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Cement shortages were being reported in the US media last week in Alabama and South Carolina. The owner of a ready-mixed concrete supplier in South Carolina was blaming it on labour and supply shortages. Dan Crosby, the president of Metrocon, told Fox News that his business could only take on 60% of the work it could normally cope with due to the issue despite demand for construction growing in the state. Meanwhile, the Alabama Concrete Industries Association said that its home state saw a 14% increase in the demand for concrete in 2021 but that a cement shortage might cause delays to projects. The association also pointed the blame at labour and supply issues. It pointed out that high demand for concrete during the winter prevented inventory being built up and then the annual cement plant maintenance breaks in the spring added to the problems. Once contractors actually secured supplies of cement they then faced further delays due to a nationwide truck driver shortage!

Graph 1: Annual rolling cement shipments in the South of the US. Source: USGS.

Data from the United States Geological Survey (USGS) doesn’t especially shed light on the situation in Alabama and South Carolina. Alabama was the fifth largest cement producing state in the country in January 2022 but this is unsurprising as it’s the state with the fifth largest cement production capacity. Rolling annual data on Portland and blended cement shipments by origin show the effects of the coronavirus outbreak in the south from the start of 2020 to January 2022. Shipments took a dive in 2020 and then mostly recovered in 2021. However, Alabama, Kentucky and Tennessee saw shipments rise from 7.1Mt pre-pandemic to 7.6Mt in January 2022. South Carolina’s shipments grew from 3Mt to 3.2Mt. Regionally, the North East had a similar pattern although, unlike the South, shipments have surpassed those at the start of 2020. The Midwest and West were different with a general upwards trend over the two years, although the West softened slightly from mid-2021 onwards. Overall the US as a whole has seen its shipments grow throughout this period.

Ed Sullivan from the Portland Cement Association (PCA) told the May 2022 issue of Global Cement Magazine that the US cement sector did well in 2021 with a 4.1% year-on-year rise in sales to 104Mt. However, he flagged up supply chain problems that actually slowed growth, led by a lack of staff.

The other point along these lines that Sullivan made was that imports of cement might not necessarily be able to compensate for domestic supply issues due to global demand for shipping post-coronavirus. USGS data placed imports to the US at 13.7Mt in 2019 compared to 16.3Mt in 2021. Notably, Cemex restarted one production line in 2021 at its CPN cement plant in Sonora State in Mexico to export cement to the west of the US. In March 2022 it added that it was going to restart another line at the plant also. It’s not alone though as GCC reported in January 2022 that a line at one of its plants in Chihuahua, Mexico, was exporting cement to Texas. Sullivan reckoned that January 2022 was ‘weak’ but that it was followed by an ‘extremely strong’ February 2022. The first quarter results from Holcim and CRH seem to back this up with the former describing the period as ‘outstanding’ and the region leading its sales and earnings growth rate globally. CRH reported strong demand in central and southern regions.

As the US economy restarted following the peak of the early coronavirus waves in 2020, various supply chain issues have manifested. Staff shortages are one issue and this can also worsen other logistic problems. The south seems particularly vulnerable to all of this as it is both the country’s largest cement market and because demand has held up. In January 2022 research by the International Monetary Fund (IMF) identified several reasons for staff shortages in the US and the UK. These included increased inactivity among older workers, the so called ‘She-cession’ (where female employment has overly reduced due to coronavirus trends) and shifting worker preferences amid strong labour demand.

Staff shortages are expected to sort themselves out throughout 2022 but favourable forecast demand for cement in the US is balanced by inflationary pressure. Persistent low staffing levels could further add to inflation growth. The US cement sector may be doing well at the moment but even success carries risks.

Global Cement’s Robert McCaffrey will be giving a keynote presentation at the IEEE-PCA Cement Conference in Las Vegas on Tuesday 3 May 2022. The May 2022 issue of Global Cement Magazine, including interviews with PCA chief executive officer Mike Ireland and chief economist Ed Sullivan, is available to download now.

Germany: ThyssenKrupp Uhde, Holcim and the Technische Universität Berlin have started a joint project to investigate the use of a novel amine scrubbing technology for carbon capture. The goal is to significantly reduce CO₂ emissions from existing cement plants and at the same time utilise the captured CO₂ for other applications. This includes the development of new mass transfer process equipment that is more efficient and resilient to contaminations. The project is being funded by the German Federal Ministry for Economic Affairs and Climate Action.

