Displaying items by tag: Research

Malaysia: YTL Cement has signed a memorandum of understanding (MOU) with the Construction Research Institute of Malaysia (CREAM) to support the transition of the local construction industry to sustainable construction practices. Under the deal, YTL Cement will also contribute to the Construction Industry Development Board’s (CIDB) goals by rolling out human resource development programmes, research and development initiatives.

As part of the MOU, YTL and the CIDB will jointly design training programmes for young adults to be certified as concrete technicians and develop the training syllabus for accreditation programmes of qualified personnel in operations. It is hoped that this will assist in attracting, retaining and growing skilled workers in the construction industry. CREAM will work with YTL Cement’s team of experts to conduct research and development on lower embodied carbon alternatives in materials and construction methods. CIDB and YTL Cement will also work together to increase awareness on the embodied carbon of the construction sector by providing channels for discussions and knowledge transfer among industry practitioners and experts.

US: A team from the Massachusetts Institute of Technology (MIT) has developed a new method to sequester CO₂ in concrete before curing it. The method is based on the addition of bicarbonate of soda, which reacts with cement to produce a calcium carbonate-calcium silicone hydrate composite. The Journal of Engineering has reported that the method adds the benefits of CO₂ mineralisation during production and casting, doubling the mechanical performance of early-stage concrete. It also eliminates the effects of carbonation reactions in cured concrete, which weaken the concrete by lowering its alkalinity, which accelerates the corrosion of rebar. The method has the potential to sequester 15% of CO₂ emissions from cement production.

The team said “The pre-curing capacity of concrete to sequester CO₂ has been largely underestimated and underutilised. Our new discovery could further be combined with other recent innovations in the development of lower carbon footprint concrete admixtures to provide much greener, and even carbon-negative, construction materials.”

Canada/UAE: Supplementary cementitious materials (SCMs) producer Carbon Upcycling Technologies has signed a strategic partnership agreement with technical consultancy A³&Co. The partners will now work towards the delivery of an SCM enhancement reactor that bolts on to existing cement plant equipment. Canada-based Carbon Upcycling Technologies expects to be able to offer the technology to global cement industry customers by March 2025.

Carbon Upcycling Technologies CEO Apoorv Sinha said "We look forward to collaborating with A³&Co. Their extensive experience working with over 125 facilities across the globe will prove invaluable as we continue to adapt our technology for seamless integration at cement plants, enabling onsite sequestration and utilisation of CO₂."

Switzerland: Holcim has commissioned the world's first cement plant digital twin at one of its cement plants in Switzerland. The software models the plant and is integrated with sensors, analytics and machine learning technology. UK-based HyBird also participated in the development of the technology. Holcim expects it to help to optimise its operations. Under its Plants of Tomorrow automation strategy, it will now aim to roll out the system across all of its cement plants, beginning with those in Europe.

Holcim's global head of Plants of Tomorrow, Rozemarijn Wesby, said "Our digital twin in Switzerland is a breakthrough for the entire industry. By leveraging digital technologies like this, we are generating massive amounts of data, allowing smarter decision-making to take our operational efficiency to the next level."

Vietnam: Analysis by SSI Research forecasts that the reopening of the Chinese economy, following its change in public health policy towards Covid-19, should increase cement exports in the second half of 2023. If this happens it is expected to reduce competition between producers in central and northern regions, according to the Việt Nam News newspaper. Signs of a recovery in cement exports to China were already noted in the fourth quarter of 2022. However, an increase in clinker export tariffs from the start of 2023 may presents a fresh issue for the producers. Cement and clinker exports from Vietnam fell by 29% year-on-year to 31.7Mt in 2022.

Cement 2 Zero (C2Z) has officially launched in the UK this week. The project is an industrial scale pilot of the Cambridge Electric Cement (CEC) process. The Materials Processing Institute will lead on this stage with two-year funding of around Euro7m provided by UK Research and Innovation (UKRI). Partners include the University of Cambridge, Atkins, Balfour Beatty, Brewster Brothers, Celsa Group, Day Aggregates and Tarmac.

CEC’s method uses recycled concrete paste in place of lime-flux in steel recycling. Slag is formed as the steel melts and this is then used in place of clinker to make more cement. This way of making cement cuts out the decarbonisation of limestone step from conventional clinker production. If renewably-sourced electricity is used to power the heating and grinding parts of manufacture, then cement production in this way could potentially cut out most of its CO₂ emissions. The first phase of trial melts by C2Z will be conducted by the Materials Processing Institute using a 250kg induction furnace and this will be scaled up to 6t in an electric arc furnace (EAF). Later, industrial scale melts will be tested in Celsa Steel's EAF in Cardiff, Wales.

