Displaying items by tag: Mining

Afghanistan: The Jabal al-Saraj cement plant project in Parwan province has completed 90% of initial exploration work, along with the drilling of 18 deep wells for mineral sampling, according to Tolo news.

The facility has been contracted between the Ministry of Mines and Petroleum and a Qatari firm, and is valued at US$220m.

Mohammad Idris Anwari, the governor of Parwan, said "The contracting company has completed 90% of the exploration work within six months, ahead of schedule. We are hopeful that the remaining construction and technical work will be completed within two years."

The plant will initially produce 3000t/day (0.96Mt/yr) of cement, rising to 9000t/day (2.9Mt/yr) in later phases. The project will reportedly create 5000 jobs.

Kenya: The government has warned cement producers about buying materials from unlicensed sources. Cabinet Secretary Hassan Ali Joho has berated cement producers for purchasing minerals from unauthorised sellers, arguing that this practice enables the operations of illegal miners who exploit the country’s natural resources.

During a meeting with cement producers and representatives from the Kenya Association of Manufacturers and Kenya Chamber of Mines, Joho said "We need your support in fighting against illegal mining operations, but sadly some of you provide markets for minerals extracted illegally by faceless entities that are not paying taxes, royalties and are giving nothing to communities for those minerals. This must stop.”

In the past three years, the government has closed 3000 illicit mines that were operating without licenses. The Cabinet Secretary noted that gypsum was a heavily exploited material by the illegal miners, who use it as an ingredient in cement.

Joho added “You have been buying and using gypsum in cement manufacturing, yet there is no record of anyone licensed to mine gypsum in Kenya. There are no records on production, payment of taxes and royalties or community programs undertaken by any gypsum dealer because they are doing it illegally.”

Kenya: Mining and Blue Economy Cabinet Secretary Hassan Ali Joho has ordered the closure of the Simba Cement plant in Kilifi County due to pollution concerns. Residents have reported issues from stone blasting and dust, with one resident reporting that early morning blasting has caused ‘cracks’ in their house and exposed families to respiratory diseases, according to the Kenyan Post newspaper. It was also reported that the company has allegedly displaced residents to expand its mining operations.

US: Terra CO₂ has received a US$52.6m federal grant from the US Department of Energy to support the construction of a new plant in Magna, Utah, that will produce up to 240,000t/yr of supplementary cementitious materials using mining waste from the nearby Kennecott copper mine. This method reportedly aims to cut CO₂ emissions by 70% per tonne of traditional cement replaced, according to the company’s CEO Bill Yearsley. The project is expected to create 61 jobs.

One unusual thing about coverage of cement in the media is the way that discussions often centre precisely on its absence – that is, on alternatives to cement. These alternatives boast unique chemistries and performance characteristics, but are all produced without Portland cement clinker. They are generally called ‘alternative cements,’ perhaps because ‘cement-free cement’ does not have such a commercially viable ring to it. This contradictory tendency reached a new high in the past week, with developments in alternative cement across Asia, Europe, the Middle East and North America. Together, they hint at a more diverse future for the ‘cement’ industry than the one we know today.

Asia

In Indonesia, Suvo Strategic Minerals has concluded tests with Makassar State University of a novel nickel-slag-based cement. Huadi Nickel-Alloy Indonesia supplied raw materials, and tests showed a seven-day compressive strength of 37.5MPa. Suvo Strategic Minerals says that a partnership with Huadi Nickel-Alloy Indonesia for commercial production is a likely next step.

Europe

Cement producer Mannok and minerals company Boliden partnered with the South Eastern Applied Materials (SEAM) research centre in Ireland to launch a project to develop supplementary cementitious materials (SCMs) from shale on 7 October 2024. The project will additionally investigate CO₂-curing of cement paste backfill for use in mines. Irish state-owned global commerce agency Enterprise Ireland has contributed €700,000 in funding.

