Displaying items by tag: Research

India: Odisha has received its first cement-free road near Amanapada, Cuttack District. The Pioneer newspaper has reported that researchers from the Kalinga Institute of Industrial Technology (KIIT) developed the new material, made from 100% industrial waste, in order to cut the CO₂ emissions involved in cement production and in anticipation of an acute limestone shortage in India in 25 – 50 years. KIIT founder Achyuta Samanta thanked the students whose work brought this pilot project to fruition. “The new technology has the potential to bring about a revolution in engineering construction,” he said.

Germany: Lubricants specialist Fuchs has announced its collaboration with chemicals company BASF in performing a cradle-to-grave analysis of different mineral oil hydraulic fluids that takes into account all environmental and economic aspects of their lifecycle. The study concluded that high performance multigrade hydraulic oil (HVLP) has a lower environmental impact and lower overall cost than monograde hydraulic oil (HLP). Fuchs said, “This advantage is mainly based on an improved diesel fuel economy throughout the use phase - primarily due to improved volumetric fluid efficiency, lower friction and lower fluid mass circulation ratio.”

Fuchs and BASF both supply lubricants and chemical products to the cement industry.

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.’

Mexico: Cemex Ventures has partnered with BCG and Tracxn to launch a list of 2019’s global 50 ‘most promising’ construction start-ups. Assessment categories were technical innovation, project management and sustainability. Companies like the UK’s Cloud Cycle, a concrete management platform provider, and the US’s Concrete Sensors, which provides remote concrete strength, temperature and relative humility measurement solutions, typify the promising developments in how the construction industry uses its cement.

Microsoft co-founder Bill Gates entered the world of cement this week with a public relations blitz for Heliogen. He’s one of the backers of a new Californian technology startup looking to use concentrated solar power (CSP) to power heavy industrial processes like clinker or steel production. The company says it has concentrated solar energy commercially to levels above 1000°C.

Its process, called HelioMax, uses a closed-loop control system to improve the accuracy of a heliostat system. It says it achieves this by using computer vision software to better align an array of mirrors to reflect sunlight towards a single target. Temperatures of up to 1500°C is one of its targets so that it can apply itself to a variety of processes in the cement, steel, mining, petrochemical and waste treatment industries. It says it can do this for US$4.5/MCF. Another target once it hits 1500°C is to start manufacturing hydrogen or synthetic gas fuels.

Heliogen’s press release was picked up by the international press, including Global Cement, but it didn’t mention the similar work that SOLPART (Solar-Heated Reactors for Industrials Production of Reactive Particulates) project is doing in France. This project, backed by European Union Horizon 2020 funding, is developing a pilot scale high temperature (950°C) 24hr/day solar process for energy intensive non-metallic minerals’ industries like cement and lime. It’s using a 50kW solar reactor to test a fluidised bed system at the PROMES (PROcédés, Materials and Solar Energy) testing site in Odeillo, France.

Heliogen’s claim that it can beat 1000°C is significant here but it doesn’t go far enough. Clinker production requires temperatures of up to around 1450°C in the sintering phase to form the clumps of clinker. SOLPART has been only testing the calcination stage of clinker production that suits the temperature range it can achieve. Unless Heliogen can use its method to beat 1450°C then it looks likely that it will, similarly, only be able to cut fossil fuel usage in the calcination stage. If either Heliogen or SOLPART manage to do even this at the industrial scale and it is cost effective then the gains would be considerable. As well as cutting CO₂ emissions from fossil fuel usage in cement production this would reduce NO_x and SO_x emissions. It would also cut the fuel bill.

As usual this comes with some caveats. Firstly, it doesn’t touch process emissions from cement production. Decomposing limestone to make calcium oxide releases CO₂ all by itself with no fuel. About one third of cement production CO₂ emissions arise from fossil fuel usage but the remaining two thirds comes from the process emissions. However, one gain from cutting the amount of fossil fuels used is a more concentrated stream of CO₂ in the flue gas. This can potentially reduce the cost of CO₂ capture and utilisation. Secondly, concentrated solar power systems are at the mercy of the weather, particularly cloud cover. To cope with this SOLPART has been testing a storage system for hot materials to allow the process to work in a 24-hour industrial production setting.

