Displaying items by tag: testing

US: Heidelberg Materials North America has begun test well drilling at its Mitchell cement plant in Indiana as part of the CarbonSAFE carbon capture and storage (CCS) project led by the Illinois State Geological Survey (ISGS).

The drilling started on 22 January 2025 to assess the geology beneath the plant, which is located in the Illinois Basin, for CO₂ storage potential. The test will evaluate three carbon storage formations to a depth of 2210m to determine if the site can safely store 50Mt of CO₂ over 30 years.

The project began in early 2023 with seismic data collection across 87km of roadways, leading to the installation of the geologic test well.

Greg Ronczka, vice president of Carbon Transport & Storage Development said "This is an exciting step for the project as we learn which potential formations may be suitable to permanently and safely store the CO₂. This knowledge will help us design the injection and observation well network and allow us to prepare a complete and accurate US Environmental Protection Agency Class VI permit application."

Sweden: Heidelberg Materials has successfully operated a 300kW plasma-heated cement kiln at its Slite cement plant, which it claims is the first of its kind. The producer has achieved 54 hours of continuous operation, with 60% CO₂ concentration in the flue gas. The aim is to reach 99%.

The kiln is part of the ELECTRA project, which aims to replace traditional combustion processes with electricity-based solutions, like plasma. The project consists of 17 partners from 8 countries.

Project manager Bodil Wilhelmsson said "It looks very promising. We started the tests at the end of last year and can now say with certainty that this is the right way to go: we will be able to produce clinker with plasma."

Fuel-related CO₂ emissions from cement production are eliminated because no fuel needs to be used in the production process. Instead, CO₂ is heated to over 5000°C, where it becomes a plasma jet that heats the material in the kiln.

Wilhelmsson added "The absence of fuel in the process means that there is no ash in the product. This means that a parameter that could affect the quality of the product if it fluctuates is no longer considered. So, it looks like the quality of the clinker can actually be slightly higher in this process."

Heidelberg Materials plans to build a 1MW kiln in Skövde cement plant in 2026, where further tests will continue.

UK: Cemvision has launched one of the UK’s first commercial applications of its low-carbon Re-ment cement technology at a STOREX self storage development in Sunbury, near London. The foundational slabs for the site employ Cemvision's Re-ment Massive product, which replaces traditional Portland cement. Recent laboratory tests have shown that the product achieves a 75% CO₂ reduction and a 28-day compressive strength, that reaches the C50/60 classification, compared to traditional Portland cement. STOREX and Cemvision have signed a Letter of Intent for further collaboration in the UK and other markets.

“This project is a landmark achievement for Cemvision as we bring the benefits of green cement to UK customers,” said Oscar Hållén, CEO of Cemvision.

Cemvision says that its Re-Ment Massive technology reaches different levels of CO₂ reduction depending on application and local conditions, with the product already having achieved more than a 95% reduction compared to Portland cement in demo production in the EU, according to the company.

US: The US Department of Energy's (DOE) Office of Fossil Energy and Carbon Management has selected Cemex's Knoxville cement plant in Tennessee as the site for a carbon capture, removal and conversion test centre. The project is part of a US$101m initiative shared among five projects that aim to decarbonise cement plants and power facilities.

Cemex, in collaboration with the University of Illinois Urbana-Champaign (UIUC) and a coalition of US cement producers, will develop the conceptual design, business, technical and managerial frameworks for the test centre under Phase 1. Phase 2 will involve constructing and operating the centre to evaluate advanced carbon management systems.

Jaime Muguiro, president of Cemex US, said “While we are making steady progress, the cement industry has the opportunity to accelerate the pace of our decarbonisation even more. I am excited that our Knoxville cement plant has been selected as the host site for the carbon capture test centre. Through collaboration and continuous innovation with the University of Illinois and industry peers, Cemex is committed to advancing decarbonisation solutions.”

France: Bouygues Construction and Ecocem have signed a partnership to facilitate the use of Ecocem’s low-carbon ACT cement technology in Bouygues Construction’s projects.

The collaboration involves three stages of testing and validation. First, Bouygues Construction will conduct independent laboratory tests to evaluate ACT’s performance. Next, structural concrete walls will be built at Bouygues Construction’s facilities in Chilly-Mazarin, France starting in early 2025, and monitored to ensure thorough testing. Finally, a full-scale mock-up, including all structural elements, will be constructed to assess the in-situ application of ACT technology.  The testing programme aims to integrate ACT technology into Bouygues Construction projects following successful validation.

Germany: Capsol Technologies has signed a cooperation agreement with Holcim to deliver a CapsolGo carbon capture demonstration campaign at Holcim’s Dotternhausen plant in southern Germany. The CapsolGo campaign will test Capsol’s carbon capture technology using its hot potassium carbonate (HPC) solvent. Capsol Technologies will provide the demonstration as a turnkey solution, including testing and validation to supply critical data and insight into the technology.

Dieter Schillo, plant manager of Holcim (Süddeutschland), said “The CapsolEoP (End-of-Pipe) unit’s design, requiring no external steam supply and exhibiting low energy consumption, makes it an attractive option for our Dotternhausen plant.”

If successful, Holcim plans to deploy Capsol’s technology across multiple cement plants globally. This builds on a feasibility study conducted by Aggregate Industries UK, a Holcim subsidiary, for the Cauldon cement plant in Stoke-on-Trent. Testing at Dotternhausen will run for four months, starting in the second quarter of 2025.

Australia: Suvo Strategic Minerals has been offered an opportunity to field test its lower carbon cement made from kaolin in the Victorian government's level crossing removal project (LXRP). This trial aims to evaluate Suvo’s cement formulation, which the company hopes can reduce up to 70% of Portland cement typically used in construction.

The company utilises ‘hydrous’ kaolin from its Pittong operation, located 40km west of Ballarat, Victoria, in producing this cement. The LXRP trial will allow Suvo to demonstrate the feasibility of using their product in real-world infrastructure projects, with help from the government to navigate the commercial and technical approval processes to introduce its cement product to the market.

Germany: Aumund and Holcim have demonstrated an electric linear calcination conveyor (eLCC) at Aumund’s headquarters in Rheinberg, Germany. Initial tests of the eLCC have reportedly demonstrated efficient thermal activation of clay through a combination of radiant heat and material circulation. In 2020, Aumund Fördertechnik teamed up with Holcim for a project focused on the electrical calcination of clay using an Aumund pan conveyor.

The company stated that the eLCC system is fully enclosed and insulated, minimising energy requirements and heat loss, with its compact design allowing for expansion of production capacities. It can operate with electrical heating elements powered by 100% renewable energy sources like wind or solar. The first industrial plant utilising this technology will be constructed in 2025.

Türkiye: Limak Çimento has carried out a month-long test on hydrogen fuel blends at its cement plant in Ankara. The company partnered with France-based Air Liquide for the supply of hydrogen, which was injected into the preheater tower. The pair previously used a 50% hydrogen blend during a test at Limak’s Polatli plant in June 2024, with ‘excellent results’, according to Hydrogen Insight.

Erkam Kocakerim, CEO of Limak Çimento, said "The purpose of this investment is to enable safe and effective use of hydrogen technologies in our cement kilns and to increase the rate of alternative fuel substitution. We aim to operate the kilns in our seven integrated cement plants with a low-carbon fuel mix between 2030 and 2035."

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.