Displaying items by tag: Cimpor
A short look at low carbon cement and concrete
01 April 2020Cement and concrete products with sustainability credentials have increased in recent years as societies start to demand decarbonisation. In spite of the recent drop in the European Union (EU) Emissions Trading Scheme (ETS) price, there has been a trend in recent years in the construction industry towards offerings with better environmental credentials. Indeed, this week’s position paper from Cembureau on a carbon border mechanism concerns directly the growth of these kinds of products within Europe. Typically, the higher profile projects have been slag cement or concrete implementations such as Hanson’s use of its Regen cement substitute in a London sewer project or David Ball Group’s Cemfree concrete in a road project also in the UK. In this short review we’ll take a selective look at a few of the so-called low carbon cement and concrete products currently available.
Table 1: Some examples of methods to reduce embodied CO2 in cement and concrete. Note - the product examples are selective. In some cases many other products are available.
Material | Type | Method | Product examples |
Cement | SCM cement | Lower clinker factor | Many products |
Cement | Limestone calcined clay cement | Lower clinker factor | LC3, FutureCem, Polysius activated clay, H-EVA |
Cement | Calcium silicate cement | Reduced process emissions | Solidia, Celitement |
Cement | Recycled concrete fines | Reduced lifecycle emissions | Susteno |
Cement | Geopolymer cement | Reduced process emissions | Vertua |
Cement | Calcium sulphoaluminate cements | Reduced process emissions | Many products |
Concrete | CO2 curing/mineralisation | Uses CO2 and reduces water usage | Solidia, CarbonCure Technologies |
Concrete | Recycled concrete coarse | Reduced lifecycle emissions | Evopact, EcoCrete, FastCarb |
Concrete | SCM concrete | Uses less or no cement | Cemfree, Carbicrete, Regen |
Concrete | Uses less cement in mix | Uses less cement | |
Concrete | Admixtures | Uses less cement | |
Concrete | Locally sourced aggregate / better supply chain logistics | Reduced transport emissions | |
Concrete | Geopolymer concrete | Uses no cement | E-Crete |
Concrete | Graphene concrete | Uses less cement | Concrene |
Concrete | Carbon offsetting | Separate offsetting scheme | Vertua |
Looking at cement first, the easiest way for many producers to bring a lower carbon product to market has been to promote cements made using secondary cementitious materials (SCM) such as granulated blast furnace slag or fly ash. These types of cements have a long history, typically in specialist applications and/or in relation to ease of supply. For example, cement producers in eastern India often manufacture slag cements owing to the number of local steel plants. However, cement producers have more recently started to publicise their environmental credentials as they reduce the clinker factor of the final product. Alongside this though, in Europe especially, a number of so-called low carbon cement producers have appeared on the scene such as EcoCem and Hoffman Green Technologies. These newer producers tend to offer SCM cement products or other low carbon ones built around a grinding model. It is likely that their businesses have benefitted from tightening EU environmental legislation. How far cement producers can pivot to SCM cement products is contentious given that slag and fly ash are finite byproducts of other industries that are also under pressure to decarbonise. Although it should be noted that other SCMs such as pozzolans exist.
As will be seen below a few of the methods to reduce embodied CO2 in cement and concrete can be used in both materials. SCMs are no exception and hold a long history in concrete usage. As mentioned above David Ball Group sells Cemfree a concrete product that contains no cement. Harsco Environmental, a minerals management company, invested US$3m into Carbicrete, a technology start-up working on a cement-free concrete, in late 2019.
Limestone calcined clay cements are the next set of products that are starting to make an appearance through the work of the Swiss-government backed LC3 project, more commercial offerings like FutureCem from Cementir and H-EVA from Hoffman Green Technologies and today’s announcement about ThyssenKrupp’s plans to fit the Kribi cement plant in Cameroon with its Polysius activated clay system. They too, like SCM cements, reduce the clinker factor of the cement. The downside is that, as in the name, the clay element needs to be calcined requiring capital investment, although LC3 make a strong case in their literature about how fast these costs can be recouped in a variety of scenarios.
Calcium silicate cements offer reduced process emissions by decreasing the lime content of the clinker lowering the amount of CO2 released and bringing down the temperature required in the kiln to make the clinker. Solidia offers its calcium silicate cement as part of a two-part system with a CO2 cured concrete. In the US LafargeHolcim used Solidia’s product in a commercial project in mid-2019 at a New Jersey paver and block plant. Solidia’s second core technology is using CO2 to cure concrete and reducing water usage. They are not alone here as Canada’s CarbonCure Technologies uses CO2 in a similar way with their technology. In their case they focus more on CO2 mineralisation. In Germany, Schwenk Zement backed the Celitement project, which developed a hydraulic calcium hydro silicate based product that does not use CO2 curing. Celitement has since become part of Schwenk Zement.
