Displaying items by tag: clay

Switzerland/UAE: The COP28 UAE Presidency named École Polytechnique Fédérale de Lausanne (EPFL) among its Energy Transition Changemakers in the Heavy Emitting Sectors category. EPFL won the prize for its LC3 limestone calcined clay cement, which replaces 50% of clinker content with calcined kaolinite clay and limestone. LC3 cement reduces CO₂ emissions by 40% compared to ordinary Portland cement (OPC), and is a readily available solution that can be scaled worldwide. EPFL noted the special importance of LC3 cement for CO₂ reduction efforts in developing countries, and sees it as having the potential to eliminate 500Mt/yr of global CO₂ emissions by 2030. In a post to LinkedIn, the LC3 Project said that nine plants around the world currently produce LC3 cement, with a further 20 planned before 2025.

Ghana: CIMPOR has appointed Germany-based ThyssenKrupp Polysius to build a 1280t/day flash activator for clay. The activator will supply calcined clay for use in the production of cement with a clinker factor as low as 50%. This can reduce the cement’s CO₂ emissions by 40% compared with ordinary Portland cement (OPC). The supplier’s contract covers engineering, supply of core equipment and supervision of the project. The equipment includes parts for clay handling, a hammer mill, a flash dryer and preheating and cooling equipment, as well as storage silos. The activator will be natural gas-fired.

Polysius Activated Clay product owner Leo Fit said "Our technology is not only more environmentally friendly, but also creates cost benefits for our customers like CIMPOR. In many regions, limestone is scarce and clinker has to be imported at high cost. At the same time, suitable clay sources are available. The increasing pressure to reduce greenhouse gas emissions is leading cement manufacturers to rethink. They need an alternative that is cost-efficient and at the same time provides high-quality cement. This is exactly what Polysius activated clay offers."

US: Texas-based Solidia Technologies has patented a synthetic pozzolan that may be used as a supplementary cementitious material (SCM) in cement production. The product is based on previously low-value materials, including minimally processed oil shales and clay minerals. Solidia Technologies produces the material by various methods, including firing the materials to yield a mix of crystalline components and activatable amorphous phase material. Alternatively, production may also involve the aqueous decomposition of manmade silicates in the presence of CO₂.

Spain: Switzerland-based Synhelion and Cemex España plan to build a new clinker plant near Madrid. The plant will use Synhelion’s synthetic fuel to produce clinker from clay and crushed sand at 1200°C. The fuel consists of a gas produced from green hydrogen and captured CO₂, using solar heat. La Tribune de Genève Online News has reported that Synhelion’s thermochemical reactor further helps to capture CO₂ emissions from clinker production. A study by the Swiss Federal Institute of Technology Lausanne indicated that this can halve the cost of carbon capture at cement plants, to below Euro85/t.

France: Vicat and Materrup plan to build their first reduced-CO₂ MCC1 raw clay cement plant at Carbonne in Occitanie. The plant will have a capacity of 60,000t/yr. Vicat and Materrup plan for their joint venture to subsequently build three further units across France.

Vicat's chair and chief executive officer Guy Sidos said "This new structure will enable Vicat to provide complementary very low-carbon solutions and meet the different needs of players in the construction sector. Development prospects are promising."

China: Asia Cement has launched its 2050 decarbonisation strategy, entitled 'Net-Zero Carbon Emissions By 2050 - Asia Cement Advanced Deployment.' The strategy consists of multiple pillars, namely 'alternative fuels,' 'reducing cement's clinker factor,' 'increasing renewable energy reliance' and 'carbon capture.'

During 2022, Asia Cement reduced its limestone, clay, iron and sand consumption by 266,000t, its coal consumption by 17,000t and its gypsum consumption by 56,000t year-on-year. This eliminated 95,100t of CO₂ emissions throughout the year, according to the producer.

France: Hoffmann Green Cement Technologies has commissioned its H2 plant, a 1000t/day clinker-free cement plant, adjacent to its existing H1 clinker-free cement plant in Bournezeau, Pays de la Loire. L'Usine Nouvelle News has reported that the new plant took 24 months to build and cost Euro22m. The main part of the plant consists of a 70m tower, where activated clay, ground granulated blast furnace slag (GGBFS) and gypsum are mixed to produce the cement. It is installed with solar panels capable of supplying 50% of its energy consumption. The producer says that its clinker-free cement has over 90% lower CO₂ emissions than cement produced with ordinary Portland cement (OPC). It aims to sell 24,000t of the product throughout 2023.

France: Vicat and Materrup have formed a joint venture to industrialise production and accelerate marketing of Materrup's Clay Cement 1 (MCC1) raw clay cement. The Le Moniteur newspaper has reported that the technology is based on a precursor and activator mixture which removes the need for calcination of the clay. Materrup said that this halves MCC1 cement's CO₂ emissions compared with ordinary Portland cement (OPC).

The partners say that clay has better long-term feasibility than other alternative raw materials for cement production, because global reserves are currently 2Tnt.

Australia: First Graphene has partnered with Suvo Strategic Minerals to develop graphene-enhanced metakaolin for use in cement and concrete production. Metakaolin is a pozzolanic material derived from kaolinite clay. The partners believe that the technology has commercial potential to improve concrete performance and reduce CO₂ emissions.

Australia/China: A Charles Sturt University team has found that the use of clay in soft soil foundation stabilisation can eliminate 40% of cement used in this type of construction. Australian Associated Press News has reported that China-based Kunming University of Science and Technology also supported the research.