Displaying items by tag: Switzerland

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

Russia: Holcim Russia says that it is continuing to work as normal and is “fully fulfilling its obligations” to its customers. In a statement on its website it said that its priorities were to, “...maintain the efficient operation of production sites, meet the needs of construction industry customers, and the well-being of the company's 1800 employees in Russia.”

Parent company Holcim, based in Switzerland, said that it was appalled by the human suffering in Ukraine and Eastern Europe. It added that its operations in Russia were continuing to run in full compliance of all regulations and that it would continue to supply the local market. However, it said that it had decided to suspend further capital investments in Russia and keep the situation under review.

Switzerland: Vigier Ciment is operating a self-charging electric dump truck at its limestone and marl quarry in Biel. The 45t truck’s regenerative braking system recharges its 600kwh lithium battery on the downhill trip from the quarry to the primary crusher. Its 65t capacity more than doubles its weight when laden, easily enabling it to recover charge for the return trip. Each trip generates an estimated 10kwh of surplus energy. In ordinary use, this would equate to 77Mwh/yr. It saves 50,000 – 100,000l/yr of diesel and eliminates an estimated 196t/yr of CO₂. Green Car Reports has reported that Kuhn Schweiz built the dump truck, based on Japan-based Komatsu’s HB model truck. It is the world’s largest electric vehicle.

Switzerland: Holcim has appointed Toufic Tabbara as Region Head North America and a member of the group executive committee. He succeeds René Thibault, who has decided to leave the company.

Tabbara was most recently working as the chief executive officer for US Cement. He joined the group in 1998 as Director Strategy & Development in the US and has led Holcim’s ready-mix concrete, aggregates and cement businesses in the US, Canada, Egypt, Jordan, Lebanon and Algeria.

He holds a Master of Business Administration from the Thunderbird School of Global Management in Arizona, US and a Bachelor of Business Administration from the American University of Beirut in Lebanon.

Switzerland: Holcim’s full-year 2021 results show a 16% year-on-year rise in the group’s consolidated sales to US$28.3bn from US$24.4bn. Its recurring earnings before interest, taxation, depreciation and amortisation (EBITDA) increased by 26% to US$5bn from US$3.98bn. The group’s net debt also rose, by 18% to US$10.8bn from US$9.17bn.

CEO Jan Jenisch said “2021 was a record year for Holcim, reaching new levels of performance, across our financial and environmental social governance (ESG) targets. What makes me most proud is how we navigated the Covid-19 pandemic with such extraordinary resilience and agility, working tirelessly to keep our people and communities safe.” Jenisch continued “We delivered our Strategy 2022 one year in advance, setting solid foundations for our next era of growth. Putting sustainability at the core of our strategy, we accelerated the deployment of our green building solutions, from ECOPact green concrete and ECOPlanet green cement to smart roofing and energy efficiency systems. My sincere thanks goes to our 70,000 people who made all of this possible while keeping safety top of mind at all times.”

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."

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.”

Switzerland/Germany: Holcim has announced the launch of a strategic partnership with inductive charging technology developer Magment to test and commercialise magnetisable concrete technology for use in roads. The technology will power and charge electric vehicles as they drive on roads fitted with Magment. Another possible application is in industrial floors, to charge robots and forklifts.

Holcim’s Global Innovation Center head Edelio Bermejo said: “At Holcim we are innovating to put concrete at the centre of our world’s transition to net-zero. With Magment, we are excited to be developing concrete solutions to accelerate electric mobility. Partnering with start-ups all over the world, we are constantly pushing the boundaries of innovation to lead the way in sustainability.”

US: Holcim says that it has completed its acquisition of Washington-based ready-mix concrete and aggregates producer Cowden. The group said that the acquisition expands its footprint in the Pacific Northwest region.

Chief executive officer Jan Jenisch said “This acquisition is another step in our Strategy 2025 – Accelerating Green Growth plan to become the global leader in innovative and sustainable building solutions. We warmly welcome the more than 100 Cowden employees who join the Holcim family. With Cowden and its strong local roots we will strengthen our presence in this growing market and contribute to Holcim’s overall strategy to expand our range of low-carbon products and solutions.”

Switzerland: Holcim has launched the DYNAMax range of high-performance concretes. The producer says that the range offers higher compressive strength, rigidity and durability than its other concrete products. In 2022, it plans to begin marketing DYNAMax in ten markets in its Asia Pacific, Europe, Latin America and North America regions.

Chief executive officer Jan Jenisch said “I’m excited by the launch of our DYNAMax high-performance concrete, advancing our global range of innovative and sustainable building solutions. With today’s population and urbanisation trends, DYNAMax is an ideal material to build smarter cities. It offers high performance to build more with less with no compromise on aesthetics and functionality.”