Displaying items by tag: decarbonisation

South Korea: A recent study from Daejeon explored the potential of low-lime calcium silicate cement as a low CO₂ emission alternative to Ordinary Portland Cement. Researchers from the Korea Institute of Geoscience and Mineral Resources examined the setting and flow characteristics of a mixture of Ordinary Portland Cement and low-lime calcium silicate cement under carbonation curing conditions. The study was financially supported by the Ministry of Trade, Industry & Energy's industrial strategic technology development programme.

The study aimed to explore the reaction and microstructural characteristics of these cement pastes. The low-lime calcium silicate cement was synthesised using limestone and silica fume, with varying proportions added to the Portland cement pastes. The research findings suggest improvements in compressive strength with the inclusion of 30% or more low-lime calcium silicate cement, highlighting its ability to enhance the durability and sustainability of construction materials.

US: A research team from Lehigh University has won a three-year, US$2m grant from the Department of Energy's industrial efficiency and decarbonisation office for a project on concrete decarbonisation. The team, including Carlos Romero, director of Lehigh's Energy Research Centre, aims to develop a sustainable concrete binder using calcined clay, reducing emissions associated with Ordinary Portland Cement production. The project collaborates with Buzzi Unicem USA and focuses on processing and testing calcined clay to mimic the properties of conventional cement.

Lehigh's team will explore various low-grade calcined clays, supplied by Buzzi, testing their compressive strength and durability. The goal is to halve the CO₂ emissions of traditional concrete mixes.

Chair of the Department of Civil and Environmental Engineering Shamim Pakzad said "I am excited about the expansion of the research portfolio of CEE departments into this area of greener cement, which opens many opportunities for future research and implementation in industry."

The US Department of Energy (DOE) announced a US$1.6bn investment in the cement sector this week. The funding was part of a total of US$6bn for 33 projects in over 20 states to decarbonise energy-intensive industries also including chemicals and refining, iron and steel, aluminium and metals, food and beverages, glass, process heat applications and pulp and paper. The DOE was keen to link the money to “the President’s Bipartisan Infrastructure Law and Inflation Reduction Act.” Politics is never far away it seems! The projects are part of the Industrial Demonstrations Program, managed by DOE’s Office of Clean Energy Demonstrations (OCED).

Table 1: Summary of US Department of Energy funding announced on March 2024 to decarbonise cement and concrete production

Table 1 above shows the main approaches each of the projects aim to use. The two most expensive ones involve carbon capture and sequestration (CCS) at Heidelberg Materials US’ Mitchell cement plant in Indiana and National Cement’s Lebec plant in California respectively. In a complimentary press release Chris Ward, the CEO of Heidelberg Materials North America, said “This substantial federal funding investment will help create the first full-scale deployment of carbon capture and storage on a cement plant in the US.” The proposed CCS unit at the plant will capture around 2Mt/yr of CO₂ from 2030. If Ward’s forecast is accurate (and no one beats them to it), then Heidelberg Materials will likely have set up the first full-scale CCS units at cement plants in both North America and Europe. This will be a significant achievement. The National Cement project, by contrast, is a mixed bag of approaches to decarbonising cement production that follows the multi-lever approach advocated for in many of the industry net-zero roadmaps. It intends to use agricultural by-products such as pistachio shells, as alternatives fuels to lower the fuel-based emissions, calcined clay to lower the clinker factor and CCS to capture the remaining 950,000t/yr of CO₂ emissions.

The other projects either involve using calcined clay or substituting limestone with calcium silicate. The Summit Materials proposal is noteworthy because it aims to build four clay calcination units in locations in Maryland, Georgia and Texas. None of these appear to be near Summit’s (or Cementos Argos’) cement plants. This suggests that the company may be intending to use calcined clay in ready-mixed concrete production. The Roanoke Cement Company calcined clay project will be baseEuropead at its cement plant in Troutville, Virginia.

The remaining two grant recipients, Brimstone and Sublime Systems, will both test the companies’ different methods of manufacturing cement by using calcium silicate instead of limestone. Brimstone’s method produces ordinary Portland cement (OPC) and supplementary cementitious materials (SCM). The company said in July 2023 that its OPC met the ASTM C150 standards. However, the company has released less information about its actual process. Sublime Systems’ uses an electrolysis approach to create its ASTM C1157-compliant cement. It calls this ‘ambient temperature electrochemical calcination.’

