Pakistan: A court has ordered a report by the Environmental Protection Agency (EPA) into alleged breaches of emissions rules at Kohat Cement's Kohat Cement plant in Babri Banda, Khyber Pakhtunkhwa. The Dawn newspaper has reported that alleged dust and chemical emissions from the plant have contributed to a local rise in cases of cancer, asthma and lung diseases, according to complainants.

Residents have filed a petition for contempt proceedings against the EPA and Kohat Cement, as well as local and provincial government authorities. The court previously ordered the EPA to monitor Kohat Cement's emissions in 2018. At that time, it also instructed Kohat Cement to operate its electrostatic precipitators system at all times that cement is being produced. Local residents claim that the plant has continually failed to operate the system.

India: JK Cement has announced a planned investment of US$60.6m in construction of a new 2.5Mt/yr grinding plant at Prayagraj, Uttar Pradesh. Asian News International has reported that the producer hopes to strengthen its presence in Eastern India. The project increases JK Cement's total investments in Uttar Pradesh to US$145m. It previously inaugurated its 2Mt/yr Hamirpur grinding plant in the state in October 2022. It also operates a 1.5Mt/yr grinding plant at Aligarh.

JK Cement's deputy managing director and CEO Madhavkrishna Singhania said "We are proud to be a part of this dynamic state that not only offers us a geographic advantage but also gives a plethora of opportunities for investment and expansion. With its favourable business environment, abundant resources, and highly skilled workforce, Uttar Pradesh is undoubtedly an ideal location for our expansion plans."

Cement 2 Zero (C2Z) has officially launched in the UK this week. The project is an industrial scale pilot of the Cambridge Electric Cement (CEC) process. The Materials Processing Institute will lead on this stage with two-year funding of around Euro7m provided by UK Research and Innovation (UKRI). Partners include the University of Cambridge, Atkins, Balfour Beatty, Brewster Brothers, Celsa Group, Day Aggregates and Tarmac.

CEC’s method uses recycled concrete paste in place of lime-flux in steel recycling. Slag is formed as the steel melts and this is then used in place of clinker to make more cement. This way of making cement cuts out the decarbonisation of limestone step from conventional clinker production. If renewably-sourced electricity is used to power the heating and grinding parts of manufacture, then cement production in this way could potentially cut out most of its CO₂ emissions. The first phase of trial melts by C2Z will be conducted by the Materials Processing Institute using a 250kg induction furnace and this will be scaled up to 6t in an electric arc furnace (EAF). Later, industrial scale melts will be tested in Celsa Steel's EAF in Cardiff, Wales.

CEC is taking a similar approach to HeidelbergCement with its research into using recycled concrete paste. However, HeidelbergCement says it is using the paste to help capture CO₂ in an enforced carbonation step it is testing at cement plants. It too though wants to create a secondary cementitious material (SCM) afterwards. There are also links here to construction and demolition waste and electric cement kilns as covered by Global Cement Weekly previously. The latter is different with regards to what CEC is doing because it is recycling concrete waste to produce an SCM (slag) rather than using an electrically powered kiln to make clinker from limestone. Coolbrook, VTT and the like have had to build electric kilns effectively from scratch or adapt technology from elsewhere for their approaches whilst CEC appears to be about to use existing EAFs in its industrial scale pilot.

Figure 1: Projection of how the Cambridge Electric Cement production process could be used at scale in the UK. Source: UK FIRES. Click to view larger version.

CEC’s forecast of how its process could be used at scale in the UK can be seen above in Figure 1. If the majority of the country’s steel scrap was recycled in this fashion each year then 2.4Mt/yr of CEC cement could be produced. This would represent a quarter of the c10Mt of cement sales reported by the MPA in 2021. Assuming the EAFs were powered by renewables then this could reduce the cement sector’s CO₂ emissions significantly. Although it would still leave the industry looking for other decarbonisation routes for the other three-quarters of cement demand.

C2Z and CEC offer a novel spin on cement production by recycling concrete waste, using an electrical heating step and dodging the process emissions associated with normal ordinary Portland cement (OPC) clinker production. If it did progress to a commercial stage then it would see a continued relationship between steel and cement producers. Currently this is mainly centered around iron and steel slag usage as a SCM. One point of interest here would be how much higher levels of steel recycling and a process like CEC being used regularly would affect existing slag usage as an SCM. It doesn’t look like CEC could solve the cement sector’s CO₂ emission problem all on its own but it could certainly make a difference if it progressed to a commercial stage. As ever with cement sector decarbonisation there appear to be a range of options available to producers.

