Displaying items by tag: pozzolan
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!
Ash Grove Cement acquires Geofortis
13 September 2024US: 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."
Kenya: East African Portland Cement Company (EAPCC) has announced plans to build a new clinker plant in Kajaido. The Nation newspaper has reported that it will cost US$200m to build. EAPCC plans to use local pozzolana, along with limestone and coral transported from Kenya’s Coast Province, in cement production at the plant. The producer says that it will clarify the timeframes of the project in 2024.
SRMPR Cements launches Portland pozzolana cement
02 November 2023India: SRMPR Cements has launched its Portland pozzolana cement (PPC) for the first time, in Tamil Nadu. The Hindu BusinessLine newspaper has reported that the company controls 420,000t/yr of cement production capacity across three facilities in Tamil Nadu and neighbouring Andhra Pradesh. It invested a total US$27m in its production facilities and warehouses. SRMPR Cements will sell its PPC in 50kg bags. It also plans to launch ordinary Portland cement (OPC) in the future. It said that its products will help to meet ‘massive’ demand from public construction projects.
CEO Ohm Prakash said that the producer has already concluded deals with 100 different regional retailers of cement.
Solidia Technologies patents new synthetic pozzolan
11 September 2023US: 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: Residents of Cartagena, Murcia, have protested Cemex’s plans to begin mining pozzolan at new sites locally. The Murcia Plaza newspaper has reported that the protestors are calling for a mining ban, in line with their interpretation of the area’s Rural Area of Special Environmental and Social Sensitivity designation.
Neocrete plans first Neocrete activator plant
24 July 2023New Zealand: Neocrete has launched an investment round to raise over US$1.86m in funding. The start-up will use the funds to build an industrial-scale plant for its Neocrete activator for pozzolan-based concrete. The use of Neocrete's activator can eliminate up to 50% of cement in concrete. Neocrete aims to ultimately displace 100% of concrete's cement content. The Hawke's Bay Today newspaper has reported that pozzolan-based concrete made using Neocrete's additive offers resilience benefits compared to conventional ordinary Portland cement (OPC)-based concrete. It is especially suited construction in seawater-exposed settings.
Germany: Dyckerhoff has launched Dyckerhoff Weiss Blue Star, a pozzolanic white cement CEM IV/A (P) 42.5 R product. It was approved by the German cement association, the VDZ, in mid-June 2023 and is now being manufactured at the Amöneburg plant. The lower CO2 credentials of the new product have been promoted as it releases around 15% less CO2 compared to CEM I cements. It is also notable for being a blended white cement.
Cem'In'Eu launches FUSIOCIM 43% reduced-CO2 cement
13 July 2023France: Cem'In'Eu has launched FUSIOCIM, a CEM II/C pozzolan cement, that offers a 43% reduction in CO2 emissions compared with ordinary Portland cement (OPC). FUSIOCIM has specific CO2 emissions of 506kg/t. It is suitable for various concrete applications and comes in 25kg bags.
Cem’In’Eu general manager Fabien Charbonnel said "We created Cem’In’Eu with the ambition of reducing the carbon footprint of the cement industry. And we are proving it today with a low-carbon offer that easily replaces traditional cements, without any change for construction professionals. We are convinced that this transition can only be done with pragmatism and taking into account the needs of users.”
Global Cement and Concrete Association announces Innovandi Open Challenge 2023 shortlist
30 June 2023World: The Global Cement and Concrete Association (GCCA) has named the 15 anticipated deliverers of low-CO2 cement and concrete production shortlisted for participation in its second Innovandi Open Challenge. The association chose the start-ups based on their potential to deliver CO2 emissions reduction in the global cement and concrete sector in line with its Concrete Future 2050 Net Zero Roadmap. The applicants are presenting their pitches to GCCA members on 30 June 2023. All those accepted will gain access to members' plants, labs, networks and expertise. The following start-ups made the Innovandi Open Challenge 2023 shortlist:
Arrakis Materials |
US |
Carbon negative materials for concrete |
Chement |
US |
Room temperature cement production |
EcoAdmix Global |
UK |
Nanotechnology ('HDT') for concrete |
EcoLocked |
Germany |
Biocarbon-based admixtures |
EnviCore |
Canada |
Low temperature supplementary cementitious material production |
Enzymatic |
US |
Carbon negative enzymatic concrete corrosion inhibition and recycling |
Louis Structures |
US |
Municipal solid waste-based lightweight aggregates |
MEP - SeaMix |
US |
Basalt fibre and graphene-based admixture |
Nano Crete |
US |
Graphene-enhanced CO2 sequestration |
Nanospan India |
India |
Graphene-based admixture |
NeoCrete |
New Zealand |
Nano-activator for natural pozzolans |
Queens Carbon |
US |
~500°C cementitious materials production |
The Cool Corporation |
UK |
Carbon negative carbon nanotube-based additive for concrete |
Ultra High Materials |
US |
Clinkerless cement |
Versarien Graphene |
UK |
Graphene-based admixture ('Cementene') |
GCCA cement director and innovation lead Claude Loréa said “We received more than 70 quality applications, so drawing up a shortlist was challenging." Loréa continued "Our essential industry needs something easily scalable and affordable. Those start-ups on the list demonstrated the most potential, and we look forward to hearing more about their ideas. But we’ll also be keeping in touch with other start-ups who didn’t make this year’s shortlist, with future projects in mind.”