Displaying items by tag: net zero
New developments in alternative cement
16 October 2024One 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!
Azerbaijan Cement Producers Association reviews Net Zero Roadmap
08 October 2024Azerbaijan: The Azerbaijan Cement Producers Association (ASIA) has held the third Net Zero Accelerator workshop to discuss the final report on its 2050 Net Zero Roadmap. ASIA members, construction companies and government and non-governmental organisations (NGOs) all participated in the two-day event. TurkicWorld News has reported that topics include Azerbaijani cement’s clinker factor, alternative fuel (AF) substitution rate, construction and design aspects, carbon capture and related regulatory frameworks. ASIA will launch its finalised roadmap in partnership with the European Cement Research Academy (ECRA) and the Global Cement and Concrete Association (GCCA) at the COP29 climate conference in Baku, Azerbaijan.
ASIA said "The association is making use of the expertise of the GCCA and ECRA to ensure our roadmap aligns with national policies."
Ambuja Cements joins Alliance for Industry Decarbonisation
26 September 2024India: Ambuja Cements has entered the Alliance for Industry Decarbonisation (AFID), becoming the first cement manufacturer worldwide to join this global platform. AFID aims to accelerate the net zero transition in energy-intensive sectors, like cement, in accordance with the Paris Agreement. Ambuja Cements has set a net zero target for 2050, with goals approved by the Science Based Targets initiative (SBTi). The company plans to invest US$1.2bn in renewable energy projects totalling 1GW and 376MW from waste heat recovery systems to power 60% of its expanded capacity by the 2028 financial year. This strategy will reportedly lower its carbon footprint, and utilise more than 8.6Mt of discarded materials in the financial year 2024.
Non-executive director of Ambuja Cements, Mr Karan Adani, said "This marks another significant step for Ambuja in its sustainability journey. We are already amongst the lowest emission intensity cement producers globally and are undertaking a number of strategic initiatives to further reduce our greenhouse gas emissions footprint. Being a member of the Alliance for Industry Decarbonisation will allow us to leverage the experiences of global cross-sector industry peers. And, in turn, share our approach to decarbonisation."
Material Evolution to launch low carbon cement plant
23 August 2024UK: Material Evolution will launch the UK's ‘largest ultra-low carbon cement plant’ in Wrexham in October 2024, reports the Construction Enquirer. The new facility will produce 150,000t/yr of a cement that emits up to 85% less embodied CO₂ than Ordinary Portland Cement (OPC), according to the company. Material Evolution is the driving force behind the €9m Mevocrete project, funded by government-led Innovate UK, and utilises byproducts from the steel industry. Business co-founder Liz Gilligan said that Material Evolution aims to remove one gigatonne of carbon by 2040, while replacing OPC as the ‘go-to’ product for UK construction. The company plans to replicate and scale its production across the UK and Europe.
Chief science officer at Material Evolution and co-lead of the ‘Mevocrete’ project, David Hughes, said "Cement is a binder and what we’re looking at here is creating a net zero embodied carbon cement which is inherently more durable, which means our houses, infrastructure and transport highways would be transformed on mass industry scale, really tapping into a local and national picture of a net zero environment.”
UK: Heidelberg Materials has announced the launch of a public consultation for its carbon capture and storage (CCS) project at Padeswood Cement Works. The consultation, which runs from 2 July - 12 August 2024, will gather public input on the proposed plans to install the CCS technology, which will capture up to 800,000t/yr of CO₂, according to local news reports.
The Padeswood CCS project is expected to create over 400 jobs and forms part of the HyNet North West initiative, a major industrial decarbonisation effort that includes constructing a 60km pipeline to transport CO₂ to depleted gas reservoirs in Liverpool Bay for storage.
Ban ‘green’ cement!
05 June 2024The Indonesian government emphasised its intention this week to use ‘green’ cement in the construction of its new capital city Nusantara in Borneo. However, this begs the question: what exactly is ‘green’ cement?
In this case, Mohammad Zainal Fatah, the secretary general of the Ministry of Public Works and Public Housing, told state media that his department was “seeking to encourage the supply of domestic-industry-based material resources and construction equipment, which can support sustainable infrastructure development principles." The ministry is working with state-owned cement producers such as Semen Indonesia (SIG) to ensure the provision of sustainable cement and related products. SIG was selected as a supplier for the project in late 2022 and, as of February 2024, has reportedly provided 400,000t of cement from its plants at Balikpapan and Samarinda.
This is admirable stuff. However, the timing of the announcement is curious given that both the head and deputy head of the Nusantara Capital City Authority resigned this week forcing the government to reassure investors that the project was still on. Cue some swift discussion about ‘green’ cement! Previously it was hoped that the first phase of the US$34bn project could be inaugurated on the country’s independence day in August 2024 with civil servants scheduled to start relocating to the site in the autumn.
SIG sells a number of ‘green’ blended cement products and some of these have received Green Label Cement certification from the Green Product Council Indonesia. The group says that these products have contributed up to a 38% drop in CO2 emissions compared to Ordinary Portland Cement (OPC). This compares to the group’s clinker factor reduction rate of 69% and its Scope 1 emissions intensity reduction of 17% to 585kg/CO2/t of cement in 2023 compared to 2010 levels.
Along similar lines, the Alliance for Low-Carbon Cement & Concrete (ALCCC) in Belgium also announced this week that it had released a new policy roadmap aimed at achieving net zero emissions by 2040. Amongst its recommendations were a focus on the standards for cement and concrete to promote low-carbon products and encouragement to create lead markets to develop demand for them.
