Displaying items by tag: US

US: Researchers at UCLA's Institute for Carbon Management have developed a new method called ZeroCAL that could eliminate ‘nearly all’ of the carbon dioxide emissions from the process of cement production, according to the UCLA Newsroom. The team created a process using limestone and a water-based solution containing ethylenediaminetetraacetic acid. Through membrane nanofiltration and an electrochemical process, they produced calcium hydroxide.

To meet ZeroCAL’s water demand, the team suggests focusing on cement plants near coasts or rivers. The researchers are reportedly working with Ultratech Cement to build a demonstration plant that will produce ‘several’ tonnes of lime per day using the ZeroCAL process. Currently, the process requires more energy than traditional lime production methods, but ongoing research aims to reduce its energy consumption.

Gaurav Sant, director of the Institute and professor at UCLA Samueli School of Engineering, said “The ZeroCAL approach offers an elegant solution to eliminate carbon dioxide emissions associated with the process of cement production. First, it addresses the carbon emissions resulting from limestone’s decomposition while providing clean hydrogen and oxygen to heat the cement kiln. Second, it enables onsite decarbonisation while making use of existing kilns and limestone feedstocks without having to build separate carbon capture and storage facilities.”

US: C-Crete Technologies has poured its granite-based cement-free concrete in its first construction application at the upcoming JPMorgan Chase headquarters at 270 Park Avenue, Manhattan. Ecology, Environment and Conservation News has reported that the concrete generates no net CO₂ emissions by sequestering atmospheric CO₂ in its curing process. The concrete conforms to ASTM International standards, with a compressive strength exceeding 5000psi. Other partners on the project included engineering firm Severud Associates Consulting Engineers and construction management firm AECOM Tishman.

C-Crete Technologies president Rouzbeh Savary said "We are thrilled to introduce our new granite-based concrete at such a prestigious and iconic location. The building at 270 Park Avenue is set to become a landmark not only for its architectural grandeur, but also for its sustainable construction practices."

Severud Associates Consulting Engineers senior associate Fortunato Orlando said "The performance of C-Crete for concrete on metal deck, topping slabs, pavements and landscape work, coupled with its eco-friendly attributes, makes it a revolutionary product for the future of the construction industry."

AECOM Tishman chief operating officer John Kovacs said "Just a few years ago, constructing devoid of Portland cement and CO₂ emissions would have seemed unimaginable. And yet today, we stand as the world's first, setting new thresholds of what's possible in sustainable construction. We thank all of our partners on this project and look forward to the day when CO₂ emission-free construction is not simply an idea or a new innovation, but the industry standard across every build."

US: Colorado-based energy company NovoHydrogen plans to establish a hydrogen production facility at the Ash Grove Cement plant near Durkee, Oregon. Funded by the 2021 federal Bipartisan Infrastructure Act, the plant aims to start producing hydrogen fuel by 2028, according to CEO and founder Matt McMonagle. The hydrogen produced would be stored at the plant to be used to fuel trucks and other vehicles on-site, as well as potentially being used to power the plant. The construction of the plant will reportedly create 50 jobs.

Phillip Teintze, manager at the Durkee plant, said "The Ash Grove Cement Durkee plant is active in many opportunities to decarbonise our industry. Solutions for low carbon cement manufacturing are significantly challenging in terms of processes and expense. The Durkee plant is excited to see the development of NovoHydrogen’s efforts with the Department of Energy’s Pacific Northwest Hydrogen Hub. As hydrogen becomes environmentally and economically viable, we believe our facility could act as a distribution site, and potentially utilise hydrogen as a fuel to displace traditional fossil fuels.”

CRH, formerly Cement Roadstone Holdings, announced this week that CEO Albert Manifold is retiring at the end of 2024. He will be replaced by current chief financial officer Jim Mintern in the role. Manifold will continue to work as an advisor to CRH in 2025. Manifold’s time at the head of CRH marks a decade of considerable change at the group. Crudely, CRH had a market capitalisation of US$19bn at the start of 2014 when Manifold became CEO. At the end of 2023 the group’s market capitalisation was US$50bn.

From a cement sector perspective the big events during Manifold’s tenure include CRH’s acquisition of assets around the world from the Lafarge-Holcim merger in 2015, the purchase of Ash Grove Cement in the US in 2018, the divestment of various businesses in emerging markets and the move of the company’s primary listing to the New York Stock Exchange in 2023. However, at the same time, CRH has been constantly sharpening its portfolio. So, for example, the group bought Germany-based lime and aggregates company Fels in 2017 only to later sell off its European lime business in 2023 and 2024. In the late 2010s the group sold off its US and Europe-based distribution businesses. Then, in 2022, it divested its Building Envelope business. Manifold was also the inaugural president of the Global Cement and Concrete Association (GCCA) when it formed in 2018.