Looking more broadly, plenty of cement producers have been building and using solar power to supply electricity. Mostly, these are photovoltaic (PV) plants but HeidelbergCement built a CSP plant in Morocco. Notably, PPC Zimbabwe said this week that it was building a solar plant to supply energy to two of its cement plants. It is doing this in order to provide a more reliable source of electricity than the local grid. India’s Birla Corporation has also said that it is buying a solar energy company today. The next step here is to try and run a cement plant kiln using electricity. This is exactly what Cementa, HeidelbergCement’s subsidiary in Sweden, and Vattenfall have been exploring as part of their CemZero project. The pilot study demonstrated that it was technically possible but only competitive compared with ‘other alternatives in order to achieve radical reductions in emissions.’

None of the above presents short or medium-term reasons for the cement industry to switch to solar power in bulk but it clearly deserves more research and, critically, funding. One particular strand to pull out here about using non-fossil fuel powered clinker production systems is that it produces purer process CO₂ emissions. Mounting carbon taxes could gradually force cement plants to capture their CO₂ but once the various technologies above become sufficiently mature they could bring this about sooner and potentially at a lower cost. In the meantime the more billionaires who take an interest in cement production the better.

UK: The Global Cement and Concrete Association (GCCA) has launched ‘Innovandi,’ a research network between industry and scientific institutions. The network intends to research the areas of process technology, including the impact of co-processing, efficiency of clinker production and implementation of CCUS/ technologies, and products. This will include the impact of clinker substitutes and alternative binders in concrete, low carbon concrete technology and improve the understanding of CO₂ reduction through re-carbonation.

“Our industry is fully committed to taking action to reduce CO₂ emissions. As such, Innovandi is an industry led initiative and will bring together the best minds from all corners of the cement and concrete world, academia and business. Together we will truly collaborate on a global scale and use our expertise to find new ways of working and developing effective innovations,” said Benjamin Sporton, the chief executive officer (CEO) of the GCCA.

24 companies from the cement and concrete industry, including cement and concrete manufacturers, admixture specialists and equipment suppliers, have committed to the initiative, with scientific institutions and additional companies set to join as its work begins work. These include Buzzi Unicem, Cementir Holding, Cementos Argos, Cementos Molins, Cementos Pacasmayo, Cemento Progresso, Cemex, CNBM, Chryso, CRH, Dalmia Cement, FLSmidth, Grupo Cementos de Chihuahua (GCC), GCP Applied Technologies, Mapei, HeidelbergCement, LafargeHolcim, Nesher Israel Enterprises, SCG Cement, Titan Cement, Refratechnik Cement, Sika Technology, Subote New Materials and Votorantim.

As part of the new initiative, the GCCA also intends to establish an annual Innovandi global conference to promote collaboration on innovation and research in the sector.

US: A team of researchers at the Massachusetts Institute of Technology (MIT) have demonstrated an electrochemical process to make clinker in a laboratory. A paper on the work by Yet-Ming Chiang, the Kyocera Professor of Materials Science and Engineering at MIT, with postdoctoral researcher Leah Ellis, graduate student Andres Badel and others has been published in the Proceedings of the National Academy of Sciences of the United States of America (PNAS).

In the new process, pulverised limestone is dissolved in acid at one electrode in an electrolyser and carbon dioxide (CO₂) is released in a pure, concentrated stream. Lime is precipitated out as a solid at the other electrode. The lime can then be processed in another step to produce clinker.

Benefits of the new process include potentially substituting fossil fuels with electricity supplied from renewable sources and the production of a pure source of CO₂ that could be captured with less or no scrubbing compared to conventional clinker production.

Dalmia Cement threw down the gauntlet this week with the announcement of a large-scale carbon capture unit (CCU) at one of its plants in Tamil Nadu, India. An agreement has been signed with UK-based Carbon Clean Solutions Limited (CCSL) to use its technology in building a 0.5Mt/yr CCU. The partnership will explore how CO₂ from the plant can be used, including direct sales to other industries and using the CO₂ as a precursor in manufacturing chemicals. No exact completion date or budget has been disclosed.