CEC is taking a similar approach to HeidelbergCement with its research into using recycled concrete paste. However, HeidelbergCement says it is using the paste to help capture CO₂ in an enforced carbonation step it is testing at cement plants. It too though wants to create a secondary cementitious material (SCM) afterwards. There are also links here to construction and demolition waste and electric cement kilns as covered by Global Cement Weekly previously. The latter is different with regards to what CEC is doing because it is recycling concrete waste to produce an SCM (slag) rather than using an electrically powered kiln to make clinker from limestone. Coolbrook, VTT and the like have had to build electric kilns effectively from scratch or adapt technology from elsewhere for their approaches whilst CEC appears to be about to use existing EAFs in its industrial scale pilot.

Figure 1: Projection of how the Cambridge Electric Cement production process could be used at scale in the UK. Source: UK FIRES. Click to view larger version.

CEC’s forecast of how its process could be used at scale in the UK can be seen above in Figure 1. If the majority of the country’s steel scrap was recycled in this fashion each year then 2.4Mt/yr of CEC cement could be produced. This would represent a quarter of the c10Mt of cement sales reported by the MPA in 2021. Assuming the EAFs were powered by renewables then this could reduce the cement sector’s CO₂ emissions significantly. Although it would still leave the industry looking for other decarbonisation routes for the other three-quarters of cement demand.

C2Z and CEC offer a novel spin on cement production by recycling concrete waste, using an electrical heating step and dodging the process emissions associated with normal ordinary Portland cement (OPC) clinker production. If it did progress to a commercial stage then it would see a continued relationship between steel and cement producers. Currently this is mainly centered around iron and steel slag usage as a SCM. One point of interest here would be how much higher levels of steel recycling and a process like CEC being used regularly would affect existing slag usage as an SCM. It doesn’t look like CEC could solve the cement sector’s CO₂ emission problem all on its own but it could certainly make a difference if it progressed to a commercial stage. As ever with cement sector decarbonisation there appear to be a range of options available to producers.

US: The Department of Energy’s (DOE) Carbon Storage Assurance Facility Enterprise (CarbonSAFE) initiative has awarded funding of US$8.9m to Heidelberg Materials North America to study the subsurface geology for suitability for the storage of carbon dioxide at the Mitchell integrated cement plant in Indiana. The proposed project will geologically characterise several prospective reservoirs under the Mitchell plant for storage of more than 50Mt of CO₂ over a 30-year timeframe.

The award, which is managed by the National Energy Technology Laboratory, will be issued to the Illinois State Geological Survey at the University of Illinois (ISGS) as the prime contractor, with the company acting as a technical and industrial partner. Heidelberg Materials is contributing about US$1.5m in funding while ISGS will be contributing approximately US$0.6m for a project total of US$11.1m. The funding was part of a DOE initiative that generated nearly US$125m in funding for 10 projects to characterise suitability for carbon storage across the US.

Heidelberg Materials’ Mitchell cement plant is being upgraded with a new production line. Full production on the new line is anticipated to start in early 2023.

China: China Resources Cement (CRC) has inaugurated its Cement International Innovation Centre. The producer says that the centre will contribute to the sustainable growth of its operations across three platforms, namely: cutting-edge research and development, international technologies exchange and international talent introductions.

CRC chair Ji Youhong said that the start of operations at the Cement International Innovation Centre constituted a 'major achievement' under the government's 14th Five Year Plan.

Philippines: Holcim Philippines carried out 70 upgrades aimed at increasing automation in its operations during 2022. The projects aim to optimise cement production, generate cost savings and ensure best safety practices. The Manila Times has reported that new Industry 4.0 initiatives include equipment monitoring systems offering 90-day performance projections, software capable of predicting cement's strength development and drones to replace visual inspections in remote spaces.

Holcim Philippines said that it is currently exploring the use of new predictive technologies in its operations.

China: Gansu Shangfeng Cement has announced plans for the establishment of a new building materials digital intelligence research company. Local press has reported that the company will function as a joint venture of a Gansu Shangfeng Cement subsidiary and another company. Gansu Shangfeng Cement says that the new venture will have registered capital of US$70.3m.