Solidia isn’t the only company looking at two complementary technologies along the cement-concrete production chain. A number of companies are looking at recycling concrete and demolition waste. Generally this splits into coarse waste that is used as an aggregate substitute in concrete and fine waste that is used to make cement. LafargeHolcim has Evopact for the coarse waste and Susteno for the fine. HeidelbergCement has EcoCrete for the coarse and is researching the use of fines. Closing the loop for heavy building material producers definitely seems like the way to go at the moment and this view is reinforced by the involvement of the two largest multinational producers.
Of the rest of the other low carbon cement methods detailed in table 1 these cover other non-Ordinary Portland Cement (OPC) such as geopolymer and calcium sulphoaluminate cements. The former are a type of alkali activated binder and generally lack common standards. The latter are similar to slag cements in that they are established specialist products with lower CO2 emissions than OPC.
With concrete when trying to make a low carbon product the first choice is whether to choose a low-carbon cement as the binder or even not to use cement at all in the case of Regen or Cemfree. From here the next step is to simply use less cement in a concrete mixture. There are a number of ways to do this from optimising aggregate gradation, following performance specifications more closely, using strength tests like maturity methods and generally adhering to quality control protocols better to deliver more consistency. Read the Mineral Production Association (MPA) publication Specifying Sustainable Concrete for more detail on this. Using concrete admixtures can also help make concrete more sustainable by improving quality and performance at construction sites through the use of plasticisers and accelerators, by decreasing embodied carbon through the use of water reducers and by improving the whole life performance of concretes. The use of locally-sourced aggregates is also worth noting here since it can reduce associated transport CO2 emissions.
More novel methods of reducing embodied CO2 emissions in concrete include the use of geopolymer concrete in the case of Zeobond Group’s E-Crete or adding graphene as Concrene does. Like geopolymer cements, geopolymer concretes are relatively new and lack common standards. Products like Concrene, meanwhile, remain currently at the startup level. Finally, if all else fails, offsetting the CO2 released by a cement or concrete product is always an option. This is what Cemex has done with its Vertua Ultra Zero product. The first 70% reduction in embodied CO2 is gained through the use of geopolymer cement. Then the remaining 30% reduction is achieved through a carbon offsetting scheme via a carbon neutral certification verified by the Carbon Trust.
As can be seen, a variety of methods exist for cement and concrete producers to reduce the embodied CO2 of their products and call them ‘low-carbon.’ For the moment most remain in the ‘novelty section’ but as legislators promote and specifiers look for sustainable construction they continue to become more mainstream. What has been interesting to note from this short study is that some companies are looking at multiple solutions along the production and supply chain whilst others are concentrating on single ones. The companies looking at multiple methods range from the biggest building material producers like LafargeHolcim and HeidelbergCement to smaller newer ones like Solidia and Hoffman Green Technologies. Also of note is that many of these products have existed already in various forms for a long time like SCM cements and concretes or the many ways concretes can be made more sustainable through much simpler ways such as changing aggregate sourcing or working more efficiently. In many cases once markets receive sufficient stimulus it seems likely that low carbon cement and concrete products will proliferate.
Global Cement is researching a market report on low carbon cement and concrete. If readers have any comments to make please contact us at This email address is being protected from spambots. You need JavaScript enabled to view it.
Cameroon: Germany-based Thyssenkrupp Industrial Solutions has won an engineering, procurement, construction and commissioning (EPCC) contract with Netherlands-based Cimpor Global Holdings for the installation of a clay calcination plant at its new integrated Kribi cement plant in the Port of Kribi in South Cameroon. The system calcines clay at just 800°C, which can then replace clinker at a ratio of one to two, lowering the finished cement’s clinker factor by up to 33%.
ThyssenKrupp says that use of the system, the first of its kind in Cameroon and second at a Cimpor Global Holdings cement plant, will help cut CO2 emissions by 120,000t/yr, corresponding to a reduction of 40%.
OYAK to invest in pozzolan extraction in Cape Verde
12 February 2020Cape Verde: Turkey’s OYAK is planning to invest in pozzolan extraction following a meeting between OYAK's Cement Concrete Paper Group chairman Suat Çalbiyik and prime minister Ulisses Correia e Silva. Mining activity has remained muted since Cabocem, an Italian company, closed in 2013, according to Sapo. OYAK has operations in the country via Portugal’s Cimpor, which it acquired in 2019.