The equipment is being tested using exhaust gas at Holcim’s Beckum plant. Various possibilities for using the captured CO₂ are also being examined, such as manufacturing methanol or sustainable fuels. The aim is develop a technology that can be retrofitted at existing cement plants.

Ralph Kleinschmidt, head of technology, innovation and sustainability at ThyssenKrupp Uhde said, "Amine scrubbing is already commonly used to recover CO₂ from process gases or exhaust gases. Now, we are developing the technology further and optimising it for the cement industry. Additional applications for capturing CO₂ direct at source, such as in waste incineration plants, are also possible."Arne Stecher, head of decarbonisation at Holcim Germany added that the company is testing different processes to find the best carbon capture technology.

From the Nordics to the Mediterranean, European countries lead the field in reduced-clinker cement production using supplementary cementitious materials (SCMs). While consumers, faced with ever-greater choice, continue to opt for sustainability, projects to improve existing SCMs and develop new ones have won government backing and have become a matter of serious investment for other heavy industries beside cement. European cement producers’ decisions are steering the course to a world beyond CEM I. Yet, even in Europe, great untapped potential remains.

Companies generated a good deal of marketing buzz around their latest reduced-CO₂ cement ranges in 2021 and the first quarter of 2022: Buzzi Unicem’s CGreen in Germany and Italy, Holcim’s EcoPlanet in six markets from Romania to Spain, Cementir Holding’s Futurecem in Denmark and Benelux, and Cemex’s Vertua in Spain and several other countries. All boast reduced clinker factors through the use of alternative raw materials. This, however, is really a rebranding of a long-established norm in Europe.

Since 2010, cements other than CEM I have constituted over 75% of average annual cement deliveries across Cembureau member countries (all cement-producing EU member states, plus Norway, Serbia, Switzerland, Turkey, the UK and Ukraine). This statistic breaks down differently from country to country. CEM II is the norm in Austria, Finland, Portugal and Switzerland, with deliveries in the region of 90%. Portland limestone cement (PLC) makes up a majority of deliveries in all four. It has been central to Switzerland’s transition to 89% (3.72Mt) of CEM II deliveries out of a total 4.18Mt of cement despatched in 2021. There, the main types of cement were CEM II/B-M (T-LL) Portland composite cement, with 1.38Mt (33%), and two different classifications of PLC: CEM II/A-LL PLC, with 1.28Mt (31%), and CEM II/B-LL PLC, with 888,000t (21%).

A second approach is that of the Netherlands, where CEM III blast furnace slag cement with a clinker factor below 65% predominates, favoured for its sulphate resistance and the protection it offers against chloride-initiated corrosion of steel reinforcement in marine settings. By contrast, the UK has traditionally maintained a higher reliance on CEM I cement. This can be partly explained by the preference of builders there for adding fly ash or ground granulated blast furnace slag (GGBFS) at the mixing stage. Nonetheless, CEM II Portland fly ash cement held a 14% (1.43Mt) market share in the UK’s 10.2Mt of cement consumption in 2021.

The UK Mineral Products Association (MPA) has identified limestone as an underutilised resource in the country’s cement production. Together with HeidelbergCement subsidiary Hanson Cement, it has applied for a change to National Application standards to allow the production of Portland composite cement from fly ash and limestone or GGBFS and limestone. The association has forecast that Portland composite cement could easily rise to 30 – 40% of UK cement consumption, and that this has the potential to eliminate 8% of the sector’s 7.8Mt/yr-worth of CO₂ emissions.

Metallurgical waste streams have long flowed into European cement production, primarily as GGBFS, but also as bauxite residue. In 2021, alumina production in the EU alone generated 7Mt of bauxite residue, of which the bloc recycled just 100,000t (1.4%) that year. Two projects – the Holcim Innovation Center-led ReActiv project and Titan Cement and others’ REDMUD project – aim to produce new alternative cementitious materials from bauxite residue.

By collaborating with other industries, cement producers’ investments can most effectively reduce the overall cost of using these materials in cement production. In Germany, HeidelbergCement and ThyssenKrupp’s Save CO₂ project aims to develop new improved latent hydraulic binders or alternative pozzolan from GGBFS by producing slag from directly reduced iron (DRI). The Save CO₂ team believes that GGBFS substitution for clinker has the capacity to eliminite 200Mt/yr of CO₂ emissions from global cement production.

