Displaying items by tag: Alternative raw materials

UK: Breedon Group, together with Australia-based First Graphene, Morgan Sindall Construction & Infrastructure and the University of Manchester, is developing a new reduced-CO₂ graphene-enhanced cement. The consortium is currently formulating the cement using varying doses of First Graphene’s PureGRAPH graphene-enhanced grinding aid. The project received a research grant from the UK government earlier in 2022. First Graphene says that the study involves one of the largest commercial trials of its kind to date globally. It is simultaneously collaborating on another similar trial with a Europe-based speciality chemicals producer.

On 29 September 2022, First Graphene launched its latest range of graphene-enhanced cement grinding aids and concrete additives. These join recent launches PureGRAPH AM, an admixture developed in collaboration with South Africa-based Nanoproof/Glade Chemicals, and HexMortar, a dry mortar mix which will be distributed by New Zealand-based GtM Action.

First Graphene says that its cement and concrete segment’s order pipeline totals US$113m in value. Managing director and CEO Michael Bell said “It is pleasing to see our efforts, and those of our collaboration partners, coming to fruition at a commercial scale. One of the primary drivers for the adoption of graphene solutions in this segment is the reduction of CO₂ emissions. We’re seeing considerable benefits both in the immediate reductions that can be achieved through the use of graphene-enhanced grinding aids, as well as the potential reductions in concrete usage because of the enhanced physical properties these products provide.” Bell concluded “Working with industry-focused partners such as Nanoproof/Glade Chemicals, GtM Action, Breedon Cement and Fosroc opens the way to an estimated addressable market of more than 12,000t of PureGRAPH across the medium to long term.”

UK: Innovative Ash Solutions, a joint venture of Levenseat and Organic Innovative Solutions, has launched a new air pollution control residue (APCR)-based supplementary cementitious material (SCM). The supplier produces the material at its Lanarkshire treatment facility using APCR local from municipal solid waste (MSW) and wood biomass incinerators. Innovative Ash Solutions has received planning permission for a 54,000t/yr industrial-scale APCR-based SCM plant, and plans to establish a total of three plants in the UK, one of which will reach a capacity of 500,000t/yr. It has also signed an exclusive licensing agreement with an Australia-based importer for the material.

The SCM is designed to replace pulverised fly ash (PFA), of which the UK imported 325,000t in 2019, more than four times its 2012 import volumes of 76,000t.

Innovative Ash Solutions director Robert Gren said “We are excited to bring this new product to market. Innovative Ash Solutions is the first and, so far, the only company in the UK to have achieved ‘End of Waste’ accreditation for a PFA replacement for this type of use. Our research shows there is potential to produce more than 500,000t/yr of PFA replacement from UK APCRs every year, which would reduce the need for importing materials and support the decarbonisation of cement and concrete products.”

Algeria: Lafarge Algeria has launched Chamil cement, a 40% reduced-CO₂ cement, which contains locally sourced clay and ferrous materials. The producer developed Chamil cement based on technology from the Rouiba Construction Development Laboratory.

Lafarge Algeria aims to achieve export volumes of 3Mt across its product range in 2022.

US: A team from Washington State University (WSU) and Pacific Northwest National Laboratory has successfully used waste crustacean shells in the production of concrete. ZME Science News has reported that the materials consist of calcium carbonate and 20 – 30% chitin, a nanoparticle biopolymer. When used as an additive in concrete production, the shells increase the set product’s compressive strength by 12% and its flexural strength by 40%. The team is now developing a methodology for the industrial-scale production of shell-based additives.

WSU researcher Professor Michael Wolcott said “Those are very significant numbers. If you can reduce the amount that you use and get the same mechanical function or structural function and double its lifetime, then you’re able to significantly reduce the carbon emissions of the built environment.”

US: Calucem, part of Cementos Molins, plans to establish a new calcium aluminate cement plant in New Orleans, Louisiana. The company will invest US$35m in the project and expects to commission the plant in mid-late 2023. It expects to create 70 new direct jobs and a total of 228 new jobs locally.