Investment on the same scale of the DOE has also been happening in Europe. In July 2023, for example, the European Commission announced an investment of Euro3.6bn in clean tech projects to be funded from the proceeds of the European Union emissions trading scheme (ETS). This was the third call for large-scale projects following previous announcements of recipients in 2021 and 2022. Euro1.6bn of the third call funding went towards cement and refining projects including five cement and lime projects in Belgium, Croatia, Germany and Greece. The money granted for each of these schemes was in the region of Euro115 - 235m.

Both the US and Europe are throwing serious finance at the cement industry to try and kickstart the various pathways towards net zero. They are also doing it in different ways, with the US aiming to boost its economy by onshoring sustainable industry, and Europe hoping to fund its approach via carbon taxation. Government-driven decarbonisation investment for cement in other large countries and regions around the world appears to be lagging behind the US and Europe but these may spring up as net zero targets are set, roadmaps drawn up and government policy formulated. These places could also benefit from watching what works and does not work elsewhere first. Back in the US and Europe the next tricky part of this process will be bridging the gap between government subsidy and commercial viability.

France: Ecocem has launched a new low-carbon advanced cement technology (ACT) cement, aiming for widespread adoption in European construction projects. The ACT range promises a clinker concentration of 20%, lower than the current norm of 35% minimum.

Jean-Christophe Trassard, Director, Marketing of Sustainable Innovation, said "We achieve competitive rates by controlling granularity, the fineness of grinding and admixtures. We have also greatly developed our thinking on the addition of additives in our formulations, which required more than fifteen years of R&D and the filing of six patents."

This product contains locally sourced additives, with the capability to adapt mixes to regional availability. The ACT cement is expected to reduce water usage by one-third compared to conventional concrete. An ACT-based concrete reportedly emits 198kg CO₂/t, a substantial reduction from the 614kg CO₂/t for standard concrete in France.

Gaining market entry for ACT required European technical evaluation and European assessment document certification, currently pending in the EU Official Journal. Trassard added, "As we are dealing with clinker rates below the standards, we had to go through this certification, which gives us a very good passport for the European markets. However, local administrative variations will have to be carried out subsequently."

In France, Ecocem has already applied for ATEX certification to facilitate deployment of the ACT range, expected later in 2024. Ecocem aims to include the ACT range in standard norms by 2026.

US: The US Department of Energy has selected four cement producers to receive funding under the Bipartisan Infrastructure Law and the Inflation Reduction Act.

Heidelberg Materials US secured up to US$500m for its planned 2Mt/yr carbon capture project at the Mitchell cement plant in Indiana. National Cement also received up to US$500m, for its Lebec Net Zero limestone calcined clay cement (LC3) project in California. Summit Materials received up to US$216m for a series of clay calcination projects in Georgia, Maryland and Texas. Lastly, Roanoke Cement will receive up to US$61.7m for an LC3 project at its Troutville cement plant in Virginia.  These projects also involve developing a training, education and certification consortium in the cement sector.

Portland Cement Association (PCA) president and CEO Mike Ireland said "This funding is a welcome acknowledgement from the government that America's cement manufacturers are taking ambitious and significant steps toward reaching carbon neutrality. This will move the needle closer to achieving what industry considers the 'heavyweight' of carbon solutions: carbon capture utilisation and storage (CCUS). Once established nationwide, CCUS will greatly accelerate cement manufacturers' charge toward net zero."

Senior vice president of government affairs Sean O'Neill added “From passage of the Bipartisan Energy Act of 2020 to securing funding through the Inflation Reduction Act and the Infrastructure Investment and Jobs Act, today's announcement is another major milestone in the cement industry's decarbonisation efforts. The PCA is committed to continuing to work with policymakers to ensure the regulatory environment facilitates rather than impedes these and future investments.

US: Alternative cement developer Sublime Systems has entered award negotiations with the US Department of Energy for a grant worth up to US$87m. Gulf Oil & Gas News has reported that Sublime Systems plans to build an electrolysis-based cement plant in Holyoke, Massachusetts. The department’s Office of Clean Energy Demonstrations would provide any eventual funding under the Bipartisan Infrastructure Law and Inflation Reduction Act. Sublime Systems’ plant is one of 33 scalable decarbonisation solutions in energy-intensive industries selected for potential funding.

