Displaying items by tag: UK

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

UK: Cemex UK has announced a partnership with The Pallet LOOP to roll out reusable pallets for its Rugby Cement products from October 2025. The company said that it is the first cement manufacturer to adopt the LOOP system. The initiative forms part of Cemex’s ‘Future in Action’ strategy to reach carbon neutrality by 2050. Initially, the LOOP pallets will be used for the core Rugby packed range, including Premium Cement (paper and plastic bags), High Strength and Sulphate, with expansion across the portfolio planned for later phases.

Vicki Elliott, national sales manager for bagged cement at Cemex UK, said “This is a significant step forward for the cement industry. We’ve supported The Pallet LOOP from day one, signing its charter back in 2022. Now, we’re proud to be the first in our sector to integrate this solution into our supply chain. It’s about doing the right thing, as simply as possible: reducing waste, cutting carbon and helping our customers make more sustainable choices.”

The Pallet LOOP addresses the construction sector’s reliance on single-use pallets, of which fewer than 10% are reused, generating over 250,000t/yr of wood waste, according to the company. The Pallet LOOP’s FSC-certified pallets are built for multiple trips and backed by a nationwide collection service that offers financial incentives for returns.

Ireland/UK: Mannok has completed Phase 1 of a two-phase upgrade to its pyroprocessing system with the installation of a new satellite burner in collaboration with FLSmidth. The €2.5m project enables the use of solid recovered fuel (SRF) as a replacement for coal, achieving up to 30% substitution and reducing CO₂ emissions by 23,000t/yr.

Phase 2 will involve upgrading the main burner to a Jetflex system, targeting 65–70% coal substitution across the kiln. Mannok produces about 1.4Mt/yr of cement for customers across the UK and Ireland.

UK: Cement production dropped to 7.3Mt in 2024, the lowest level since 1950 and around 50% of 1990 volumes, according to the Mineral Products Association (MPA). Imports have nearly tripled over the past 20 years, rising from 12% of sales in 2008 to 32% in 2024, leaving supply chains more dependent on volatile international markets.

Diana Casey, executive director for cement and lime at the MPA, said “We’re calling on the government to help put domestic production on a level playing field so that it can compete fairly with imports. The UK has a choice: to build these vital development projects with UK-made cement, or to build them with imports – sending jobs, investment and economic growth overseas.”

The MPA said that high energy, regulatory and labour costs are threatening competitiveness and jobs, with 40% of cement produced in the Peak District and 60% across the rest of the UK. The group said the carbon border adjustment mechanism (CBAM) due in 2027 must be paired with a procurement policy that prioritises domestic cement.

UK: Heidelberg Materials UK and Turners have entered into a 50/50 joint venture for bulk cement haulage, with the haulier distributing the producer’s bulk cement from autumn 2025. Heidelberg Materials UK will transfer its bulk cement distribution business and employees into the JV, which will have a board with representatives from both companies.

Heidelberg Materials UK CEO Simon Willis said “Heidelberg Materials is constantly looking into ways to optimise its operational model and deliver the best value for customers. As a result, we have decided to create a joint venture arrangement with Turners for the distribution of our bulk cement. Our aim is to enhance the distribution of our bulk cement and upgrade our fleet and operations. Partnering with Turners, which we already have a strong working relationship with, will enable us to be more efficient by leveraging its broad logistics experience, systems and network.”

The JV is expected to take effect no sooner than 26 October 2025. Heidelberg Materials UK operates more than 300 sites across aggregates, concrete, asphalt and contracting, cement and recycling, employing over 4000 staff.

UK/Norway: UK-based marine carbon capture firm Seabound has launched an onboard carbon capture project in partnership with Hartmann Group, InterMaritime Group and Heidelberg Materials Northern Europe. The solution equips the UBC Cork, a 5700 gross tonne cement carrier, with Seabound’s calcium looping carbon capture system. This system captures up to 95% of CO₂ and 98% of sulphur emissions from the ship’s exhaust using calcium hydroxide to absorb the CO₂ and convert it into limestone that is stored onboard until returning to port. The captured carbon will be offloaded at the Port of Brevik for use at Heidelberg Materials’ Brevik cement plant, host of the first industrial-scale carbon capture facility in the cement sector.

