Displaying items by tag: US

US: Holcim US has announced an investment of US$20.5m in its Midwest operations. A key component of the investment is the new 35m-high cement storage dome in Fremont, Nebraska, which will increase its production capacity of ECOPlanet low-carbon cement. The dome has the capacity to store 50,000t of cement. Construction of the dome, which began in 2021, has contributed to local economic development and job creation at the terminal.

In line with the Nebraska Department of Transportation's blended cement requirement, the cement blended and distributed at the terminal incorporates natural pozzolan, a binding agent, to produce a lower carbon product compared to ordinary Portland cement.

US: The Portland Cement Association (PCA) has commended the Connecticut Department of Transportation's approval of Portland limestone cement (PLC), marking its acceptance in all US states and the District of Columbia. PLC, with increased limestone content, maintains traditional Portland cement's efficacy but reduces CO₂ emissions by up to 10%. The US avoided more than 4Mt of CO₂ emissions in 2023 by using PLC and other blended cements. This achievement coincides with growing cement consumption by state transportation departments, fuelled by the Bipartisan Infrastructure Law.

Mike Ireland, president and CEO of PCA, said "This milestone is a huge step forward for sustainable American construction. Switching to PLC promises to save millions of tonnes of CO₂. Using a lower-emission product that meets all the performance requirements of traditional cement means the construction sector can build with durability, safety and sustainability in mind."

US: A research team from Lehigh University has won a three-year, US$2m grant from the Department of Energy's industrial efficiency and decarbonisation office for a project on concrete decarbonisation. The team, including Carlos Romero, director of Lehigh's Energy Research Centre, aims to develop a sustainable concrete binder using calcined clay, reducing emissions associated with Ordinary Portland Cement production. The project collaborates with Buzzi Unicem USA and focuses on processing and testing calcined clay to mimic the properties of conventional cement.

Lehigh's team will explore various low-grade calcined clays, supplied by Buzzi, testing their compressive strength and durability. The goal is to halve the CO₂ emissions of traditional concrete mixes.

Chair of the Department of Civil and Environmental Engineering Shamim Pakzad said "I am excited about the expansion of the research portfolio of CEE departments into this area of greener cement, which opens many opportunities for future research and implementation in industry."

The US Department of Energy (DOE) announced a US$1.6bn investment in the cement sector this week. The funding was part of a total of US$6bn for 33 projects in over 20 states to decarbonise energy-intensive industries also including chemicals and refining, iron and steel, aluminium and metals, food and beverages, glass, process heat applications and pulp and paper. The DOE was keen to link the money to “the President’s Bipartisan Infrastructure Law and Inflation Reduction Act.” Politics is never far away it seems! The projects are part of the Industrial Demonstrations Program, managed by DOE’s Office of Clean Energy Demonstrations (OCED).

Table 1: Summary of US Department of Energy funding announced on March 2024 to decarbonise cement and concrete production

Table 1 above shows the main approaches each of the projects aim to use. The two most expensive ones involve carbon capture and sequestration (CCS) at Heidelberg Materials US’ Mitchell cement plant in Indiana and National Cement’s Lebec plant in California respectively. In a complimentary press release Chris Ward, the CEO of Heidelberg Materials North America, said “This substantial federal funding investment will help create the first full-scale deployment of carbon capture and storage on a cement plant in the US.” The proposed CCS unit at the plant will capture around 2Mt/yr of CO₂ from 2030. If Ward’s forecast is accurate (and no one beats them to it), then Heidelberg Materials will likely have set up the first full-scale CCS units at cement plants in both North America and Europe. This will be a significant achievement. The National Cement project, by contrast, is a mixed bag of approaches to decarbonising cement production that follows the multi-lever approach advocated for in many of the industry net-zero roadmaps. It intends to use agricultural by-products such as pistachio shells, as alternatives fuels to lower the fuel-based emissions, calcined clay to lower the clinker factor and CCS to capture the remaining 950,000t/yr of CO₂ emissions.

The other projects either involve using calcined clay or substituting limestone with calcium silicate. The Summit Materials proposal is noteworthy because it aims to build four clay calcination units in locations in Maryland, Georgia and Texas. None of these appear to be near Summit’s (or Cementos Argos’) cement plants. This suggests that the company may be intending to use calcined clay in ready-mixed concrete production. The Roanoke Cement Company calcined clay project will be baseEuropead at its cement plant in Troutville, Virginia.