CEO Leah Ellis said “Access to sufficient capital for industrial-scale demonstrations is the single biggest obstacle preventing breakthrough innovations from reaching the scale humanity needs to combat the climate crisis. The Department of Energy has cleared this obstacle through funding from OCED’s Industrial Demonstrations Program, embracing its unique role in supporting the deployment of the decarbonised technologies of tomorrow. We look forward to collaborating with them on funding our first commercial manufacturing scale-up, which will ship our clean cement while creating meaningful economic opportunities for the surrounding community.”

New Zealand: Neocrete, a New Zealand start-up that decarbonises concrete production, has raised US$4m in seed funding. Wavemaker Partners, a Singapore-based venture capital firm, led the funding round with a 15% stake for US$2.7m. The funding also included contributions from five other investors, including NZ Green Investment Finance, which acquired a 3.8% share for US$700,000. Neocrete, founded in 2018, has developed an additive that can reduce the cement in concrete by 30-50% without loss in strength, increasing its durability.

Wavemaker Partners' managing partner Paul Santos said "Neocrete is designed to scale rapidly by using a cost-efficient production process that can leverage existing infrastructure."

Zarina Bazoeva, Neocrete co-founder and CEO, said that the funding will enable the company "to scale to meet initial global demand for Neocrete’s additive”. The company plans to complete setting up an Auckland manufacturing facility and scale up a research and development programme, "which is on track to produce cement-free, zero-carbon concrete by 2027,” according to Bazoeva.

US: Brimstone is negotiating a US$189m Federal award with the Department of Energy to finance the construction of a new decarbonised cement plant. This plant will produce up to 140,000t/yr of Ordinary Portland Cement and supplementary cementitious materials, reducing CO₂ emissions by 120,000t/yr.

Brimstone's process uses carbon-free calcium silicate rocks, reducing its CO₂ footprint. In July 2023, Brimstone's cement met ASTM C150 standards, confirming the effectiveness of its decarbonised process. The company is preparing to construct a pilot plant near Reno, Nevada.

Sweden: Researchers at Chalmers University of Technology, Sweden, have developed a method to simplify the construction of textile-reinforced concrete structures, a move that is expected to lead to more environmentally friendly infrastructure like bridges, tunnels, and buildings. The new technique addresses the high carbon footprint of cement.

This innovation, involving carbon fibre textiles as a replacement for steel reinforcement, enables lighter structures with reduced cement usage, thereby lowering the overall carbon impact. Karin Lundgren, Professor of Concrete Structures at Chalmers Department of Architecture said "A great deal of the concrete we use today has the function to act as a protective layer to prevent the steel reinforcement from corroding. If we can use textile reinforcement instead, we can reduce cement consumption and also use less concrete, thus reducing the climate impact."

The research is detailed in a paper titled 'Textile reinforced concrete members subjected to tension, bending, and in-plane loads: Experimental study and numerical analyses', which was published in the Construction and Building Materials journal. The study, a collaborative effort between Chalmers University and Gdansk University of Technology in Poland, is supported by the Swedish Research Council.

Switzerland: ABB and Captimise have enhanced their collaboration, focusing on advancing cost-effective carbon capture, utilisation, and storage (CCUS) technologies in the cement industry. Under a new Memorandum of Understanding, the partnership will develop various studies, including screening, feasibility, and FEED, aiding cement producers to identify efficient carbon capture solutions across their operations. The joint effort is expected to bolster the cement industry's efforts to meet its climate and net-zero targets.

CEO of Captimise, Mattias Jones, said “We draw on a track-record of more than 25 live case studies with CO₂ emitters across Europe and the US and know we’ll be able to support operations of all sizes in cement through combined CCUS, automation and electrification technologies.”

Global Business Unit Manager at ABB Process Industries, Max Tschurtschenthaler, said “Reducing the CO₂ emissions from cement manufacturing is a major challenge and a top priority for this industry. We are on a mission to make it more cost-effective. By combining our world-class automation, electrification and digital technologies with the know-how of partners like Captimise, we can further support the cement industry in achieving their climate and net zero targets.”