UK-based SCM developer Karbonite expects to launch trial production of its olivine-based SCM with a concrete company in 2025. The start-up launched Karbonite Group Holding BV, with offices in the Netherlands, to facilitate this new phase. Karbonite’s SCM is activated at 750 – 850°C and sequesters CO₂ in the activation process, resulting in over 56% lower CO₂ emissions than ordinary Portland cement (OPC). Managing director Rajeev Sood told Global Cement that talks are already underway for subsequent expansions into the UAE and India.

Back in the UK, contractor John Sisk & Son has received €597,000 from national innovation agency Innovate UK. John Sisk & Son is testing fellow Ireland-based company Ecocem’s <25% clinker cement technology in concrete for use in its on-going construction of the Wembley Park mixed development in London.

At the same time, Innovate UK granted a further €3.23m to other companies for concrete decarbonisation. Recipients included a calcined clay being developed by Cemcor, an SCM being developed from electric arc furnace byproducts by Cocoon, a geopolymer cement technology being developed by EFC Green Concrete Technology UK and an initiative to develop alternative cement from recycled concrete fines at the Materials Processing Institute in Middlesbrough. Also included was the Skanska Costain Strabag joint venture, which is working on the London stretch of the upcoming HS2 railway. The joint venture, along with partners including cement producer Tarmac and construction chemicals company Sika UK, will test low-kaolinite London clay as a raw material with which to produce calcined clay as a cement substitute in concrete structures in HS2’s rail tunnels.

Middle East

Talks are underway between UK-based calcined clay producer Next Generation SCM and City Cement subsidiary Nizak Mining Company over the possible launch of a joint venture in Riyadh, Saudi Arabia. The joint venture would build a 350,000t/yr reduced-CO₂ concrete plant, which would use alternative cement based on Next Generation SCM’s calcined clay.

North America

Texas-based SCM developer Solidia Technologies recently patented its carbonatable calcium silicate-based alternative cement, which sequesters CO₂ as it cures.

Meanwhile, C-Crete Technologies made its first commercial pour of its granite-based cement-free concrete in New York, US. C-Crete Technologies says that the product offers cost and performance parity with conventional cement, with net zero CO₂ emissions. Its raw material is globally more abundant than the limestone used as a raw material for clinker. Other abundantly available feedstocks successfully deployed within C-Crete Technologies’ repertoire include basalt and zeolite.

Across New York State, in Binghamton, KLAW Industries has succeeded in replacing 20% of concrete’s cement content with its powdered glass-based SCM, Pantheon. KLAW Industries has delivered samples to local municipalities and the New York State Department of Transportation. Its success expands the discussion of possible circular cement ingredients from the industrial sphere into post-consumer resources.

In Calgary, Canada, a novel SCM has drawn attention from one of the major cement incumbents: Germany-based Heidelberg Materials. It invested in local construction and demolition materials (CDM)-based SCM developer EnviCore on 9 October 2024. The companies plan to build a pilot plant at an existing Heidelberg Materials CDM recycling centre.

Conclusion

Alternative cement developers are still finding the words to talk about their products. They may be more than ‘supplementary’ up to the point of entirely supplanting 100% of clinker. Product webpages offer ‘hydraulic binder,’ ‘pozzolan’ and even ‘cement.’ As alternative ‘cements’ are developed, they build on the work of pioneers like Joseph Aspdin and Louis Vicat. Start-ups and their backers are now reaching commercial offerings, on a similar-but-different footing to cement itself. None of these novel materials positions itself as the sole, last-minute ‘super sub’ in the construction sector’s confrontation with climate change. Rather, they are a package of solutions which can combine into a net zero-emissions heavy building materials offering, hopefully before 2050.

Related to this is the need for ‘technology neutral’ standards, as championed this week by the Alliance for Low-Carbon Cement and Concrete (ALCCC), along with 23 other European industry associations, civil society organisations and think tanks. The term may sound new, but the concept is critical to the eventual uptake of alternative cements: standards, the ALCCC says, should be purely performance-based. They ought not attempt to define what technology, for example cement clinker, makes a suitable building material. According to the ALCCC, Europe’s building materials standards are not technology neutral, but instead ‘gatekeep’ market access, to the benefit of conventional cement and the exclusion of ‘proven and scalable low-carbon products.’

