Displaying items by tag: Trial

UK: Breedon Group, together with Australia-based First Graphene, Morgan Sindall Construction & Infrastructure and the University of Manchester, is developing a new reduced-CO₂ graphene-enhanced cement. The consortium is currently formulating the cement using varying doses of First Graphene’s PureGRAPH graphene-enhanced grinding aid. The project received a research grant from the UK government earlier in 2022. First Graphene says that the study involves one of the largest commercial trials of its kind to date globally. It is simultaneously collaborating on another similar trial with a Europe-based speciality chemicals producer.

On 29 September 2022, First Graphene launched its latest range of graphene-enhanced cement grinding aids and concrete additives. These join recent launches PureGRAPH AM, an admixture developed in collaboration with South Africa-based Nanoproof/Glade Chemicals, and HexMortar, a dry mortar mix which will be distributed by New Zealand-based GtM Action.

First Graphene says that its cement and concrete segment’s order pipeline totals US$113m in value. Managing director and chief executive officer Michael Bell said “It is pleasing to see our efforts, and those of our collaboration partners, coming to fruition at a commercial scale. One of the primary drivers for the adoption of graphene solutions in this segment is the reduction of CO₂ emissions. We’re seeing considerable benefits both in the immediate reductions that can be achieved through the use of graphene-enhanced grinding aids, as well as the potential reductions in concrete usage because of the enhanced physical properties these products provide.” Bell concluded “Working with industry-focused partners such as Nanoproof/Glade Chemicals, GtM Action, Breedon Cement and Fosroc opens the way to an estimated addressable market of more than 12,000t of PureGRAPH across the medium to long term.”

US: Lehigh Hanson has secured US$3.7m-worth of funding from the US department of energy for its planned front-end engineering design (FEED) installation of a carbon capture system at its Mitchell cement plant in Indiana. The funding was part of a total US$31m pot awarded to 10 different carbon capture projects across multiple industries. All of the projects have the capacity to capture over 95% of emissions from their respective plants.

Mitsubishi Heavy Industries America is supplying its carbon capture system for use at the Mitchell cement plant, at a total project cost of US$4.8m.

Australia: Adbri is part of a consortium of eight Australian industrial manufacturers, developers and port operators collaborating with AGL Energy on a feasibility study for a green hydrogen plant at the site of the latter’s Torrens Island power plant in South Australia. AFR Online News has reported that any future hydrogen plant established by the partners would rely on solar and wind power, which has large potential in the region.

The South Australian government previously launched its first US$414m green hydrogen project in Whyalla in March 2022.

Germany: ThyssenKrupp Industrial Solutions’ Polysius division says that it has been commissioned by Buzzi Unicem, HeidelbergCement, Schwenk Zement and Vicat to build a pure oxyfuel kiln system at the Mergelstetten cement plant as part of the Cement Innovation for Climate (CI4C) project. No dates of the start of construction or final project commissioning of the industrial trial have been disclosed. CI4C was originally formed in 2019.

The Polysius pure oxyfuel process is a new type of clinker production process in which the otherwise normal ambient air is replaced by pure oxygen in the kiln combustion process. One advantage of the technology is that atmospheric nitrogen is eliminated from the clinker burning process leading to much higher concentrations of CO₂ in the exhaust gas compared to a conventional kiln. As such the process aims to concentrate, capture and reuse almost 100% of the CO₂ produced in a cost-effective manner. The medium-term goal is to further process the captured CO₂ with the help of renewable energy into products such as kerosene for air traffic.

UK: Hanson plans to install a C-Capture solvent-based carbon capture system at its Ketton cement plant in Rutland. The producer says that the technology reduces energy requirements per tonne of CO₂ by 40% compared to other capture systems.

Chief executive officer Simon Wills said “Carbon capture is a critical part of our strategy to decarbonise cement production, and essential if we are to reach net zero carbon by 2050. If successful, the C-Capture process has the potential to be rolled-out across other sites across the HeidelbergCement Group.”

Mexico: Cemex has reported its successful completion of laboratory tests aimed at converting CO₂ emitted by cement kilns into carbon nanomaterials. The producer said that it was able to turn 50% of available carbon in a flue gas stream into nanomaterials. Possible industrial uses for carbon nanomaterials include in building materials, biomedicines, electronics and agriculture. Cemex says that its next step will be to scale the technology for a cement plant pilot study.

CEO Fernando Gonzalez said “This breakthrough technology is significant for Cemex, not only because it offers the potential to commercialise carbon emissions, but because it demonstrates the value of our Smart Innovation platform. The path to carbon neutrality will be built with innovation, and we remain committed to being at the forefront in developing new circular technologies and processes.”

France: Vicat plans to use a kiln at its 1Mt/yr Xeuilley, Meurthe-et-Moselle, cement plant for trials of cement production using new alternative raw materials developed under the international CO₂Redres supplementary cementitious materials (SCM) project. The project brings together Vicat, HeidelbergCement subsidiary CBR, Buzzi Unicem subsidiary Cimalux and CRH subsidiary Eqiom in an effort to map mineral resources, waste deposits and usable residues ‘on a cross-border scale.’ On the basis of this research, the partners will seek to develop new SCMs for use in cement production.

India: Shree Cement has fired up the kiln of a new clinker line at its Raipur cement plant in Baloda Bazar, Chhattisgarh. The Business Standard newspaper has reported that the company funded the project, involving the reactivation of the Raipur plant’s Kiln 3, from its internal accruals. It has also installed a new waste heat recovery (WHR) plant alongside the kiln. The line will augment Shree Cement’s supply of clinker to its grinding plants in Eastern India. It hopes thereby to contribute to growth and development in Chhattisgarh and beyond.

Germany: Rohrdorfer and Austria-based Andritz Group are in the process of installing a 2t/day CO₂ separation plant on the roof of the former’s Rohrdorf cement plant in Bavaria. The pilot plant will capture CO₂ from the plant’s emissions for use by the regional chemicals industry. The Ingenieur newspaper has reported that it will cost Euro3m and is scheduled for commissioning before June 2022. It is the first installation of its kind at a German cement plant.

Rohrdorfer’s plant and process engineering manager Helmut Leibinger said “We must begin to see CO₂ as a product of value rather than a problem. With CO₂ as a carbon source, Germany can protect the climate and at the same time become less dependent on oil and natural gas. In addition, value creation and jobs will remain in the country.”

Spain: Cemex’s Mósteles clinker pilot batch production unit at IMDEA Energy Institute in Madrid Autonomous Community has produced its first batch of solar-heated clinker. The unit uses Switzerland-based Synhelion solar radiation technology. The technology uses a solar receiver and gaseous heat transfer fluid to heat raw materials.

Cemex chief executive officer Fernando Gonzalez said “The production of the first solar clinker is an exciting milestone for this transformational technology. It is proof of our commitment to deliver tangible outcomes through innovation to achieve our goal of delivering only net-zero CO₂ concrete by 2050.” He concluded “Cemex is building a better future, and that future must be sustainable.”