Displaying items by tag: Calcined Clay
Decarbonising the cement sector in the US, March 2024
27 March 2024The 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).
Company | State | Funding | Scale | Method |
Heidelberg Materials US | Indiana | US$500m | Full | CCS |
National Cement | California | US$500m | Full | Alternative fuels, calcined clay, CCS |
Summit Materials | Georgia, Maryland, Texas | US$216m | Demonstration | Calcined clay |
Brimstone Energy | TBD | US$189m | Commercial | Raw material substitution |
Sublime Systems | Massachusetts | US$87m | Commercial | Raw material substitution |
Roanoke Cement | Virginia | US$62m | Demonstration | Calcined clay |
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.
Global: The Green Cement Technology Tracker, launched by the Global Cement and Concrete Association (GCCA) and the Leadership Group for Industry Transition (LeadIT), has expanded its scope to include calcined clay production, a significant step in cement industry decarbonisation. This tool, vital for tracking progress towards net zero emissions, initially focused on various decarbonising technologies and has now broadened to cover calcined clay kilns, which have lower energy requirements and CO2 reduction potential.
LeadIT Head Per Andersson said “In order to empower the industry and policymakers committed to emission reductions, our goal is to provide comprehensive tracking of public announcements of investments in low-carbon cement technologies.”
GCCA’s Cement, Innovation and ESG Director Claude Loréa said “Driving down emissions requires investment in new technologies and production methods and incorporating calcined clay can contribute significantly, making it a valuable strategy for sustainable construction.”
Germany: Heidelberg Materials has secured a patent for a new method for producing Portland composite cement (PCC) using calcined clay and recycled waste cement. GlobalData News has reported that the process involves grinding clay with quartz and feldspar and calcining the clay, before mixing it with the cement. The PCC’s cement content varies from 30% to 80%, while its calcined clay content varies from 10% to 70%.
NeoCem to build €50m clay calcination plant
27 February 2024France: NeoCem plans to build a €50m clay calcination plant at Saint-Maximin, Picardy. The company recently raised €23m in investments in its Series A funding round. The Le Journal des Enterprises newspaper has reported that the Saint-Maximin plant will enter operation in 2025, and will subsequently grow to 200,000t/yr in capacity. NeoCem aims to employ 100 people by 2030.
Head of industrial deployment Guillaume Luu said “To be used in concrete, limestone must be heated for several hours at 1400°C. Our clay-based binder generates CO2 emissions of 120kg/t, compared to almost 1000kg/t of limestone binder, and our technology can transform all types of clays available. The idea is not to open new quarries, but to give a second life to materials already on the surface." He continued “The up-cycling of clays and their transformation into a low-carbon binder addresses several challenges for the construction sector. On the one hand, the reuse of clay waste, and on the other hand, the decarbonisation of the building materials sector.”
Middle East Calcined Clay and Kaolin Group International to build limestone calcined clay cement plant
11 January 2024Oman: Middle East Calcined Clay and Netherlands-based Kaolin Group International plan to build a limestone calcined clay cement plant in Oman. The partners have hired Spain-based turnkey plant engineer IPIAC to supply equipment including its Plug and Clay clay calcination unit. The new plant will produce limestone calcined clay cement with 40% lower CO2 emissions than ordinary Portland cement (OPC), according to the supplier.
IPIAC previously introduced the technology in Cuba and Ivory Coast, and is currently retrofitting it to a clinker line in Angola.
