Greece/Italy: The Hercules international research project, which has 27 partners from 10 countries, has been launched officially at Milan Polytechnic, Italy. Hercules, an acronym for ‘Heroes in Southern Europe to decarbonise industry with CCUS’ will test new solutions in the CO₂ capture, transport, use and storage value chain and transform them into a scalable industrial process. Buzzi Unicem and Titan Group are two of the 27 partners, alongside waste-to-energy players and developers of advanced CO₂ capture equipment. This includes ‘calcium looping’ technology from Finnish Sumitomo SHI FW and cryogenic purification technology from TPI in Italy.

A part of the pure CO₂ flow will be destined for use in production processes. These include the production of new cementitious materials that could replace conventional concrete, as well as uses in the technical gas sector. Hercules will also investigate the transport of CO₂ from the industrial capture sites to geological storage sites at Ravenna (Eni) and Prinos (Energean). The gas will be handled by Air Liquide and Titan Cement.

Germany: Holcim has signed an agreement to acquire FDT Flachdach Technologie (FDT), a leading manufacturer of thermoplastic roofs. FDT has a presence in European markets, with net sales of Euro50m in 2022. Holcim says that, as a technology and sustainability leader in its sector, FDT will complement Holcim’s integrated roofing product range and strengthen the geographical footprint of the business.

With this acquisition, Holcim roofing systems will exceed US$4bn in net sales ahead of schedule. Chief executive officer Jan Jenisch said “By acquiring FDT we are further expanding our Solutions & Products business to become a global leader in roofing systems. Due to its leadership in technology and sustainability, as well as its strong customer relationships, FDT will be a cornerstone of our continued expansion into the most attractive European roofing markets. I am excited to further grow and strengthen FDT’s business and welcome all 180 employees to the Holcim family.”

India: The Competition Commission of India (CCI) has approved a US$684m deal related to Dalmia Cement’s acquisition of cement, clinker and power plants of Jaiprakash Associates Limited (JAL).

Dalmia Cement says that the acquisition - which includes 9.4Mt/yr of cement capacity, 6.7Mt/yr of clinker capacity and 280MW of power generation capacity - will allow it to expand its footprint into the central region and transform into a pan-Indian company. More than half of JAL’s cement capacity is in central India. Dalmia Cement anticipates reaching a cement production capacity of 75Mt/yr by the 2027 fiscal year and, due to other expansion plans, 110 - 130Mt/yr by the 2031 fiscal year.

This latest transaction, once approved by the relevant regulators, will see the complete exit of JAL from the cement business.

India: Ambuja Cements, a subsidiary of Adani Group, has been declared as the 'preferred bidder' for the Uskalvagu limestone block in Odisha. An e-auction was conducted by the state government for the block, situated in Malkangiri district. Adani Group has not disclosed the amount that it bid for the block, but said it covers 547 hectares with estimated limestone resources of about 141Mt.

The company must now obtain the statutory licences and permits related to mining operations to be declared a ‘successful bidder’ and subsequently enter into a ‘Mine Development and Production Agreement (MDPA)’ with Government of Odisha.

US: Martin Marietta Materials posted lower revenue in the fourth quarter of 2022 as a slowdown in the housing market and bad weather in Texas reduced shipments of materials, especially concrete. While the company reported a net income for the fourth quarter of US$184m, a 17% rise year-on-year compared with US$157m in the fourth quarter of 2021, its revenue fell to US$1.48bn from US$1.50bn. This was partly due to a 1.7% fall in building material revenues. Cement shipments fell by 11%, mostly due to wet and cold weather in Texas, though prices rose by 21%. Ready-mixed concrete revenue fell by 35% due to the sale of the company's Colorado and Central Texas ready-mixed concrete business.

Puerto Rico: Cement sales were 46,750t in January 2023, a 3.8% rise year-on-year compared to January 2022. Cement production in the territory came to 31,930t in January 2023, a 58% rise. This means that imports fell to 14,820t, 32% of all cement consumed. In January 2022 there were 24,842t of imports, representing 55% of all cement consumed in Puerto Rico.

Nigeria: Ifeanyi Chukwuma Odii, the People’s Democratic Party’s (PDP) candidate for governor of Ebonyi State, has pledged to revive the Nigeria Cement Factory at Nkalagu if elected in the forthcoming election. Odii said the successive administrations promised to revive the factory but failed to do so. Elections will be held on 11 March 2023.

