Displaying items by tag: HeidelbergCement

Italy: Italcementi’s integrated Calusco plant near Bergamo has been awarded a Responsible Sourcing Scheme (RSS) certificate for its concrete and related supply chain operations. The certification looks at the entire production process from transportation to recycling raw materials. It is the first cement plant in the Italian subsidiary of HeidelbergCement to obtain the certification.

Italcementi suspended operation at its plants in March 2020 due to the coronavirus outbreak due to government decree.

Cement 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.

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. In Germany Schwenk Zement backed the Celitement project along similar lines. 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.

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.

US: Germany-based Lehigh Hanson has announced a suspension of work on its 2.0Mt/yr expansion of the 0.8Mt/yr Mitchell plant in Indiana to 2.8Mt/yr to early 2021 at the latest due to ‘uncertainties resulting from’ the coronavirus. The target date for commissioning has also moved, to late 2023 from September 2022. Lehigh Cement Mitchell plant manager Jerry Miller said, “A construction project of this magnitude has numerous components, such as supply chain certainty, material deliveries and, importantly, worker availability.”

The upgrade received environmental clearance in July 2019 and the company broke ground at the site in October 2019.

India: Germany-based HeidelbergCement has announced the successful expansion of two grinding plants. Accord Fintech News has reported that the company took advantage of the suspension of cement production since 24 March 2020 to complete debottlenecking work at the Jhansi, Uttar Pradesh, and Imlai, Madhya Pradesh, grinding plants, bringing their cement production capacities to 3.3Mt/yr and 2.5Mt/yr respectively.

HeidelbergCement India has an integrated capacity of 3.7Mt/yr and a grinding capacity of 6.3Mt/yr (total capacity: 10Mt/yr).

Europe: Australia-based Calix has announced that construction will begin on its second low emissions intensity lime and cement (Leilac) carbon capture and storage (CCS) installation at a ‘European cement plant’ on 7 April 2020. ASX ComNews has reported that collaborators on the project, which has received Euro16m under the EU’s Horizon 2020 grant scheme, are Portugal-based Cimpor, Germany-based HeidelbergCement, Germany and France-based energy companies Ingenieurbüro-Kühlerbau-Neustadt (IKN) and Engie and Belgium-based minerals and lime company Lhoist. Calix has said that the 100,000t/yr process emissions capture facility will be operational in late 2024.
The company has appointed Emma Bowring Leilac-2 project leader.

The first Leilac installation was completed at HeidelbergCement’s 1.5Mt/yr integrated Lixhe plant in Belgium’s Limburg province in mid-2019.

Germany: HeidelbergCement started the new year better than ever before, according to chief executive officer (CEO) Dominik von Achten. He reported that this had been mainly due to good weather before the onset of the coronavirus outbreak. Von Achten warned that the situation had already changed beyond recognition since mid-February 2020 for the multinational.

He said that the coronavirus outbreak had not only caused plants to be closed, either by enforcement or due to a lack of demand, but because migrant workers are unable to travel to construction sites. For example, workers from Eastern Europe are increasingly lacking in Western Europe. In Indonesia, a market that is important for HeidelbergCement, the lack of Chinese construction workers is stark, as they remain confined to their home country.

According to Von Achten, HeidelbergCement is now paying particular attention to its costs, has deferred all unnecessary investments and has considerable liquidity leeway. He added that the group is likely to benefit significantly from lower fuel costs as conditions improve over the course of 2020. HeidelbergCement is currently particularly affected in Lombardy, where its Italcementi subsidiary has its headquarters. HeidelbergCement has shut down its factories in Italy and imposed a freeze on hiring and non-essential spending. "You can see it's hitting the world like a wave," says Von Achten. "It's a tough test."

World: Cement producers are mobilising human and material resources and implementing strategies to keep operations going with the minimum possible impact from the coronavirus. Germany-based HeidelbergCement subsidiary Lehigh Hanson has closed a minority of its facilities and prepared a contingency plan for further reduced operations ‘if conditions worsen.’ Brazil-based Votorantim Cimentos has established a Special Coronavirus Crisis Management Commission to aid communications and emergency response implementation across its facilities. UK-based Quinn has suspended all non-essential travel for employees.

Germany: HeidelbergCement’s profit was Euro1.24bn in 2019, down by 3.4% from Euro1.23bn in 2018. Its revenue grew by 4.3% to Euro18.9bn from Euro18.1bn. HeidelbergCement says that it reduced its specific net CO₂ emissions by 1.5% year-on-year to 590kg/t from 599kg/t in 2018 and ‘intensified its research and development (R&D) efforts on carbon capture and utilisation/storage (CCU/S)’ in every operating region globally.

The group announced a year-on-year increase in volumes in the first two months of 2020, with all but three of its plants (HeidelbergCement subsidiary Italcementi’s 2.8Mt/yr Calusco plant, 2.5Mt/yr Rezzato plant and 0.6Mt/yr Tavernola plant in Lombardy region, Italy) still operating through the coronavirus pandemic, though it noted that construction is slowing in the US, Australia and Western Europe due to the outbreak.

HeidelbergCement cancelled its 7 May 2020 annual general meeting (AGM) ‘due to the spread of the coronavirus.’

Italy: HeidelbergCement and its Italian subsidiary Italcementi are each donating Euro100,000 to the Ospedale Papa Giovanni XXIII in Bergamo. The region in Lombardy in Northern Italy has been markedly affected by the coronavirus outbreak with over 400 fatalities since February 2020. Italcementi’s headquarters is located in the city. Italcementi's managing director Roberto Callieri has also invited employees to support the hospital and other institutions.

Bosnia & Herzegovina: Germany-based HeidelbergCement subsidiary Tvornica Cementa Kakanj (TCK) recorded a profit of Euro7.35m in 2019, down by 15% year-on-year from Euro8.63m in 2018. Sales rose by 1.8% over the period, to Euro37.7m from Euro37.0m. The company explained the profit drop in terms of increased operating costs, which rose by 3.8% to Euro29.4m from Euro22.7m in 2018.