Fairly or unfairly, CRH has given the sense over the last decade of often being ahead of the curve in following the cement markets. After it increased its portfolio when Lafarge and Holcim merged, it sold up relatively quickly in India and Brazil. Famously during an earnings call for CRH’s second quarter results in 2019, Manifold said that the group was prioritising its businesses in the developed world. CRH’s focus on the US in the late 2010s through the acquisition of Ash Grove Cement set it up well for the current strength of the cement market in North America, long before others joined the party. Another striking Manifold statement came at the company’s annual general meeting in 2023 when, in the run-up to the US listing move, he described his company as a ‘de facto’ American company.

Things that may have gone less well for Manifold on the cement side, that we know about, include CRH’s quiet attempt to divest its business in the Philippines in the late 2010s. The company wasn’t alone in trying through. Holcim publicly said that it had signed a deal to sell its local business in 2019 only to declare that it wasn’t happening the following year. Cemex is currently in the process of selling its subsidiary in the country, DMCI Holdings, but it hasn’t concluded yet. More recent acquisitions such as assets from Martin Marietta Materials in Texas in early 2024 and a majority stake in Adbri in Australia are clearly strategic and fit the definition of ‘bolt-on’ but they seem to lack the grand ambition of the earlier big deals.

Questions have also been asked about Manifold’s pay over the years. From 2016 onwards the Institutional Shareholder Services (ISS), for example, has repeatedly raised concerns about executive pay rises at CRH and recommended on occasion that shareholders reject them. Manifold became the highest paid head of an Irish public company and was reportedly the third highest paid CEO on the Financial Times Stock Exchange 100 Index (FTSE 100) in 2022. His response from one interview with the Irish Times newspaper in 2018 was simply: “I’m employed and paid very well to deliver shareholder returns.”

Looking back over the last decade, CRH was well placed to take advantage of the Lafarge-Holcim merger before Manifold started in 2014 but once he was in place it went for it and he led the charge. Yet, the Ash Grove Cement acquisition may prove to be the more momentous move given the current divergence of the European and North American markets. As readers may remember from the time, Summit Materials made a public counter offer but it was rebuffed. Albert Manifold was in charge of CRH and so he takes the credit. These are big shoes to fill. As Richie Boucher, the chair of CRH said in Manifold’s outgoing statement, “Under Albert’s leadership CRH has delivered superior growth and performance with consistently improving profitability, cash generation and returns.”

US: Holcim has invested in Sublime Systems to expand its range of solutions to decarbonise the construction industry. The partnership will advance Sublime’s first commercial manufacturing facility in Massachusetts, US, giving Holcim a large share of Sublime Cement produced there through a binding offtake reservation. Sublime’s first commercial-scale plant is set to start production in 2026 with a capacity of 30,000t/yr.

Chief sustainability officer at Holcim, Nollaig Forrest, said “The Sublime Systems team has developed a unique technology to decarbonise cement, cutting across the entire production process from the use of clean electricity to carbon-free raw materials. We are excited about this technology’s potential and are delighted to be partnering to bring it to market at scale. This investment advances our strategy to decarbonise construction by scaling up the most innovative technologies across our operations.”

CEO and cofounder of Sublime Systems, Leah Ellis, said “In the cement industry, scale is everything. We are proud to collaborate with Holcim, which supports our mission of swift and massive impact. By pairing Sublime’s technology with Holcim’s advanced global operations from manufacturing and logistics to commercial distribution, we can scale up our impact together.”

US: Buzzi Unicem has blamed a late tax payment in Pennsylvania on an accounting error. The cement company made the US$18m payment five months late, in May 2024, according to the Express Times newspaper.  The issue was highlighted by a lien filed in December 2023 in Northampton county civil court. Stockertown cement plant manager Rad Slavov clarified that the payment was timely but misallocated. He said "The company is financially strong and able to meet its obligations.”

US: Ash Grove Cement has acquired Geofortis, which operates a raw natural pozzolan milling and classifying line in Toole, Utah, along with a nearby deposit.

President of Ash Grove Cement Serge Smith posted on LinkedIn "Integrating the Geofortis plant and team into the Ash Grove family aligns perfectly with our long-term growth strategy and commitment to sustainability. These high-quality natural pozzolan products complement our existing portfolio and will enable us to offer more environmentally friendly solutions to our customers. This acquisition reinforces our dedication to developing sustainable solutions that build, connect and improve our world."