The remaining two grant recipients, Brimstone and Sublime Systems, will both test the companies’ different methods of manufacturing cement by using calcium silicate instead of limestone. Brimstone’s method produces ordinary Portland cement (OPC) and supplementary cementitious materials (SCM). The company said in July 2023 that its OPC met the ASTM C150 standards. However, the company has released less information about its actual process. Sublime Systems’ uses an electrolysis approach to create its ASTM C1157-compliant cement. It calls this ‘ambient temperature electrochemical calcination.’

Investment on the same scale of the DOE has also been happening in Europe. In July 2023, for example, the European Commission announced an investment of Euro3.6bn in clean tech projects to be funded from the proceeds of the European Union emissions trading scheme (ETS). This was the third call for large-scale projects following previous announcements of recipients in 2021 and 2022. Euro1.6bn of the third call funding went towards cement and refining projects including five cement and lime projects in Belgium, Croatia, Germany and Greece. The money granted for each of these schemes was in the region of Euro115 - 235m.

Both the US and Europe are throwing serious finance at the cement industry to try and kickstart the various pathways towards net zero. They are also doing it in different ways, with the US aiming to boost its economy by onshoring sustainable industry, and Europe hoping to fund its approach via carbon taxation. Government-driven decarbonisation investment for cement in other large countries and regions around the world appears to be lagging behind the US and Europe but these may spring up as net zero targets are set, roadmaps drawn up and government policy formulated. These places could also benefit from watching what works and does not work elsewhere first. Back in the US and Europe the next tricky part of this process will be bridging the gap between government subsidy and commercial viability.

US: Summit Materials has appointed John Terembula as Senior Director, Grinding Technology. He previously worked for FLSmidth from 1994 to early 2024 in a variety of engineering and then product manager roles for grinding applications. His final position at FLSmidth was as Global Product Line Manager, Vertical Roller Mills. Terembula holds a degree in chemical engineering and materials from Lafayette College and an MBA from Temple University.

US: The US Department of Energy has selected four cement producers to receive funding under the Bipartisan Infrastructure Law and the Inflation Reduction Act.

Heidelberg Materials US secured up to US$500m for its planned 2Mt/yr carbon capture project at the Mitchell cement plant in Indiana. National Cement also received up to US$500m, for its Lebec Net Zero limestone calcined clay cement (LC3) project in California. Summit Materials received up to US$216m for a series of clay calcination projects in Georgia, Maryland and Texas. Lastly, Roanoke Cement will receive up to US$61.7m for an LC3 project at its Troutville cement plant in Virginia.  These projects also involve developing a training, education and certification consortium in the cement sector.

Portland Cement Association (PCA) president and CEO Mike Ireland said "This funding is a welcome acknowledgement from the government that America's cement manufacturers are taking ambitious and significant steps toward reaching carbon neutrality. This will move the needle closer to achieving what industry considers the 'heavyweight' of carbon solutions: carbon capture utilisation and storage (CCUS). Once established nationwide, CCUS will greatly accelerate cement manufacturers' charge toward net zero."

Senior vice president of government affairs Sean O'Neill added “From passage of the Bipartisan Energy Act of 2020 to securing funding through the Inflation Reduction Act and the Infrastructure Investment and Jobs Act, today's announcement is another major milestone in the cement industry's decarbonisation efforts. The PCA is committed to continuing to work with policymakers to ensure the regulatory environment facilitates rather than impedes these and future investments.

US: Alternative cement developer Sublime Systems has entered award negotiations with the US Department of Energy for a grant worth up to US$87m. Gulf Oil & Gas News has reported that Sublime Systems plans to build an electrolysis-based cement plant in Holyoke, Massachusetts. The department’s Office of Clean Energy Demonstrations would provide any eventual funding under the Bipartisan Infrastructure Law and Inflation Reduction Act. Sublime Systems’ plant is one of 33 scalable decarbonisation solutions in energy-intensive industries selected for potential funding.

CEO Leah Ellis said “Access to sufficient capital for industrial-scale demonstrations is the single biggest obstacle preventing breakthrough innovations from reaching the scale humanity needs to combat the climate crisis. The Department of Energy has cleared this obstacle through funding from OCED’s Industrial Demonstrations Program, embracing its unique role in supporting the deployment of the decarbonised technologies of tomorrow. We look forward to collaborating with them on funding our first commercial manufacturing scale-up, which will ship our clean cement while creating meaningful economic opportunities for the surrounding community.”

