Displaying items by tag: circular economy

Mexico: Moctezuma inaugurated a US$12m alternative fuels storage system at its Tepetzingo cement plant in Morelos, after two years of engineering, planning and execution. The facility will process over 150,000t/yr of waste, including end-of-life tyres, municipal solid waste and non-recyclable materials, which will replace fossil fuels in cement production, with a goal of 30% substitution by 2030. The company said that the benefits of the project include saving thousands of tonnes of waste from landfill and mitigating methane emissions.

The producer, the Morelos government and the Ministry of Sustainable Development are also developing a circular economy centre in Jiutepec with an additional investment of US$1.6m. The facility will collect, shred and convert up to 3000t/month of tyres into alternative fuels.

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.”

Colombia: Holcim Colombia has invested US$2m to modernise its co-processing platform at its Nobsa cement plant in Boyacá. The upgraded facility will process 100,000t/yr of waste into alternative fuels for the cement plant, raising thermal substitution to 40% in the short term, with a target of 70% by 2030.

CEO of Holcim Colombia Martín Costanian said “This project realises our dream of optimising the crushing circuit and scaling our capacity to replace fossil fuels with more sustainable and truly circular solutions.”

The system renovation includes the addition of a shredder with a nominal capacity of 10t/hr, as well as new transfer systems and a modern dosing system capable of feeding up to 20t/hr of alternative fuels to the kiln. The waste used will consist of paper, cardboard, plastics and biomass.

Manager of Geocycle José Méndez said “This project represents true circularity and a solution for the thousands of pieces of waste that end up in landfills each year.”

Japan: Mitsubishi UBE Cement’s joint project with the city of Kitakyushu to pilot carbon recycled materials in public infrastructure has been selected for the Ministry of Economy, Trade and Industry’s 2024 grant programme.

Centred around the producer’s Kyushu plant in Kurosaki, Kitakyushu, the project will recycle CO₂ and waste cement from local sources for use in municipal construction. Mitsubishi UBE Cement said it aims to establish a model for resource circulation that can be expanded nationwide.

Sweden: Cemvision has developed a patent-pending beneficiation process to upcycle electric arc furnace (EAF) and basic oxygen furnace (BOF) slags into high-performance supplementary cementitious material (SCM), while recovering valuable metals.

Third-party testing found the material performs as well as or better than ground granulated blast-furnace slag (GGBS). Cemvision recovers 99% of the iron oxide content from EAF slag for reuse in steelmaking, as well as other metals like chromium.

The output will support Cemvision’s Re-Ment Massive and Rapid products as clinker-replacing SCMs. The process was piloted with metallurgical research institute Swerim.

Cemvision CEO Oscar Hållén said “This is a game-changer not only for the cement industry but for steel producers as well. Our process enables high-performing cement products from materials that would otherwise be treated as waste. With this innovation, we're proving that decarbonisation and circularity can go hand in hand, and at scale.”

Portugal: Cimpor will invest €155m in establishing a new research and development centre focused on sustainable construction, CO₂ reduction and digital transformation. The investment will also cover the modernisation of Kiln 7 at the producer’s Alhandra cement plant. The new centre will focus on technologies such as low-clinker cement development, carbon capture and alternative fuels, using recycled concrete and 3D printing. The building itself will incorporate calcined clay-based cement and recycled aggregates.

The new centre will create over 100 jobs and serve as a hub for collaboration with universities and startups, as well as serve as a location for conferences and workshops. The building will operate as a ‘living lab’, with real-time monitoring of its thermal and structural performance and energy consumption.

The chair of Cimpor Global Holdings, Suat Çalbiyik, said “In 2018, we operated only in Portugal and Cape Verde with around 1800 employees. Today, we are the world’s third-largest cement group… with 8000 employees in 14 countries and a production capacity of 112.5Mt/yr of cement.”

Azerbaijan: The Global Cement and Concrete Association (GCCA) has called on governments at the COP29 climate conference to support the decarbonisation of the cement industry. The association published its Net Zero Progress Report 2024/25 to coincide with the conference. The report details the ‘extensive decarbonisation work’ currently underway in the industry, including accelerating carbon capture, utilisation and storage (CCUS), switching to renewable energy sources, advancing the circular economy and reducing cement’s clinker factor. The sector expects to commission its first net zero cement plant, following a carbon capture upgrade to Heidelberg Materials’ Brevik plant in Norway, later in 2024.

GCCA president Fernando González said “Our industry is engaged in the most significant transformation in its history. To fully unlock our decarbonisation progress in this crucial Decade to Deliver, we urgently need effective policy support."

UK: Heidelberg Materials UK has launched evoBuild, a global brand for low-carbon and circular cement, ready-mixed concrete, aggregates and asphalt products, in line with its parent company's sustainability strategy. According to the company, EvoBuild products either reduce CO₂ emissions by at least 30% or incorporate at least 30% recycled content.

This launch complements evoZero, the ‘world's first carbon-captured net-zero cement’, launched by Heidelberg Materials in November 2023. All eligible products from Heidelberg Materials UK will be integrated into the evoBuild portfolio ‘over the coming years.’

One 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!

For a further discussion of alternative cement and binders in Europe, see Global Cement’s interview with ALCCC co-ordinator Joren Verschaeve in the forthcoming November issue of Global Cement Magazine on 17 October 2024.

Spain: Packaging and paper manufacturer Mondi has co-founded Paper Sacks Go Circular Spain, an alliance aimed at enhancing the circularity of used paper bags within the construction sector. The alliance consists of 12 European companies collaborating to eventually elevate recycling processes for construction materials like cement, plaster and insulation. The alliance will start with paper bags, then expanding to other streams such as construction and demolition materials. The initiative aligns with the goal of increasing the recovery rate of construction byproducts in Spain, currently at 48%, according to the latest data from the Spanish National Statistics Institute.

Circular economy manager at Mondi Flexible Packaging, Carlos Martinez Ezquerra, said "This initiative demonstrates Mondi’s commitment to collaborating with industry partners across the value chain to increase recycling rates for used paper bags. It creates a scalable approach for the rest of Europe and other industries, leading to a reduction in ‘waste’ management costs and a significant increase in the valorisation rate, and supports transparency and traceability of the circular economy. We are proud to be one of the founding initiators."