Meanwhile in the world of mining, ThyssenKrupp and others’ NEMO project is investigating the recovery of a useable mineral fraction for cement production from the extractive waste of the Luikonlahti and Sotkamo mines in Finland and the Tara mine in Ireland, through bioleaching and cleaned mineral residue upcycling. This may give cement producers full access to Europe’s 28Bnt stockpiles of sulphidic mining waste, of which mines generate an additional 600Mt each year.

Denmark-based CemGreen, which produces the calcined clay supplementary cementitious material CemShale, is developing a shale granule heat-treating technology called CemTower. This consists of three pieces of equipment vertically integrated into cement plants’ preheaters, kilns and coolers, and brings the processing of waste materials – here oil shale – to the cement plant.

Lastly, cement producers are exploring the possible uses of waste made of cement itself. In Wallonia, HeidelbergCement subsidiary CBR’s CosmoCem project is investigating the production of alternative cement additives from large available flows of local demolition, soil remediation and industrial waste. Similarly, the Greece-based C2inCO₂ project seeks to mineralise fines from concrete recycling for HeidelbergCement to use in the production of novel cements in its Greek operations.

In Switzerland, ZND Portland composite cement (produced using fine mixed granulate from building demolitions) is the third largest cement type, with 178,000t (4.3%) of total deliveries – narrowly behind CEM I with 239,000t (5.7%).Holcim Schweiz developed its Susteno 4 ZND Portland composite cement with Switzerland’s lack of any ash or slag supply in mind, demonstrating the potential flexibility of a circular economic approach to cement production.

On 21 March 2022, the University of Trier reported that it is in the process of mapping mineral resources, waste deposits and usable residues ‘on a cross-border scale,’ in an effort to produce new materials for use in cement production. Industry participants include France-based Vicat, CBR, Buzzi Unicem subsidiary Cimalux and CRH subsidiary Eqiom. Vicat is preparing a kiln at its 1Mt/yr Xeuilley cement plant in Meurthe-et-Moselle to use in testing new alternative raw materials developed under the project.

For Cembureau and its members, work continues, with the goal of Net Zero by 2050 constantly in sight. This goal includes a reduction in members’ clinker-to-cement ratios to well below 65%. In this, the association and its members are working towards a world not just beyond CEM I, but beyond CEM II, too. What exactly this will mean remains to be seen.

Sources

CemSuisse, ‘Lieferstatistik,’ 11 January 2022, https://www.cemsuisse.ch/app/uploads/2022/01/Lieferstatistik-4.-Quartal-2021.pdf

WSA, ‘December 2021 crude steel production and 2021 global crude steel production totals,’ 25 January 2022, https://worldsteel.org/media-centre/press-releases/2022/december-2021-crude-steel-production-and-2021-global-totals/

MPA, ‘Low carbon multi-component cements for UK concrete applications,’ July 2018, https://prod-drupal-files.storage.googleapis.com/documents/resource/public/Low%20carbon%20multi-component%20cements%20for%20UK%20concrete%20applications%20PDF.pdf

European Commission, ‘European Training Network for Zero-waste Valorisation of Bauxite Residue (Red Mud),’ 16 July 2020, https://cordis.europa.eu/project/id/636876

European Commission, ‘Industrial Residue Activation for sustainable cement production,’ 16 February 2022, https://cordis.europa.eu/project/id/958208

Recycling Portal, Zement der Zukunft – Forschungsprojekt „SAVE CO₂“ gestartet, 28 May 2021, https://recyclingportal.eu/Archive/65677

h2020-NEMO, ‘Project,’ https://h2020-nemo.eu/project-2/

European Commission, ‘Green cement of the future: CemShale + CemTower,’ 14 April 2021, https://cordis.europa.eu/project/id/101009382

CosmoCem, ‘Communiqué de Presse,’ https://cosmocem.org/

CO₂ Win, ‘C²inCO₂: Calcium Carbonation for industrial use of CO₂,’ https://co2-utilization.net/en/projects/co2-mineralization/c2inco2/

Les Echos, ‘Rendre le ciment moins gourmand en CO₂,’ 21 March 2022, https://www.lesechos.fr/pme-regions/innovateurs/des-substituts-au-clinker-rendent-le-ciment-moins-gourmand-en-co2-1395002

US: The Portland Cement Association (PCA) has told the Department of Energy’s Advanced Manufacturing Office (AMO) that federal policy and support is vital to accelerate the deployment of technologies that can decarbonise the local industrial sector. In its comments to the office, the PCA said that it shares the Biden-Harris Administration’s goal of carbon neutrality by 2050 through its own Roadmap to Carbon Neutrality, which lays out a pathway to achieve this across the cement-concrete-construction value chain by 2050. However, it warned that without strong federal support the AMO’s timeline to reach carbon neutrality across industry was unrealistic due to the “significant technical, legal and economic challenges regarding technologies like carbon capture utilisation and storage (CCUS), and others including hydrogen fuel and kiln electrification.”