China: West China Cement has appointed Cao Jianshun as its chief executive officer (CEO) and as an executive director. He succeeds Ma Weiping, who has resigned for personal reasons. Cao’s appointment is for one year with the option for re-election.

Cao, aged 50 years, has worked in the cement sector since the early 1990s. He joined Yaobai Special Cement Group in 1994 and eventually became the general manager in the Ankang region of Yaobai Group from 2013 to 2015. He was the general manager of Chzhungtsai Mohir Cement from 2016 to 2018 and vice president of International Cement Investment Management Company until early 2023. He holds a bachelor’s degree in economics management from Central Party School of the Shaanxi Provincial Committee and a master’s degree in business administration from Northwest University in China.

India: Grasim Industries is preparing to appoint Ananya Birla, and Aryaman Vikram Birla as directors. The pair are the children of company chair KM Birla, who is also the chair of the parent company, Aditya Birla. Both companies are parent organisations to UltraTech Cement.

Ananya Birla is a musician and a businesswoman. She released her first single ‘Livin the Life’ in 2016 after signing with Universal Music India. She also set up her first company Svatantra Microfin, a microfinance institution, in 2012.

Aryaman Vikram Birla is a former professional cricketer who played for the Rajasthan Royals in the Indian Premier League. His work with Aditya Birla has included helping to steer the group’s TMRW venture in the fashion and lifestyle sectors. He has also invested in the hospitality business and worked with the group’s venture capital fund, Aditya Birla Ventures.

The board of Grasim Industries has also appointed Yezdi Piroj Dandiwala as an independent director. Dandiwala is a corporate lawyer. He is a partner at Mulla & Mulla and Craigie Blunt & Caroe, Advocates & Solicitors. He holds experience in corporate and commercial transactions.

All of these appointments are subject to approval by the board.

Australia: Boral recorded sales of US$1.17bn during the first half of its 2023 financial year, up by 12% year-on-year from US$1.05bn during the first half of its 2022 financial year. Cement sales were US$128m, 11% of group sales. The producer’s net profit fell by 91% year-on-year to US$62.5m from US$715m.

During the half, Boral’s subsidiary Geelong Cement commissioned a new 0.8Mt/yr grinding unit at its 0.6Mt/yr Waurn Ponds grinding plant in Victoria. The group also upgraded the chlorine bypass system at its Berrima cement plant in New South Wales to support increased alternative fuel (AF) co-processing. Throughout 2022, Boral substituted 15% AF into its fuel mix.

India: Ramco Cements recorded revenues of US$674m during the first nine months of its 2023 financial year, up by 33% year-on-year from US$509m in the corresponding period of the 2022 financial year. Costs rose, including a 45% rise in the company’s raw material costs to US$110m from US$76m. This precipitated a 75% decline in the producer’s net profit, to US$23m from US$93.1m.

UK: Cambridge Electric Cement (CEC) has launched the two-year trial of its Cement 2 Zero project, aimed at scaling up production of its net zero-CO₂, demolition waste-based alternative cement. It aims to produce 20t of the material for use in a low-impact construction project. CEC’s method, developed at the University of Cambridge, is based on the conversion of demolition waste into a slag-forming material within a steel furnace.

Developer Julian Allwood said “By combining steel and cement recycling in a single process powered by renewable electricity, we could supplement the global supply of the basic construction materials to support the infrastructure of a zero emissions world and to enable economic development where it is most needed.”

India: Amplus Solar has secured a contract with JK Lakshmi Cement for construction of a 56MW solar power plant at the producer’s 1.7Mt/yr Durg cement plant in Chhattisgarh. The producer expects to eliminate 73,000t/yr of CO₂ emissions as a result.

JK Lakshmi Cement’s president Arun Shukla said "We support the country's vision to achieve net zero emissions by 2070. We have taken multiple steps to reduce both direct and indirect carbon emissions. Last month, for the first time in India, we deployed liquefied natural gas (LNG) trucks to transport raw material. Now, with the switch to solar energy at our Durg plant, nearly 80% of the plant’s energy requirements will be met renewably.”

Amplus Energy previously partnered with UltraTech Cement for a 50MW solar installation at one of its cement plants in 2019.

Sri Lanka: Tokyo Cement recorded sales of US$74.8m during the first nine months of the 2023 financial year, up by 25% year-on-year. Its cost of sales dropped by 2% to US$49.7m, while its profit for the period rose by 60% to US$2.35m.