One surprise at the end of August 2024 was that Türkiye-based Çimsa has agreed to buy a majority stake in Ireland-based Mannok. The subsidiary of Sabancı Holding signed a deal to acquire just under a 95% stake in Mannok Holdings based on an enterprise value of Euro330m for 100% of the shares. The final purchase price will be determined later in the process, as will a potential completion date subject to the usual regulatory approvals.

Çimsa has described the deal as its “third major global initiative in the past three years” following expansions in the US and Spain. Çimsa started production at its 0.3Mt/yr white cement grinding plant in Houston, Texas in 2019. It is currently planning to set-up a 0.6Mt/yr grey cement grinding plant, also in Houston, with operation expected to start by the end of 2024. Its Spain-based business received a boost in mid-2021 when it purchased the Buñol white cement plant in Valencia from Cemex. Outside of Türkiye the company also operates a few terminals in Germany and Italy. Of interest to this article it established a subsidiary for sales in the UK in mid-2023.

Mannok was previously known as Quinn Group before it was rebranded in 2020. In addition to cement the company sells a range of construction products including PIR (polyisocyanurate) insulation, aircrete thermal blocks, roof tiles and precast concrete. The company is headquartered at Derrylin in Fermanagh, Northern Ireland in the UK but it operates in both Ireland and the UK. It runs a 1.4Mt/yr integrated plant at Ballyconnell, County Cavan in Ireland, just across the border from Derrylin. With the 17th Global CemFuels Conference scheduled to take place next week in Dublin, it is worth noting that this cement plant had a recent upgrade of interest to the alternative fuels sector. In 2023 the company said that it had installed the world’s first FLSmidth Fuelflex Pyrolyzer at a cement plant following an earlier pilot of the system back in 2018. It is used to replace coal with solid recovered fuels (SRF) in the pre-calcination stage of cement production. Later in 2023 Mannok said that the equipment was reducing its CO₂ emissions by 58,000t/yr.

As reported in the October 2023 issue of Global Cement Magazine, cement from the Ballyconnell plant is sold in both Ireland and the UK. In 2022, 35% of its sales were in Ireland, 30% in Northern Ireland and the remaining 35% in the rest of the UK. The company uses a storage unit at Warrenport in Northern Ireland to despatch cement to a 8400t cement storage and distribution at Rochester in Southern England.

Çimsa said that the acquisition is intended to help it to increase the share of its revenue in foreign currencies to over 70%. It is not a revelation that Çimsa might want to do this given the parlous state of the economy in Türkiye since 2018. Interest rates are high and the Turkish Lira has lost value. Çimsa raised the issues this has caused in its 2023 annual report. These include higher costs for imported goods and services such as energy, equipment and engineering services. In 2023 the company reported that 57% of its sales consisted of foreign currency-based revenue. The same year exports represented just under 40% of the company’s total revenue. Overall, Çimsa’s revenue fell slightly year-on-year in 2023, in part due to the divestment of a cement plant and other assets, but earnings rose significantly.

Buying Mannok gives Çimsa another route into the European Union (EU), via Ireland, and the UK. Crucially, this gives its first integrated grey cement production site outside of Türkiye. Both of these things are especially useful for an export-focused company facing increasing hurdles to sales in the guise of the EU Emissions Trading Scheme. It also helps the business to further hedge against negative currency exchange effects back home in Türkiye. So ‘Sláinte’ to Çimsa and Mannok, and good luck.

The 17th Global CemFuels Conference & Exhibition takes place in Dublin, Ireland on 18 - 19 September 2024

US: Ireland-based Ecocem has appointed Mike Donovan as Technical Director for its US business operations. He will be responsible for overseeing key aspects of Ecocem’s business in the US, with a focus on widespread commercial adoption of the company’s low-carbon cement technologies, including ACT, by the US market.

Donovan most recently developed and brought a new natural pozzolan to market with Geofortis. He started his career in concrete in the 1980s working at companies including as Sherman Industries, Blue Circle Cement Tarmac and Central Concrete Supply (US Concrete). He is a graduate in civil engineering from the University of Texas at Austin.

US: Eriez has appointed Todd Loudin as its Vice President of Global Sales.

Loudin holds a bachelor’s degree in marketing and business from Kent State University and an Executive Master in Business Administration from Loyola University Maryland. He worked as a General Manager for Larox in the 1990s and was on the Standards Committee for the International Society of Automation (ISA ANSI) in the 2000s and early 2010s. Later he became the head of Neles’ USA Flowrox business and its Head of Sales for the Americas in 2021.

Eriez is a specialises in separation technologies. It supplies products to the mining, food, recycling, packaging, aggregate sectors, and other processing industries. The company was established in in 1942 and has its headquarters in Erie, Pennsylvania.