertise alongside Osaka Gas and Daigas Energy’s gas combustion and simulation technologies, with Saibu Gas supplying natural gas from LNG tank trucks. MUCC said the trial paves the way for full-scale implementation and supports future use of e-methane in cement kilns.

MUCC aims to cut CO₂ emissions by 40% by 2030, compared to 2013 levels, and achieve group-wide carbon neutrality by 2050 under its medium-term management strategy “Infinity with Will 2025 – MUCC Sustainable Plan 1st STEP.”

US: Ash Grove Cement, part of CRH, has deployed Boston Dynamics’ autonomous robot ‘Spot’ at its cement plant in Washington in a year-long pilot to boost efficiency and safety. Operating more than 80 hours a week, the four-legged robot conducts routine inspections using a 4K camera and laser scanning, detecting anomalies and alerting teams before failures occur.

The company said that the robot can measure refractory bricks inside cement kilns, reducing risks by keeping employees out of hazardous environments. During the trial, Spot detected a failing bearing in rotating equipment, preventing unplanned downtime. Ash Grove said that the technology improves site safety, frees skilled teams for complex work and enables real-time monitoring in the hot and dusty conditions at the plant.

Plant manager Andy White said “Our aim for Spot is that, at the moment, we don’t have preventative or proactive maintenance routines on night shifts and the weekends. And, also, our labour force has to spend a lot of time recording data rather than analysing it… Spot can do this for us. When we come in the mornings, we already have reported generated, so we can proactively fix those issues thather than spending eight hours trying to find them.”

Saudi Arabia: The National Center for Waste Management (MWAN) completed a five-month trial with Riyadh Cement on the use of iron slag in ordinary Portland cement, according to the Saudi Press Agency. The study used 1274t of slag and showed that adding 1 - 2% improved the cement’s properties. MWAN said that the results confirm the feasibility of using industrial byproducts to cut waste and reduce CO₂ emissions.

China/US: A team led by Fengyin Du, then at Southeast University in Nanjing, developed a new cement formulation that reflects sunlight and emits heat more effectively than ordinary Portland cement, according to the New Scientist. The cement incorporates reflective ettringite crystals on its surface, which Du says “works like a mirror and a radiator, so it can reflect sunlight away and send heat out into the sky, so a building can stay cooler without any air conditioning or electricity.”

To make it, the researchers produce tiny pellets from limestone and gypsum, which are ground and mixed with water before being poured into a silicone mould covered in small holes. Ettringite crystals grow in slight depressions on the surface created by air bubbles, while an aluminium-rich gel allows infrared light to pass through, lowering heat retention.

Du said that tests at Purdue University, Indiana showed the cement’s surface was 5.4°C cooler than the air and 26°C cooler than conventional cement under the same conditions. The process is reportedly scalable and costs US$5/t less than ordinary Portland cement, as it can be produced at lower temperatures.

India: Tamil Nadu will host one of five national carbon capture and utilisation (CCU) testbeds aimed at lowering CO₂ emissions in the cement sector in a step towards the country’s 2070 net-zero target, according to The New Indian Express newspaper. The testbed will be located at UltraTech Cement’s Reddipalayam plant in Ariyalur district, supported by the Indian Institute of Technology Madras and Birla Institute of Technology and Science Pilani. The project is part of a Department of Science and Technology (DST) programme, which will trial an oxygen-enriched kiln system capturing up to 2t/day of CO₂ for mineralisation into concrete products. Other CCU testbeds are being established in Rajasthan, Odisha and Andhra Pradesh, with JK Cement and Dalmia Cement involved.

Union Minister for Science and Technology and Earth Sciences Jitendra Singh said the DST was currently processing financial sanctions for the projects, and full-scale implementation is expected in 2025.