Update on Turkey
20 February 2019One of the more interesting news stories in recent weeks was the completion of Oyak Cement’s acquisition of Cimpor. Previously we focused on the connection to Taiwan Cement (GCW377). Around the same time that the Oyak-Cimpor deal was announced in late October 2018 the Taiwanese company bought a 40% stake in the Turkish cement producer for around US$640m. However, as the world’s sixth largest cement producer by cement production capacity, Turkey is always a country worth keeping an eye on for both the Oyak deal and the wider industry.
Graph 1: Turkish domestic cement sales, 2007 - 2017. Source: Turkish Cement Manufacturers' Association (TÇMB).
Graph 2: Turkish cement and clinker exports, 2007 - 2017. Source: Turkish Cement Manufacturers' Association (TÇMB).
Data from the Turkish Cement Manufacturers' Association (TÇMB) shows that domestic cement sales have been rising steadily to 72.2Mt in 2017 after a blip in the late 2000s. So far 2018 has not kept the trend, with a drop of 2.01% year-on-year to 50.8Mt for the first nine months of 2018 from 51.8Mt in the same period in 2017. Turkey is also a major exporter of cement so these are the other figures to watch. After hitting a high of nearly 18Mt in 2010 they dropped for five years before rising again. The ratio of clinker in the exports total has also been growing recently. LIke domestic production ,exports were down at the nine month mark in 2018, by 1.8% to 9.9Mt, but the ratio of clinker exports has continued to grow.
Given the focus on exports for the Turkish market Oyak Cement’s international purchases via Cimpor widen its options. The deal covered assets in Portugal and Cape Verde including three integrated cement plants and two mills, with a total cement production capacity of 9.1Mt/yr. It’s not clear yet how Oyak wants to run its new foreign plants but it might be tempting to focus on a grinding model abroad using imported Turkish clinker depending on running costs. Back home in Turkey Oyak Cement is the largest local producer with a 15% market share. It operates seven integrated plants with a production capacity of 16Mt/yr according to Global Cement Directory 2019 data.
As for the other major companies, Akçansa, a joint venture of Sabancı Holding and HeidelbergCement, saw its sales rise by 4% to US$277m in 2017. Its sales volumes of cement and clinker rose but its exports fell by 13% to 1.3Mt. In its third quarter report for 2018 HeidelbergCement highlighted issues with the local economy such as high inflation, a currency crisis and a resulting loss of confidence.Sabancı also holds a majority stake in the other major producer, Çimsa Çimento. At the six month mark Çimsa Çimento reported that its sales grew by 35% year-on-year to US$162m and its net profit increased by 55% to US$23.2m. Notably, Çimsa also runs a number of international terminals in Germany, Italy, Spain, the disputed Turkish Republic of Northern Cyprus and Russia, with distribution operations in Romania and the US also.
As mentioned above the general Turkish economy faced problems in 2018 when the value of the Turkish Lira dropped sharply in mid-2018 and interest rates soared. This led to a reduction in industrial output. On the cement side this is likely visible in falling local sales in 2018 and the switch to exports. Raw materials have also risen in this environment leading the president of the TÇMB to reassure the construction industry that the price of cement would not rise too sharply in 2019. Some of the eye-watering input hikes that he cited included a 76% rise in electricity costs, a 182% rise in the price of coal and a 170% rise in the price of petcoke. With this kind of backdrop the 2018 annual results for the Turkish producers may not make easy reading. Yet this also may explain why Oyak Cement moved overseas and allowed Taiwan Cement to invest in it when it did. Looking more widely it seems exports are likely to grow in the near future.
Oyak Cement completes purchase of Cimpor
21 January 2019Portugal: Turkey’s Oyak Cement has completed it acquisition of Cimpor. The completion of the transaction follows the approval of the European Commission in mid-January 2019, according to the Expresso newspaper. The purchase includes three integrated cement plants, two grinding plants, 20 quarries and 46 ready-mix concrete plants in Portugal and Cape Verde.
European Commission approves Oyak acquisition of Cimpor Portugal
11 January 2019Belgium: The European Commission has approved the acquisition of sole control over Cimpor Portugal by Turkey’s Oyak. The commission ruled that there are no competition concerns between the cement producers given that they operate in different geographic markets. The deal was announced in late October 2018.
Proença de Carvalho resigns as president of Cimpor
07 November 2018Portugal: Proença de Carvalho has resigned as the president of Cimpor. Three independent directors of the cement producer have also resigned, according to the Jornal de Negócios. The departures follow OYAK Cement’s acquisition of Cimpor’s assets in Portugal and Cape Verde from Brazil’s InterCement.