The project is co-funded by the Eurostars partnership on Innovative SMEs, part of Horizon Europe through the Cyprus Research and Innovation Foundation. This funding supports collaborative research and development projects in a range of industries, including maritime transport.

CEO of Seabound Alisha Fredriksson said “We’re proud to partner with industry leaders like Heidelberg Materials and Hartmann to deliver scalable carbon capture solutions. We’re especially excited to be advancing this work in Brevik, a strategic location that’s rapidly establishing itself as a global hub for CCS with Heidelberg’s world-first facility and the Northern Lights pick up point. Together, we’re demonstrating how onboard carbon capture can accelerate emissions reductions in carbon-intensive sectors.”

Lars Erik Marcussen, Logistics project manager at Heidelberg Materials Northern Europe, said “Shipping cement is emissions-intensive, and Seabound’s system gives us a clear path to reduce those Scope 3 emissions while enhancing our circular use of captured CO₂. This project also brings us one step closer to decarbonising the logistics/transport part of our operations.”

UK: Material Evolution has partnered with CRH subsidiary Tarmac to launch a pilot project to test applications of its heat-free, 85% reduced-CO₂ cement, MevoCem. The partners aim to demonstrate the suitability of MevoCem cement for use in concrete production in line with the prospective BSI Flex 350 performance-based standard.

Material Evolution’s CEO Liz Gilligan welcomed Tarmac as an ‘early adopter’ of MevoCem cement. In a post to LinkedIn, she said “We have been quietly building something game-changing with CRH and their team at Tarmac. It is bold, it is industrial scale and it is all about cutting carbon where it counts. We are only just getting started.”

Material Evolution currently operates a 120,000t/yr Mevocem plant in Wrexham, Wales.

Titan Group announced this week that it will build a processing and beneficiating unit for fly ash at Warrington in the UK. The move marks both a trend in fly ash projects in the UK recently and Titan’s own focus in the country.

Titan has struck a deal to use ponded fly ash at the former Fiddler’s Ferry power station in the North-West of England. It aims to process 300,000t/yr of wet fly ash from 2027 onwards with the option to double this capacity if desired. The processed fly ash will meet the BS EN 450 standard for subsequent use in cement or concrete. Crucially, Titan intends to use the technology of its subsidiary, ST Equipment & Technology (STET). This company has a proprietary dry electrostatic process that it uses for fly ash beneficiation. Titan acquired STET in 2002. It says its process is being used at 12 power stations in the US, Canada, the UK, Poland, and South Korea. The project at Fiddler’s Ferry will be the 20th fly ash project developed with STET technology.

Titan has not commented on the specifics of its arrangement with site-owner PEEL Group other than to describe it as a ‘long-term agreement.’ It currently operates a terminal in Hull, on the other side of the country, 160km from Warrington. As for Fiddler’s Ferry, the coal-fired power plant closed in 2020. Prior to this though RockTron Group built a 800,000t/yr unit at Fiddler’s Ferry to process both ‘fresh’ and stockpiled fly ash in the late 2000s. Unfortunately the company entered administration in 2013. Later, Power Minerals was reportedly selling fly ash from the plant at the time that its closure was announced in 2019. A report commissioned by consultants Arcadis for the local council reported that ash including pulverised fuel ash (PFA) was present in the lagoons at the site.