The move is a serious declaration of intent from the Indian cement producer towards its aim of becoming carbon neutral by 2040. Dalmia has been pushing its sustainability ‘journey’ for several years now hitting targets such as reaching 6Mt of alternative raw materials usage in its 2018 financial year and reaching a clinker factor of 63% at the same time. In an article in the November 2018 issue of Global Cement Magazine it said it had achieved CO₂ emissions of 526kg/t from its cement production compared to 578kg/t from other Indian members of the Cement Sustainability Initiative (CSI). In its eastern operations it had gone further to reach 400kg/t.

Using CCU is the next step to this progression but Dalmia’s approach is not without its caveats. Firstly, despite the size of the proposed project it is still being described as a ‘large-scale demonstration.’ Secondly, the destination of all that captured CO₂, as mentioned above, is still being considered. CCSL uses a post-combustion capture method that captures flue gas CO₂ and then combines the use of a proprietary solvent with a heat integration step. Where the capture CO₂ goes is vital because if it can’t be sold or utilised in some other way then it needs to be stored, putting up the price. Technology provider CCSL reckons that its CDRMax process has a CO₂ capture price tag of US$40/t but it is unclear whether this includes utilisation sales of CO₂ or not.

The process is along similar lines to the Skyonic SkyMine (see Global Cement Magazine, May 2015) CCU that was completed in 2015 at the Capitol Cement plant in San Antonio, Texas in the US. However, that post-combustion capture project was aiming for 75,000t/yr of CO₂. Dalmia and CCSL’s attempt is six times greater.

Meanwhile, Cembureau, the European cement association, joined a group of industrial organisations in lobbying the European Union (EU) on the Horizon Europe programme. It wants the budget to be raised to at least Euro120m with at least 60% to be dedicated to the ‘Global Challenges and European Industrial Competitiveness’ pillar. This is relevant in a discussion on industrial CO₂ emissions reduction because the scheme has been supporting various European cement industry projects, including HeidelbergCement’s work with the Low Emissions Intensity Lime And Cement (LEILAC) consortium and Calix at its Lixhe plant in Belgium and its pilots in Norway. As these projects and others reach industrial scale testing they need this money.

These recent developments provide hope for the future of the cement industry. Producers and their associations are engaging with the climate change agenda and taking action. Legislators and governments need to work with the cement sector to speed up this process and ensure that the industry is able to cut its CO₂ emissions while continuing to manufacture the materials necessary to build things. Projects like this latest from Dalmia Cement are overdue, but are very encouraging.

Brazil: Repsol Sinopec Brazil, Ouro Negro and the Mechanical Engineering Department of the Centre of Science and Technology at Rio de Janiero’s Pontifical Catholic University (PUC-Rio) are working together on a through tubing logging profile tool to assess cement quality in lined wells. Arbolas has reported that, where current technologies allow only for observation of anomalies located directly around the tool, the sought-after solution will facilitate detailed recording of the integrity of the adjacent layer. Ouro Negro Chief Executive Officer (CEO) Eduardo Costa has described the proposal to incorporate its TTilt technology into the Wellrobot, yielding continuous data feedback and thus reducing well interventions. The companies say that the prospect of reliable seal integrity testing for plugging and abandonment operations on fluid-bearing formations is of enormous economic and environmental import to numerous industries.

US: The Japan Coal Energy Center (JCOAL), GreenOre Clean Tech, Columbia University and Wyoming Infrastructure Authority (WIA) have entered into a memorandum of understanding (MOU) to test carbon utilisation and recycling technology. GreenOre Clean Tech, using technology under license from Columbia University, will use testing space at the Integrated Test Center (ITC) near the Dry Fork Station coal-fired power station in Gillette, Wyoming. Calcium carbonate produced through CO₂ mineralisation could then potentially be used for aggregates, concrete production or in paper production. The test will be funded by JCOAL with additional support from project partners.

The State of Wyoming and JCOAL have been working together since 2016, when they signed an initial MOU committing to cooperation in coal research and development of technologies and coal trade. JCOAL operates under the supervision of the Ministry of Economy, Trade and Industry of Japan and is supported by more than 120 member coal-related businesses, including Kawasaki Heavy Industries, Mitsubishi Hitachi Power Systems, Nippon Steel and Toshiba. Kawasaki is scheduled to test its solid sorbent capture technology at the ITC beginning in 2021.