École Polytechnique Fédérale de Lausanne recognised as Energy Transition Changemaker for LC3 limestone calcined clay cement project
19 December 2023Switzerland/UAE: The COP28 UAE Presidency named École Polytechnique Fédérale de Lausanne (EPFL) among its Energy Transition Changemakers in the Heavy Emitting Sectors category. EPFL won the prize for its LC3 limestone calcined clay cement, which replaces 50% of clinker content with calcined kaolinite clay and limestone. LC3 cement reduces CO2 emissions by 40% compared to ordinary Portland cement (OPC), and is a readily available solution that can be scaled worldwide. EPFL noted the special importance of LC3 cement for CO2 reduction efforts in developing countries, and sees it as having the potential to eliminate 500Mt/yr of global CO2 emissions by 2030. In a post to LinkedIn, the LC3 Project said that nine plants around the world currently produce LC3 cement, with a further 20 planned before 2025.
ThyssenKrupp Polysius wins CIMPOR flash activator contract
13 October 2023Ghana: CIMPOR has appointed Germany-based ThyssenKrupp Polysius to build a 1280t/day flash activator for clay. The activator will supply calcined clay for use in the production of cement with a clinker factor as low as 50%. This can reduce the cement’s CO2 emissions by 40% compared with ordinary Portland cement (OPC). The supplier’s contract covers engineering, supply of core equipment and supervision of the project. The equipment includes parts for clay handling, a hammer mill, a flash dryer and preheating and cooling equipment, as well as storage silos. The activator will be natural gas-fired.
Polysius Activated Clay product owner Leo Fit said "Our technology is not only more environmentally friendly, but also creates cost benefits for our customers like CIMPOR. In many regions, limestone is scarce and clinker has to be imported at high cost. At the same time, suitable clay sources are available. The increasing pressure to reduce greenhouse gas emissions is leading cement manufacturers to rethink. They need an alternative that is cost-efficient and at the same time provides high-quality cement. This is exactly what Polysius activated clay offers."
West Africa: Ciments de l'Afrique (CIMAF) plans to produce limestone calcined clay cement (LC3) at cement plants in West Africa. Parent company Omnium des Industries et de la Promotion (OIP) plans to build a calcined clay production facility in Burkina Faso to supply the material. Gulf Oil & Gas News has reported that OIP secured a Euro45m loan from World Bank Group’s International Finance Corporation on 10 October 2023. It will invest Euro32.4m in construction of its upcoming calcined clay production facility and Euro12.6m in
construction of solar power plants for three CIMAF subsidiaries in Burkina Faso, Chad and Mali.
CIMAF CEO Anas Sefrioui said "IFC's green loan provides essential long-term financing for our projects in Africa. Through the green loan structure, we are bringing the best practices in financing decarbonisation initiatives in the region. We look forward to reducing our carbon footprint and replicating these best practices in our African operations.”
Spain: Switzerland-based Synhelion and Cemex España plan to build a new clinker plant near Madrid. The plant will use Synhelion’s synthetic fuel to produce clinker from clay and crushed sand at 1200°C. The fuel consists of a gas produced from green hydrogen and captured CO2, using solar heat. La Tribune de Genève Online News has reported that Synhelion’s thermochemical reactor further helps to capture CO2 emissions from clinker production. A study by the Swiss Federal Institute of Technology Lausanne indicated that this can halve the cost of carbon capture at cement plants, to below Euro85/t.
Heidelberg Materials to invest Euro65m in Bussac-Forêt cement plant calcined clay upgrade
15 May 2023France: Germany-based Heidelberg Materials announced a planned Euro65m upgrade to its Bussac-Forêt cement plant in Charente-Maritime Department on 14 May 2023. The project will involve the installation of systems for the production of calcined clay cement. The producer says that this will enable the 0.8Mt/yr plant to reduce its CO2 emissions by 20%.
Chief sustainability officer Nicola Kimm said “In Bussac-Forêt, we are investing in a technology with great potential. It will allow us to significantly expand the range of low-carbon products. Using calcined clay as a clinker substitute is an important measure to reduce the carbon footprint of cement and concrete. In principle, a CO₂ reduction of up to 40% is possible when substituting cement clinker with calcined clay.”
Heidelberg Materials is already involved in the on-going pilot trial of a 400,000t/yr clay calcination plant in Ghana.