Odii said, “As a governor, I will make sure the cement factory works, because many have promised to revamp the Nkalagu cement factory, but they failed. They failed because they lack the capacity. They failed because they are not entrepreneurs. I’m going to turn things around in Ebonyi state.”

Kenya: Five cement producers are opposing an increase in import taxes on clinker that has been championed by National Cement owner Narendra Raval Guru. They claim that he has ‘been given the ear’ of the country’s current administration and is using his position as a domestic clinker manufacturer to disadvantage cement companies that grind imported clinker. The company is reportedly seeking an increase on the duty from 10% to 25%.

The five cement companies - Rai Cement, Bamburi Cement, Savannah Cement, Ndovu Cement and Riftcot – argue that this would create an unfair playing field in the local cement sector. The say that two manufacturers, National Cement and Mombasa Cement, would dominate due to their clinker manufacturing plants. Mombasa Cement has not stated a position in the dispute.

Saudi Arabia: Yamama Cement Company recorded net profits after Zakat and tax worth US$68.2m in 2022, a year-on-year increase of 132% from US$41m in 2021. Its revenues for 2022 amounted to US$272m in 2022, up by 39% from US$196m in 2021.

Congratulations to Lafarge France for launching the first calcined clay cement unit in Europe. The subsidiary of Holcim says that the unit, based at the integrated Saint-Pierre-la-Cour cement plant, is the first of its kind on the continent. It is using the company’s proprietary proximA Tech technology and will produce up to 500,000t/yr of cement in its ECOPlanet range. The operation is also powered with biomass alternative fuels and uses a waste recovery system to further drive down overall CO₂ emissions. Once production ramps-up the producer expects that 30% of cement from the Saint-Pierre-la-Cour plant will be from the ECOPlanet range by 2024.

The investment at Saint-Pierre-la-Cour was Euro40m. Holcim is also producing calcined clay cement at its La Malle plant in France. It received an investment of Euro6m in 2022 to produce low-carbon cements. Together, both plants are aiming to produce over 2Mt/yr of calcined clay cement by 2024. As is usual for these kinds of projects, the French government partly funded the clay calcination unit at Saint-Pierre-la-Cour as part of the ‘France Relance’ scheme investing in large-scale decarbonisation and energy efficiency initiatives.

Calcined clay cements in Europe aren’t exactly new, but Holcim’s new unit in France does appear to be the first full-scale line located at a cement plant. Research by OneStone Consulting, for example, reckons that the first flash activated clay unit expressly set up to supply the cement sector was commissioned in 1995 in Toulouse, France. More recently, Hoffmann Green Cement inaugurated its 50,000t/yr pilot plant at Bournezeau in France in 2018. This site produces cements made from flash calcined clay and blast furnace slag, although it is unclear how demand for the different products varies. A new 0.25Mt/yr plant in the Vendée department was scheduled for commissioning in the second half of 2022. Another 0.25Mt/yr plant in Dunkirk is expected to be commissioned in the second half of 2024.

Cementir Group launched its calcined clay cement product FUTURECEM in Denmark in 2021 with production via a pilot plant. It then extended this to the Benelux and French cement markets in 2022. As part of its industrial plan for 2021 - 2023 it was planning to build a clay calcination unit to support the growth of FutureCem. FLSmidth revealed in June 2021 that it had won a contract to build a 400t/day clay calcination unit for Vicat’s Xeuilley integrated cement plant. The deal was worth around Euro27m and commissioning is scheduled for 2023.

Firstly, it is interesting to see a focus on France for some of the projects above. The presence of Lafarge’s technical centre in Lyon may explain the interest for that company. However, Hoffmann Green Cement and Vicat are also active in the field. It is worth noting that France also holds a busy secondary cementitious material market with standalone operators including Ecocem, Cem’In’Eu and Hoffmann Green Cement. Secondly, despite the early start, clay calcination for cement is currently more active outside of Europe. In Africa, for example, there is at least one live full production line and a number of other projects on the way. Various other pilots and projects are also happening elsewhere around the world, often in conjunction with the limestone calcined clay cement (LC3) initiative. Where calcined clay cement production in Europe goes from here is uncertain at present as it is one solution among many for lower carbon cement products in the future. Yet, the projects that have made it so far to the commercial scale will be watched closely by the companies that have invested in them - and their competitors.