Other companies have also been looking at the fly ash market in the UK. Invicta, a joint venture between Türkiye-based Medcem and Brett Group opened a terminal at Sheerness in Kent in 2024 to import PFA and cement. In April 2025 a ship unloader supplied by Van Aalst was delivered to the port. Then in May 2025 it was announced that Mecem is planning to build a terminal in Liverpool to import cement and supplementary cementitious materials (SCM), such as fly ash and granulated blast furnace slag. The terminal will have a combined storage capacity of 45,000t in four silos in its initial phase and is scheduled for completion in mid-2026. Meanwhile, the Drax power station said in March 2025 that it had signed a 20-year joint venture agreement with Power Minerals to process legacy PFA. A unit at the now biomass power plant in Yorkshire is scheduled to start by the end of 2026 with an initial production capacity of 400,000t/yr.

The background to this interest in fly ash in the UK appears to be a local cement sector struggling with high energy costs and low capacity-utilisation rates. Reports in local media in late June 2025 cited preliminary estimates that cement output may have reached an ‘all-time low’ in 2024. High electricity prices were blamed for the situation by the Mineral Products Association (MPA) and it warned of mounting imports from the EU and North Africa. All of this was timed to coincide with a release of a new Industrial Strategy by the UK government. For more on the UK cement sector in general see Global Cement Weekly in May 2025 and Edwin Trout’s feature in the June 2025 issue of Global Cement Magazine.

Readers will be aware of the growing attractiveness of SCMs for cement and concrete production for both cutting costs and meeting sustainability goals. A report by McKinsey on SCMs for the cement sector in late 2024 forecast that SCMs and fillers in Europe could represent an emerging value pool that could reach €8 – 10bn in 2035 as the price of cement steadily rises. The SCMs being used are likely to change as sources of industrial SCMs such as slag and ash dwindle and others such as clays, pozzolans or limestone become more available. The UK may have closed its last coal-powered power plant in 2024 but ash from ponds can still be reclaimed or ash can be imported if the economics makes sense. Recent investments by Titan, Medcem and Power Minerals suggest that the price is indeed right. The interest of two major cement exporting companies amongst the three names above also indicates changing market dynamics. Expect more of these kinds of deals and investments in the UK, Europe and elsewhere in coming years.

UK: Titan Group will build and operate a processing and beneficiating facility for ponded fly ash at the former Fiddler’s Ferry power station in Warrington, following a long-term agreement with site owner Peel NRE. The plant will process 300,000t/yr of wet fly ash from 2027, with scope to double the capacity at a later date. Titan will use the material in low-carbon cement, while Peel NRE will receive help to advance restoration of the site. The ash will reportedly meet BS EN 450 quality standards.

Peel NRE director Kieran Tames said “We are very pleased to have reached this agreement with Titan, which follows years of hard work fully evaluating the potential to transform the waste ash material from the power station directly into a low-carbon construction product. This agreement has the potential to accelerate the recovery of waste ash from the lagoons, enabling their restoration and enhancement as envisaged by the development framework that was approved by the local authority last year. Through our partnership, existing customers will continue to source ash from the site, ensuring continuity of supply for their applications.”

UK: Holcim UK has welcomed a €33.1m investment by the National Wealth Fund into the Peak Cluster carbon capture and storage (CCS) project, which will decarbonise 40% of the UK’s cement and lime production and support over 2000 existing jobs, as well as creating new ones. Led by Progressive Energy, Peak Cluster is a partnership between Holcim UK, Breedon, Tarmac and Sigma Roc involving cement and lime plants in Derbyshire and Staffordshire, including Holcim UK’s 1Mt/yr Cauldon plant. The project aims to reduce annual carbon emissions from its partners by 3Mt/yr from 2032 (25% of annual CO₂ output for the area), by capturing CO₂ from the plants and transporting it by pipeline to Morecambe Net Zero's disused gas fields under the East Irish Sea.

The investment will fund front-end engineering and design (FEED) and other studies to support a final investment decision in 2028. Holcim UK CEO Lee Sleight said that CCS is ‘essential’ to decarbonise cement manufacturing and achieve net zero by 2050.

Peak Cluster CEO John Egan said it will create a ‘backbone of industrial opportunity’ across northern England.