Displaying items by tag: Research

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."

UK: 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.

US: 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.“

China: A new study from Hong Kong Polytechnic University showcases sustainable cement production methods, focusing on low-clinker cements and alternative solutions for incinerator fly ash (IFA). The research demonstrates that using carbonated-washed IFA mixed with slag, coal fly ash, or metakaolin can replace 60% of Portland cement, forming ternary blended cement. This approach reportedly reduces the carbon footprint of cement production.

The study found that slag was the most effective, improving pore structure and increasing ettringite and hemicarboaluminate formation with a blend of 40% slag and 20% IFA. It achieved 90% of the compressive strength of pure Portland cement after 90 days.

The researchers said "This study demonstrated the promising potential of the blended cements to simultaneously divert IFA from landfills and reduce the clinker content of cement."

Philippines: A recent study from Cebu, Philippines presents a method for reducing greenhouse emissions in the cement industry. The research, supported by the Department of Science & Technology (DOST) of the Philippines, focuses on partially substituting cement with coal fly ash (CFA). According to the University of San Carlos researchers, CFA's efficacy as a cement substitute depends on its source, with variations in quality, performance, and water requirements when used in paste and mortar formulations.

The study evaluated CFA from a Philippine power plant, examining its use as a partial cement substitute. Researchers designed paste and mortar mixtures with different CFA-to-binder ratios and water-to-binder ratios. The study revealed that increasing the amount of CFA in cement up to 20% by weight could enhance compressive strength, ‘outperforming’ pure cement mixtures.

The study concluded that substituting a portion of cement with CFA not only reduces greenhouse gas emissions but also improves the compressive strength of the resultant material.

South Korea: A recent study from Daejeon explored the potential of low-lime calcium silicate cement as a low CO₂ emission alternative to Ordinary Portland Cement. Researchers from the Korea Institute of Geoscience and Mineral Resources examined the setting and flow characteristics of a mixture of Ordinary Portland Cement and low-lime calcium silicate cement under carbonation curing conditions. The study was financially supported by the Ministry of Trade, Industry & Energy's industrial strategic technology development programme.

The study aimed to explore the reaction and microstructural characteristics of these cement pastes. The low-lime calcium silicate cement was synthesised using limestone and silica fume, with varying proportions added to the Portland cement pastes. The research findings suggest improvements in compressive strength with the inclusion of 30% or more low-lime calcium silicate cement, highlighting its ability to enhance the durability and sustainability of construction materials.

US: A research team from Lehigh University has won a three-year, US$2m grant from the Department of Energy's industrial efficiency and decarbonisation office for a project on concrete decarbonisation. The team, including Carlos Romero, director of Lehigh's Energy Research Centre, aims to develop a sustainable concrete binder using calcined clay, reducing emissions associated with Ordinary Portland Cement production. The project collaborates with Buzzi Unicem USA and focuses on processing and testing calcined clay to mimic the properties of conventional cement.

Lehigh's team will explore various low-grade calcined clays, supplied by Buzzi, testing their compressive strength and durability. The goal is to halve the CO₂ emissions of traditional concrete mixes.

Chair of the Department of Civil and Environmental Engineering Shamim Pakzad said "I am excited about the expansion of the research portfolio of CEE departments into this area of greener cement, which opens many opportunities for future research and implementation in industry."