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If you needed a sign that the cement industry has become serious about carbon capture it was the presence of two organisations offering CO₂ transport and storage capacity in northern Europe at last week’s Innovation in Industrial Carbon Capture Conference 2020 (IICCC). Both Norway’s Northern Lights and the Rotterdam CCUS (Project Porthos) were busy at their stands during the event’s exhibition. Meanwhile, Cembureau, the European Cement Association, said that it will work on finding other potential storage sites for CO₂ and on identifying existing gas pipelines that could be converted. The industry is planning what to do about CO₂ transport and storage.

As with the previous IICCC event in 2018 the heart of the programme was the Low Emissions Intensity Lime And Cement (LEILAC) project. Since then Calix’s 60m tall pilot Direct Separation Calciner unit has been built at the HeidelbergCement cement plant in Lixhe and has been tested since mid-2019. Early results look promising, with CO₂ separation occurring, calcined material produced and the tube structure and mechanical expansion holding up. Problems with thermocouples failing, blockages and recarbonation at the base of the tube have been encountered but these are being tackled in the de-bottlenecking phase. Testing will continue well into 2020 and plans for the next demonstration project at another cement plant in Europe are already moving ahead. LEILAC 2 will see industry partners Cimpor, Lhoist, Port of Rotterdam and IKN join Calix, HeidelbergCement and other research partners to work together on a larger 0.1Mt/yr CO₂ separation pilot scheduled for completion in 2025.

Alongside this HeidelbergCement presented a convincing vision of a carbon neutral future for the cement industry at the IICCC 2020. It may not be what actually happens but the building materials producer has a clear plan across the lifecycle chain of cement. It is researching and testing a variety of methods to capture CO₂ process emissions, is looking at supply chains and storage sites for the CO₂ and is working on recycling concrete as aggregates and cementations material via recarbonation. In terms of carbon capture technology, an amine-based industrial scale CCS unit looks likely to be built at Norcem’s Brevik plant in the early 2020s. HeidelbergCement’s other joint-research projects – direct separation and oxyfuel – are further behind, at the pilot and pre-pilot stages respectively. Each technology looks set to offer progressively better and cheaper CO₂ capture as they come on line.

Or put another way, cement companies in Europe could build industrial scale amine-based carbon (CC) capture plants now. Yet the game appears to be to wait until the cost of CCS falls through new technology versus the rising emissions trading scheme (ETS) price of CO₂. CC is expected to become economically feasible in a decade’s time, sometime in the 2030s. At which point there might be an upgrade boom as plants are retrofitted with CC units or new production lines are commissioned. Other ways of reducing the cement industry’s CO₂ emissions, of course, are being explored by other companies such as further reducing the clinker factor through the use of calcined clays (LC3 and others), solar reactor or electric-powered kilns and more.

The usual problem of how the construction industry can cope with a higher cost of cement was acknowledged at IICCC 2020 but it is largely being worked around. Higher priced cement poses competitive issues for specifiers and construction companies but it is widely expected to result in price rises below 5% for most residential end users. In the short-term government policy such as requiring low carbon cement in state building projects could stimulate the market. The start of this process can be seen already with the use of slag cements in various infrastructure projects.

Hans Bergman, Head Unit ETS Policy Development at the Directorate-General for Climate Action (DG Clima) partly addressed the cost issue by talking about the EU Green Deal. The EU wants to meet its new targets but it also wants to let gross domestic product (GDP) rise whilst greenhouse emissions fall. The EU ETS is its principle vehicle for this but the commission is wary of changes, such as making modifications linked to CCS, in case it undermines the system. Discussions are ongoing as the work on the Green Deal continues.

IICCC was a wider forum beyond just what LEILAC is up to. To this extent the CC projects involve multiple partners, including those from other cement companies like Cemex and Tarmac (CRH) in LEILAC and Dyckerhoff (Buzzi Unicem), Schwenk Zement and Vicat in the oxyfuel project. The decarbonisation fair included representatives from Vicat’s FastCarb project and Polimi’s Cleanker. Speakers from the European Climate Foundation, Acatech, INEA, TCM, SINTEF and Lhoist were also present.

During one speaker discussion Calix was described as the 'Tesla' of industrial CC by one speaker, who said that, “…there is a genuine competitive opportunity for those bold enough to grasp it.” Calix’s managing director Phil Hodgson enjoyed the accolade but the point was that leading innovation or setting the agenda offers advantages. In the case of industrial CC for the cement industry, change feels a step closer.

Saudi Arabia: Tabuk Cement has appointed Saoud Bin Solaiman Al-Juhni as the chairman of its board of directors. Abdulaziz Bin Abdelrahman Alkhamis has been appointed as the deputy chairman and the cement producer has also announcement the composition of its executive and audit committees.