US: Brimstone is negotiating a US$189m Federal award with the Department of Energy to finance the construction of a new decarbonised cement plant. This plant will produce up to 140,000t/yr of Ordinary Portland Cement and supplementary cementitious materials, reducing CO₂ emissions by 120,000t/yr.

Brimstone's process uses carbon-free calcium silicate rocks, reducing its CO₂ footprint. In July 2023, Brimstone's cement met ASTM C150 standards, confirming the effectiveness of its decarbonised process. The company is preparing to construct a pilot plant near Reno, Nevada.

The Portland Cement Association (PCA) is currently considering changing its name as part of a wider rebranding exercise. As the PCA’s president and CEO Mike Ireland puts it, “Portland cement no longer adequately represents the products PCA member companies manufacture, as they increasingly produce blended cements in today's environmentally conscious marketplace.” The exercise opens up a host of issues about the promotion of cement and concrete and the role of a trade association in the 21st century.

The reason the PCA holds its name is because ordinary Portland cement (OPC) became the most popular type of cement used to make concrete (and other building materials) in the second half of the 19th century. This continued in the 20th century without any issues. So naming a national cement association after the sector’s key product made sense at the time. The parent organisation that became the PCA was formed in 1902 and the PCA proper officially started in 1916 when cement producers met in Chicago and agreed to set up an expanded organisation.

One topic that was less of an issue in 1916, was considering a national cement association in an international context. Or in other words, should a national or regional cement association say where it is from in its name? Many associations do so elsewhere in the world but not all. Cembureau in Europe, the Cement Manufacturers’ Association in India and the Mineral Products Association in the UK for instance are three examples that do not. The PCA’s current name does not indicate where it is based and it has appeared to have coped for over 100 years. Curiously though, most of the suggestions that the PCA has put forward for its potential new name do include ‘America’ in some shape or form. Another connected problem is whether the general public in the US make the assumption that the PCA is a smaller group based in Portland, Oregon!

Mike Ireland points out another dilemma facing the PCA today with the rise in popularity of blended cements. The PCA, for example, worked on supporting the use of Portland Limestone Cement in the 2010s before lots of US producers started making it in the 2020s. To illustrate the scale of the change that this and other initiatives have created, United States Geological Survey (USGS) data shows that shipments of blended cements doubled from 26Mt in 2022 to just under 55Mt 2023. At the same time, shipments of Portland Cement fell by 37% year-on-year to around 52Mt from 83Mt. More blended cements were shipped in the US than OPC in 2023. So the PCA finds itself named after a minority cement product.

The other issue that Ireland touches upon is the environmental perception of cement by the general public and the problems for marketing, branding and advocacy this presents to a trade association. Simply put, it is far easier for the environmental lobby in developed economies to portray cement as ‘bad’ than it is for the cement sector to publicise the many small but incremental changes it has made or the monumental effect that cement and concrete have made upon human society over the last 150 years. Although it may not mean much to the wider public, to whom ‘cement is cement,’ the rise of blended cements in the US has handed the PCA the opportunity to differentiate cement into ‘good’ and ‘bad’ offerings. In this case high CO₂ emitting OPC becomes the old dirty product of the past and blended cements become clean shiny symbols of the future. It follows, therefore, that retaining the name of an old product for one of the biggest cement associations in the world might be considered unhelpful.

In some respects OPC and the PCA have become victims of their own success. Cement built the modern world and has become ubiquitous. So commonplace in most countries, in fact, that people outside of the building industry often fail to realise how crucial the stuff is. The tricky proposition for those marketing cement today is to somehow recognise the historical contribution that it has made to build our world whilst also conveying how it is changing to become more sustainable. Unfortunately for fans of OPC though this may mean dumping it from the name of the PCA.

US: Furno Materials completed an oversubscribed US$6.5m seed funding round on 13 March 2023. Subsequently, the start-up unveiled plans for its Furno Brick carbon-neutral modular cement plant, which can use a variety of gaseous fuels. The plant scales on demand, drastically reducing the barrier to entry for local or small-scale cement production.

Furno CEO Gurinder Nagra said “At Furno, we have the ability to produce ordinary Portland cement now, to adapt to a range of gas-based fuels and materials innovations as they emerge and to meet demand where it exists, while still abiding by a shifting regulatory landscape. Our mission is to go the distance by innovating at the heart of cement production and operating as a complement to other technological developments in the cement space. Our cement far exceeds ASTM International standards, a bare-minimum quality threshold. While most companies tout meeting these standards and stop there, we have continued to refine our process and are on target to surpass the even higher commercial requirements set by significantly-sized customers eager for our solution.”