At the same time, cement itself is changing. Market research from USD Analytics showed an anticipated 5% composite annual growth rate in blended cement sales between 2024 and 2032, more than doubling throughout the period from US$253bn to US$369bn. If you can’t beat it, blend with it!

For a further discussion of alternative cement and binders in Europe, see Global Cement’s interview with ALCCC co-ordinator Joren Verschaeve in the forthcoming November issue of Global Cement Magazine on 17 October 2024.

Germany: FLSmidth has signed an agreement to acquire Tipco Tudeshki Industrial Process Control (Tipco), an Aachen-based technology firm. Tipco develops sensor technology for measuring particle size distribution of different mass flows, which will be integrated into FLSmidth's hydrocyclones portfolio. The terms of the transaction were not disclosed, and the acquisition does not affect FLSmidth's financial guidance for 2024.

PCV business line president at FLSmidth, Pat Turner, said “This acquisition marks an important addition to our PCV offerings and highlights our strategic focus on digital solutions across the Mining flowsheet. The optimisation of the grinding circuit plays a crucial part in maximising productivity and operational efficiency of the overall processing plant, and the addition of Tipco’s groundbreaking sensor technology will further strengthen our offerings within this area.”

Argentina: Holcim Argentina has introduced the first 100% electric mining truck in the quarry mining industry in Mendoza Province, according to the company. The ‘Pure Electric Mining’ truck, belonging to the XGMT brand, is reportedly set to reduce CO₂ emissions by more than 225t/yr. It also claims to offer further benefits, including reduced operating costs and improved raw material homogeneity. The truck can transport up to 72t and has an energy recovery braking system, allowing the battery to be charged during braking to reduce energy consumption and improve operating efficiency.

Head of decarbonisation at Holcim Argentina, engineer Marilina Moro, said “Sustainability is at the core of our strategy, and as part of this path, we aim to reduce our impact on the planet. That means transforming each of our processes throughout the company's value chain.”

Zambia: Grizzly Mining has announced an investment of US$200m to establish a cement plant in Solwezi, Northwestern Province. The announcement was made by the company’s vice chairperson Abdoul Ba during an interview, according to the Times of Zambia.

US: Boulder County has initiated action to terminate the operating licence of the Cemex cement plant near Lyons, Colorado, citing improper expansion of use. Dale Case, director of Boulder County Community Planning and Permitting, sent a notice to the company, motivated by a ‘significant’ rise in traffic. The letter said that the increased traffic created a need for new traffic construction and infrastructure, and requires a new access permit from the Colorado Department of Transportation (CDOT).

The plant has been operational since 1965, but faced changes in 1994 when Boulder County amended its land use code, necessitating special use approval for open mining at the Dowe Flats Quarry. The special use approval for the quarry expired on 30 September 2022, leading to termination of all mining operations and multiple complaints alleging the cement plant's non-compliance with county code and traffic congestion. A CDOT study revealed an increase in truck traffic since the quarry's closure, with daily trips increasing by 50% year-on-year.

Cemex now has a 30-day window to contest the director's determination, reduce plant use, or appeal to the Boulder County Board of Commissioners. The plant will continue operating under existing conditions until a final decision is reached.

Vietnam: The Vietnamese Ministry of Construction has recommended that Long Thanh Cement receive a mining licence for clay mines T51 and T52 Nui Nghe. The licence allows for an extraction capacity of 1.1Mt/yr of clay. This initiative aims to provide a stable supply of clay materials for the Long Thanh cement plant in Ha Nam province, which is undergoing expansion from 0.91Mt/yr to 2.3Mt/yr. The Ministry of Natural Resources and Environment reports that these clay mines have a claystone reserve of 4.33Mt and a sandstone and siltstone reserve of 1.6Mt viable for cement production.