Calucem president and chief executive officer Yuri Bouwhuis said “Calucem is taking on a new investment that will support our growth and diversification in the US and ensure that we continue to offer high-value products to our global customers. Our choice of Louisiana for our first all-new manufacturing project in the US is due to the availability of strategic raw materials such as limestone and natural gas, access to waterways and skilled labour and the long history of using speciality cement products in the US.”

US: National Cement Company of Alabama has reported that the new kiln line at its Ragland cement plant will reduce the plant’s CO₂ emissions by 40%. Its energy consumption will also fall by 30% as a result of the upgrade. The new line includes a 78m-high homogenisation silo, vertical crusher, five-stage preheater and automated clay storage system. AF used in the kiln will include waste tyres, woodchip and sawdust. The new kiln will help in the Ragland cement plant’s transition to 100% Portland limestone cement (PLC) production by 2023, further diminishing its carbon footprint.

Vicat CEO Guy Sidos said "Our ambition is to use AF in all our cement plants around the world. In addition to eliminating fossil fuel energy and replacing it with recycled regional waste, our investments contribute directly to local development. We are proud of the modernisation and transformation of our Ragland site, which was our very first acquisition outside France in 1974."

Ecuador: Holcim Ecuador has launched its new portfolio of ECOPlanet reduced CO₂ cements. The products bear the new green and blue branding of the Holcim group.

CEO Dolores Prado said that the company began its green transition with the September 2019 carbon neutral certification of its Agrovial, Base Vial and Maestro cements.

UK: Aggregate Industries and Coomtech have partnered to develop low-energy kinetic drying technology for pulverised fuel ash (PFA) from power plant. The partnership will see Aggregate Industries use Coomtech’s kinetic dryers in its PFA processing, as part of its effort towards increasing the volume of waste materials incorporated in its products to 3Mt/yr from 1.5Mt/yr by 2025. The project has attracted funding from the UK government Department of Business, Energy and Industrial Strategy (BEIS).

Chief commercial officer Chris Every said “We’re delighted to have the support of Aggregate Industries in this grant project. Coomtech is especially pleased to have the business’ ongoing technical and commercial input to the project operation and analysis of performance. In addition, the opportunity to work together with a brand that is leading the way in creating new materials that will prove fundamental to the future of the construction sector and meet net zero objectives.” Every continued “The added benefit of our new drying technology is its flexibility - providing the potential to dry a wide range of materials being considered to aid the greening of the cement industry, including limestone, ground blast furnace slag (GBFS), natural pozzolans and other crushed and milled minerals that can offer an activated character to combine in cement and concrete mixes.”

Switzerland: Hoffmann Green Cement Technologies has launched a new joint venture with a Switzerland-based construction industry partner. Hoffmann Green Cement Technologies will hold a minority stake in the new subsidiary, which will produce its reduced-CO₂ clinkerless cement at an upcoming plant. The producer says that the unit will apply the vertical production model of its existing H2 plant in France.

Co-founders of Hoffmann Green Cement Technologies Julien Blanchard and David Hoffmann said "After signing our first contract outside France more than a year ago, we are proud to accelerate our international development through a licensing model for Hoffmann Green technologies and processes. The opening of this first subsidiary in Switzerland proves the attractiveness of our carbon-free solution without clinker outside our borders, and constitutes a structuring step in the development of Hoffmann Green."

India: Three new Indian concrete companies have separately secured agreements for the use of Finland-based Betolar’s Geoprime alkali-activated slag and fly ash additive. Reuters News has reported that the companies are Balaiji Cement Products, Shiv Tiles and SNEH Precast. Engineering company Godrej & Boyce has also signed a letter of intent with the supplier for pilot production of concrete blocks, paving slabs and other elements.

Betolar expects producers to achieve global concrete production volumes of 250,000t/yr of concrete containing Geoprime by 2023.