Crucially, the ALCCC uses low-carbon cement in place of ‘green’ cement and this makes its definition clearer. ‘Green’ cement is a marketing term intended to associate cement with environmentalism. Yet there is no accepted definition describing how these products are more sustainable than, say, OPC. For example, a so-called ‘green’ cement could use 100% clinker manufactured with no CO2 emissions-abatement, but it might be sustainable in other ways such as saving water. For the purposes of this article we’ll assume that ‘green’ cement means a low-carbon one. To further add to the confusion, ‘green’ concrete can be made using OPC in various ways but that’s beyond the scope of this piece. Clearly the world could do with some universal definitions.
US-based research and consulting company Global Efficiency Intelligence came to the same conclusion when it published its ‘What are Green Cement and Concrete?’ report in December 2023. It decided that - despite there being plenty of standards, protocols, and initiatives - there is no general agreement on the definition of ‘green’ cement or concrete. Its emissions intensity for cement summary table can be viewed below. It demonstrates the massive range of emissions intensity between the various standards. It is worth noting here that the description the Indonesian government may have been using for ‘green’ cement could already meet SIG’s Scope 1 emissions intensity reduction for its cement in 2023 depending on the standard being used.
Standard / Initiative / Policy Name | Emissions intensity target (t/CO2 per tonne cement) |
Climate Bonds Initiative | 0.437 & 0.58 |
IEA and IDDI | 0.04 – 0.125 |
First Movers Coalition | 0.184 |
U.S. General Services Administration IRA Requirement | 0.751 |
New York (USA) Buy Clean | 0.411 |
Table 1: Emissions intensity definition for cement as stated by standards, protocols, initiatives, and policies with stated numerical quantity targets. Source: Global Efficiency Intelligence.
Part of the problem here is that there is a language gap between the simple definition of a cement that is less CO2 emissions-intensive than OPC and the technical definitions used in the specifications and standards. Simply describing a cement product as ‘green’ can potentially cover anything that is slightly better than OPC down to a bona-fide net-zero product. Added to this is pressure from the manufacturers of new and existing cement products that use less or no OPC for regulators to move to performance-based standards to replace existing prescriptive standards, because it makes it easier for their products to be used. For more on this issue see Global Cement Weekly #606. Cement associations such as Cembureau and the Global Cement and Concrete Association (GCCA) have also called in their respective net zero roadmaps for changes to the standards system to promote low-carbon cement and concrete products.
The answer to what is ‘green’ cement is whatever the promoters want it to be. So, it might be helpful if the use of the word ‘green’ were banned in connection to any marketing activity related to cement products. Everyone could then adopt some kind of universal grading system using simpler language. One approach might be to copy the colour-coding scheme used by hydrogen to describe how it is made. One could use yellow for limestone blends, silver for slag, orange for clay, black for OPC made with carbon capture and so on… but not green! Another route might be to mandate the use of the carbon labels that some cement producers have used for at least a decade. Or something like the alphabet energy rating system used in the UK and EU for electrical appliances could be used. It’s too much to hope for a global system but simpler systems in the main markets would make it much easier to determine what exactly is ‘green’ cement.
Indonesia: The Ministry of Industry is preparing a comprehensive roadmap for decarbonising the cement industry, due for initial implementation by the end of 2025. Newsbase Daily News has reported that that the roadmap includes targets for CO2 emissions reduction, alternative fuels substitution and energy efficiency. It will also focus on developing new technologies and implementing supportive policies for the transition. The ministry noted that the Indonesian cement industry is already working to reduce its carbon footprint through multiple initiatives.
Global: Policymakers, including those from the governments of Canada, the UAE and Thailand, are meeting cement industry CEOs in Bangkok to discuss how to further advance the decarbonisation of the cement industry. Thailand’s Minister of Industry, Pimphattra Wichaikul, opened the conference.
Wichaikul said “Thailand is one of the first countries in the word with a credible national roadmap for delivering on the cement industry’s net zero commitments. Key to success is innovation, cross-sectorial cooperation, strong leadership with clear targets and international collaboration to drive policy and implementation.”
Fernando González, CEO of Cemex and President of the GCCA, said “We have strong commitments and are already delivering the goal of building a more sustainable industry, and by working with governments, policymakers, built environment experts and other key players we have the opportunity to accelerate our progress in this important ‘decade to deliver’.”
The UN’s Industrial Development Organization (UNIDO) also unveiled a new package of investment, technical and other support, to help Thailand decarbonise its own cement industry.
Ireland mandates green procurement for cement
31 May 2024Ireland: In a move towards sustainability, the Irish government has mandated green procurement requirements for low carbon cement, effective from September 2024. This initiative is part of Ireland's goal to achieve a net-zero carbon society by 2050.
The new regulations require a 30% reduction in clinker use and the elimination of high clinker cement for all government and public works. Additional provisions include the necessity for Environmental Product Declarations and comprehensive life-cycle greenhouse gas emissions assessments for major new projects. This aims to significantly reduce CO₂ emissions from the construction sector.
Belgium: The Alliance for Low-Carbon Cement & Concrete (ALCCC) has marked its first anniversary with a new policy roadmap aimed at achieving net zero emissions by 2040. Initiated in May 2023, the alliance brings together environmental NGOs and industry stakeholders to transform the cement and concrete sectors. The ALCCC has grown significantly, now comprising 25 members.
Senior programme manager Joren Verschaeve from ECOS, the coordinator of ALCCC, said "Our members show that the technologies needed to make low-carbon cement and concrete the norm already exist. This uniquely positions our Alliance to raise the alarm when policies and standards lead to unfair competition instead of a greener future – and the latter is perfectly achievable if policymakers implement our roadmap."