“Federal policy must accelerate the significant technology, funding, and market innovation needed for rapid decarbonisation while preserving economic growth and international competitiveness,” said Sean O’Neill, senior vice president of government affairs at the PCA. “The adoption of CCUS is key to achieving deep decarbonisation in the cement industry.”

The PCA added that with the right federal and state policies, CCUS could become scalable within 10 years but infrastructure, policy, permitting and funding challenges remain. It suggested that tax incentive reforms and the use of Department of Energy loan programmes could accelerate early investment and adoption of CCUS.

The use of hydrogen fuels and kiln electrification was mentioned but these technologies are seen as being at least 15 – 20 years away. The association said that hydrogen remained very expensive and there was little current infrastructure for the transport and storage of hydrogen. More research and development is required to start evaluating the efficacy of kiln electrification.

UK: A consortium led by Australia-based First Graphene dedicated to developing graphene-enhanced cement has won Euro228,000 in UK government funding. Innovation agency Innovation UK selected the consortium for its work’s potential to contribute towards cement and concrete’s carbon footprint reduction of 25% by 2030. UK-based Breedon Cement represents the cement industry within the consortium.

China: China National Building Material subsidiary Nanjing Kisen has signed a long-term collaboration agreement with France-based Schneider Electric. The partners plan to develop models for increasing operational efficiency, digitisation and sustainability. Alliance News has reported that they will establish a series of joint pilot projects. They plan subsequently to explore plant engineering, procurement and construction (EPC) opportunities outside of China together.

Switzerland/France: Holcim is collaborating with Engie and and the French National Institute of Applied Sciences (INSA) Lyon to develop a cement-based energy storage technology to serve as an alternative to batteries. The solution will use cement hydration to store heat as energy and release it when needed in an infinitely repeatable cycle. The partners say that it will make energy storage local, safe, affordable and recyclable.

Holcim’s head of global innovation Edelio Bermejo said "The world needs innovative solutions to accelerate our shift towards renewable energy generation, distribution and storage – all areas in which Holcim can play a big part. With this collaboration, we are moving energy storage forward, opening up a new range of solutions based on materials that are local and recyclable."

Italy: Holcim has signed a collaboration agreement with energy company Eni for the development of ENI’s magnesium silicate-based carbon utilisation technology. The reaction of the magnesium silicate with captured CO₂ emissions yields a product which Holcim hopes to use in its cement production.

Holcim Innovation Center head Edelio Bermejo said “Reaching net zero in cement manufacturing will require the deployment of carbon capture, utilisation and storage technologies at scale. ENI’s solution is very promising, and we are happy to explore its potential as it could take us all one step further on our decarbonisation journey.”

Switzerland: Holcim has partnered with Bloomberg Media to launch the Circular Cities Barometer, an exploration of best circular economy practices from cities around the world. The platform aims to improve understandings of how to empower cities to become more circular. The partners will publish the Circular Cities Barometer’s first findings at the Bloomberg Green Summit in April 2022.

CEO Jan Jenisch said “Circularity is the opportunity of our time. It unlocks economic growth in a way that is climate-friendly, nature-positive and socially inclusive. My vision for construction is to build more new from the old with recycled materials in every new building.”

Australia: RMIT University in Melbourne, Victoria, has developed a new method of carbon capture, called the bubble column method. The method uses liquid gallium at 100 – 120°C, through which flue gas is bubbled. This activates the CO₂, leading to oxidation of the metal. The captured carbon accumulates on the surface of the pool.

Gallium is a by-product of bauxite and zinc ores mining. The United States Geological Service (USGS) has estimated its global reserves in these ores alone as 1Mt.

Project co-lead Torben Daeneke said “Turning CO₂ into a solid avoids potential issues of leakage and locks it away securely and indefinitely. Because our process does not use very high temperatures, it would be feasible to power the reaction with renewable energy.” He added “Ideally the carbon we make could be turned into a value-added product, contributing to the circular economy and enabling the carbon capture and storage (CCS) technology to pay for itself over time.”

The Australian Government plans to invest US$719m in low emissions technologies by 2050 under its Net Zero Plan.