Taiwan Cement heads to Turkey
31 October 2018The long expected move by a Chinese cement producer outside of East Asia took a step closer this week with the news that Taiwan Cement is negotiating with OYAK Cement over a joint venture in Turkey. Taiwan Cement says it is prepared to invest up to US$1.1bn in the subsidiary that will operate OYAK Cement’s business in Turkey. In its press release Taiwan Cement said, bluntly, that government peak production limits and market saturation in China had forced it to expand internationally.
This isn’t Taiwan Cement’s first flirtation with a Turkish cement producer. Back in June 2018 local press reported that it had signed a memorandum of understanding and a confidentiality clause with Sanko Holding about potential investment. However, the timing is curious this time because almost simultaneously Brazil’s InterCement announced that it was selling its operations in Portugal and Cape Verde to OYAK Cement. This sale alone deserves more attention given that it is the third by a Brazilian producer since September 2018 but that’s a discussion for another week. Back on OYAK Cement, whilst nothing is certain at this stage, a pledge of US$1.1bn from a foreign investor would certainly come in handy helping to raise the money at the Turkish company.
Whoever, if anybody, Taiwan Cement ends up pairing up with, the level of the investment suggests a multi-plant move. Indeed, the suggested OYAK Cement deal involves a 40% share in 13 integrated cement plants in Turkey with a production capacity of around 12Mt/yr or a 16% local market share. This isn’t far off the regular international price of US$200/t for integrated production capacity.
For a Chinese company to choose Turkey is resonant historically because it is towards the western end of the Silk Road. Marco Polo, for example, travelled from Venice to China via the territory of modern-day Turkey. The modern day version, the Belt and Road Initiative, seeks to evoke this trade route as China attempts to expand internationally.
Pertinent to the cement industry, both China and Turkey are both major exporters. Turkey is the bigger exporter by proportion of production, at 10% in 2017. Both countries were in the top five exporters to the US in 2017 with 2Mt from China and 1.4Mt from Turkey. The commonly accepted wisdom is that the Chinese industry faces major hurdles to exporting its overcapacity. Yet its production base is so large, 15 times larger than Turkey’s, that the little clinker and cement it has the infrastructure to export is still significant. It’s interesting that a major Chinese producer seeking to overcome structural and market obstacles to its expansion at home is targeting a major exporting nation. Typically, when a foreign cement producer buys local companies, one strategy is to use the new assets to ‘naturalise’ its clinker imports as ‘local’ product. Given Turkey’s already large export market this seems unlikely in this case.
The highly public nature of Taiwan Cement’s latest attempt to strike it lucky in Turkey smacks of bolstering investor confidence as much as closing the deal. Normally, this kind of thing gets announced once everything has been agreed, possibly bar the regulatory approval. Putting some money up front may make Taiwan Cement seem serious but OYAK Cement also stands to benefit from its acquisition of the former-Cimpor assets in Portugal and Cape Verde, since it gives it a toehold within the European Union (EU). This one could go either way.
Taiwan/Turkey: Taiwan Cement plans to spend up to US$1.1bn on setting up a new joint venture with Turkey’s OYAK Cement. Through a new subsidiary, Dutch TCC Holdings, it intends to create a new business that will be 60% owned by OYAK Cement and 40% by Taiwan Cement. It will hold talks with OYAK Cement and if an agreement is reached the new company will operate OYAK Cement’s business in Turkey giving Taiwan Cement its first presence outside of Asia.
OYAK Cement is owned by Ordu Yardimlasma Kurumu (OYAK), the pension fund of the Turkish Armed Forces. It operates 13 integrated cement plants in Turkey with a production capacity of around 12Mt/yr. It holds a 16% market share. The plans with Taiwan Cement follow OYAK Cement’s purchase of InterCement’s operations in Portugal and Cape Verde.
Taiwan Cement hopes to gain access to the local market and the wider Mediterranean region. It said that, although it holds a production capacity of 75Mt/yr in the Greater China Region, government peak production limits and market saturation had forced it to expand internationally.
Oyak buys InterCement operations in Portugal and Cape Verde
29 October 2018Brazil/Portugal/Cape Verde/Turkey: Brazil’s InterCement has sold its operations in Portugal and Cape Verde to Turkey’s OYAK Cement for an undisclosed amount. The sale includes three integrated cement plants and two mills, with a total cement production capacity of 9.1Mt/yr, 46 concrete units, two dry mortar units, 17 quarries and a cement bagging plant. The completion of the agreement is dependent on regulatory approval.
InterCement, part of Camargo Corrêa group, purchased a majority stake in Portugal’s Cimpor in 2012, including assets in Portugal and Cape Verde. It says it will allocate a portion of the net proceeds from the sale to reduce its debts. Following completion of the transaction the Brazilian building materials company intends to focus its cement business in South America and Africa. In these regions it holds 39Mt/yr of installed production capacity at 35 cement plants.