UK: Hanson has appointed Andrew Simpson as its packed products director, adding operational responsibility to his commercial remit. He is responsible for sales of all of its packed products, including cement, ready-to-use concrete and aggregates, and will now also look after manufacturing at the company’s ready-to-use production site in Nuneaton, as well as its construction aggregates packing plants across the country.

Simpson started his career with Hanson in 1997 when he was appointed area sales manager for Castle Cement, part of the HeidelbergCement Group, which bought Hanson in 2007. Since then he has held a number of different sales roles and attained a degree in Business Studies from De Montfort University in Leicester. In 2017 he was honoured with the freedom of the City of London and installed as a Liveryman of The Worshipful Company of Builders Merchants in recognition of his work within the builders’ merchants’ industry.

US: Schust, a member of the Scheuch Group, has appointed Daniel Locke as Director of Business Development – Industrial Minerals, where he will support Schust’s North American cement producer customers. Locke has nearly five years of sales and technical experience in the industrial minerals and energy industries. He holds a Bachelor of Science in Business Administration from the University of Southern Mississippi.

Schust provides turnkey industrial ventilation systems. It is part of Scheuch Group via Scheuch North America.

US: Jon K Tabor, the Chairman Emeritus of Allied Mineral Products, is to retire at the end of March 2020. He celebrates 50 years with Allied on 16 February 2020. He will remain on Allied’s board of directors following his retirement.

Tabor started a 65-year career in the refractories industry in 1955 when he started working for Norton Company (Saint-Gobain), in Worcester, Massachusetts. He joined Allied as Sales Manager in 1970, when Allied was a small company. Tabor helped transform Allied from a two-man partnership into a multi-national corporation with almost 1000 employees in 25 countries, and manufacturing facilities in eight countries and four US states. His Allied career has included the roles of Sales Manager, Vice President of Sales, President, chief executive officer (CEO), Chairman, and most recently, Chairman Emeritus. Notably, he led the transformation of Allied to an employee owned (ESOP) company in 1986.

Tabor attended the United States Merchant Marine Academy, served in the US Army and Army Reserves; graduated from Alfred University in 1955 and earned an MBA from Northeastern University in 1962.

Kenya: Devki Group subsidiary National Cement has launched its second Kenyan plant in Salgaa in Nakuru county at a cost of US$58.0m. Business Daily News has reported that the 0.75Mt integrated plant will supply cement to Kenya, South Sudan and southern Ethiopia.

Devki Group chairman Narendra Raval said that the completion of a 0.75Mt/yr second line at National Cement’s 1.2Mt/yr Kajiado County plant would bring the group’s total capacity to 3.5Mt/yr in July 2020, in a speech in which he lobbied the government to ban clinker imports. “We are gearing towards fixing the country’s clinker gap and making Kenya a regional market for raw material in cement production,” said Raval. The group also produces its Simba brand cement in Uganda.

Russia: Yakutcement has commissioned a crushed stone conveyor to circulate crushed stone of a 200 - 400mm fraction for secondary crushing at the 0.4Mt/yr Yakutcement plant in Mokhsogollokh. Yakutcement has said that the installation will save on the costs of a front-end loader and dump truck for conveying crushed stone to and from a temporary warehouse prior to secondary crushing.

Russia: Sibirsky Cement Holding (Sibtsem) subsidiary Topkinsky Cement has announced that it has entered commercial production of a new Mita slag Portland cement with granulated blast furnace slag (GBFS) at its 2.7Mt/yr integrated plant in Topki, for which it received a certification of conformity with ‘cement for general construction’ standards on 16 January 2020. Nina Poputnikova, Topkinsky Cement laboratory and quality department head, said that it is producing the cement in response to ‘construction companies’ increased interest in cement for use in reinforced, precast concrete in monolithic structures such as buried and hydraulic structures.’

“In the near future we plan to certify two new cements,” said Topkinsky Cement managing director Alexey Ospelnikov. One will be a low-heat general-purpose cement for large-sized concrete structures and the other a sulphate-resistant Portland cement. “Expanding the assortment will help strengthen the company’s position in the Russian cement market.”

Greece: Titan Cement has opened the Group Digital Centre of Competence, a facility which it says will consolidate its digital and advanced analytics capabilities. Titan says the Centre ‘accelerates its digital efforts’ set out under its Group Digital Initiative. “This is an essential part of efforts to increase operational efficiency and competitiveness,” said the company.

Russia: Eurocement has announced the continuation of its cooperation agreement with construction company PIK Group in 2020. The 30.7Mt/yr-capacity cement producer, Russia’s largest, sold 0.2Mt of cement to PIK Group in 2019, bringing the total volume exchanged in the course of their cooperation to 0.8Mt. Eurocement sales vice president Ilya Kosykh said, “We guarantee our customers stable cement performance and uninterrupted deliveries of building materials on time.”