
Displaying items by tag: Research
Japan: Mitsubishi UBE Cement Corporation (MUCC) has developed a carbon-negative artificial sand product called ‘GX-e Beads.’ It is made from by-products containing calcium and uses a proprietary accelerated carbonation technology developed by MUCC to absorb CO2 at 80 - 250kg/t from flue gas and other sources. A further granulation and solidification stage is then used to manufacture the final artificial fine aggregates, making it net-carbon negative. The artificial sand can be produced via a dry process at ambient temperature conditions. It requires no special reaction equipment.
The product can be used as a fine aggregate to make normal-strength concrete. MUCC says “…when used in conjunction with ordinary Portland cement (OPC) or blended cement, fresh properties and strength development equivalent to or better than that of normal concrete can be obtained. Therefore, it can be widely applied to ready-mix concrete and secondary concrete products.”
Materials Processing Institute prepares to open Sustainable Cement and Concrete Centre
06 February 2025UK: The Materials Processing Institute (MPI) is preparing to open its Sustainable Cement and Concrete Centre (SCCC) later in February 2025. The centre will focus on research and material development, including novel formulations for low-carbon cement and concrete and the use of electric arc furnace (EAF) slags in aggregates and clinker production. It will also provide consultancy services to further support clients to accelerate innovation, offering expertise and project management from concept through to pilot stage production.
The SCCC is a part of the EconoMISER programme, led by the Foundation Industries Sustainability Consortium (FISC), which aims to accelerate the decarbonisation of the UK’s so-called foundation industries. These include the cement, metal, glass, ceramic, paper, polymer and chemical sectors. The MPI is based in Middlesborough.
UCLA team develops ZeroCAL to cut cement CO₂ emissions
15 October 2024US: Researchers at UCLA's Institute for Carbon Management have developed a new method called ZeroCAL that could eliminate ‘nearly all’ of the carbon dioxide emissions from the process of cement production, according to the UCLA Newsroom. The team created a process using limestone and a water-based solution containing ethylenediaminetetraacetic acid. Through membrane nanofiltration and an electrochemical process, they produced calcium hydroxide.
To meet ZeroCAL’s water demand, the team suggests focusing on cement plants near coasts or rivers. The researchers are reportedly working with Ultratech Cement to build a demonstration plant that will produce ‘several’ tonnes of lime per day using the ZeroCAL process. Currently, the process requires more energy than traditional lime production methods, but ongoing research aims to reduce its energy consumption.
Gaurav Sant, director of the Institute and professor at UCLA Samueli School of Engineering, said “The ZeroCAL approach offers an elegant solution to eliminate carbon dioxide emissions associated with the process of cement production. First, it addresses the carbon emissions resulting from limestone’s decomposition while providing clean hydrogen and oxygen to heat the cement kiln. Second, it enables onsite decarbonisation while making use of existing kilns and limestone feedstocks without having to build separate carbon capture and storage facilities.”
Study finds use of reclaimed clay and brick dust reduces embodied carbon content of cement
02 September 2024UK: A new study by the Mineral Products Association (MPA), supported by Innovate UK, has found that incorporating reclaimed clays and finely ground brick powder into cement production can reportedly lower the embodied CO₂ by up to 3%. The materials are used as calcined clay in the cement production process. The project aims to offer a viable alternative to fly ash and ground granulated blast-furnace slag, as resources diminish due to the steel industry's decarbonisation efforts.
MPA director Diana Casey said "Using discarded bricks and reclaimed clays will not only lower carbon and reduce the amount of materials sent to landfill but has the potential to create a whole new market if these clays become widely used in the construction industry, helping to retain economic value in the UK, secure jobs and attract investment."
South Africa: PPC has warned of increased risks from substandard cement in the South African market, advocating for state intervention to protect the local industry from unfair competition. The broader South African cement industry continues to face challenges from dumped imports and locally blended variants, with latest Cement Import Montior research from March 2024 cautioning that local cement cement producers may be forced to mothball plants, putting thousands of jobs on the line as the number of cheap cement imports rises. PPC plans to engage with the South African Bureau of Standards for stricter compliance testing. Its recovery strategy includes exiting non-core businesses and major structural adjustments, aiming for tangible results in two years but resulting in possible in job cuts.
Germany: The University of Trier is transforming post-consumer materials into ‘ecological’ cement through a new research project that aims to find sustainable alternatives for the construction industry. The project involves using low-CO₂ industrial post-consumer materials as alternative cement binders, such as sludge from gravel and sand mining, as well as dust from quartzite extraction. The research will run for two years and is supported by the German Federal Environment Foundation.
UK: A steel and cement co-recycling process developed at the University of Cambridge has received US$2.9m in seed funding. Cambridge Electric Cement is utilising slag produced during the steelmaking process, which uses electric arc furnaces instead of blast furnaces, as clinker for cement. The researchers are conducting a US$8.4m trial called Cement 2 Zero to test the production process, aiming to produce 110t of recycled cement during the two-year program.
Germany: Alcemy, manufacturer of low-carbon ‘Cem X’ cement, has raised US$10m to scale up its cement decarbonisation solution. The funding round will support research and development and Alcemy's entry into new markets, including the US, in 2024.
CEO Leopold Spenner said "With this additional nearly US$10m in funding and support from Norrsken VC, in addition to our first-round investors, we're paving the way to a low-carbon construction industry, one project at a time."
Materials Processing Institute announces €5m investment to scale up sustainable technologies
03 July 2024UK: The Materials Processing Institute has launched the next phase of the EconoMISER programme with a €5m investment to develop sustainable technologies. The institute aims to advance research in alloy development, furnace modelling and decarbonisation of cement and concrete.
The institute will establish a new cement and concrete research centre and invest in technologies such as predictive artificial intelligence for alloy development. This initiative is part of the UK's effort to decarbonise critical sectors like cement through the EconoMISER programme, supported by UK Research and Innovation.
Princeton University team develops bio-based cement with increased toughness and ductility
26 June 2024US: A team at the University of Princeton has developed a new alternative cement using oyster shells. The team says that the oyster shells provide calcium carbonate in the form of aragonite, along with biopolymers. Together, these raise the resulting cement’s crack resistance by 19% and its ductility by 17% compared with ordinary Portland cement (OPC).
Team leader Reza Moini said “Our bio-inspired approach is not to simply mimic nature’s microstructure, but to learn from the underlying principles and use that to inform the engineering of human-made materials. One of the key mechanisms that makes a nacreous shell tough is the sliding of the tablet at the nanometer level. Here, we focus on the mechanism of tablet sliding by engineering the built-in tabulated structure of cement paste in balance with the properties of the polymer and the interface between them. In other words, we intentionally engineer defects in the brittle materials as a way to make them stronger by design.“