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Update on the UK, June 2024
26 June 2024The Hillhead Quarrying, Construction and Recycling Show is in full flow this week, taking place near Buxton in Derbyshire. As one delegate marvelled on the panoramic minibus journey down to the quarry, “It’s like a music festival without the music and… other stuff.” Indeed. Of course what one doesn’t find at Glastonbury and the like is a near comprehensive range of suppliers, over 600 of them, to the industry all in one place… in a quarry! Where else can one get up close and see the new hydrogen-powered generators and excavating vehicles that are being piloted? The official attendance figures don’t get released until after the event but on the ground it looks as busy as ever. It’s truly the place to be this week.
The show gives us a reason to take a look at the UK cement sector. Like many other countries around the world it is an election year in the UK, with a General Election scheduled for 4 July 2024. The result of this should determine the next Prime Minister and the ruling party. So, naturally, the MPA, the trade association for the aggregates, asphalt, cement, concrete, dimension stone, lime, mortar and industrial sand industries, is taking the opportunity to remind the political parties what its priorities are. The quick version is: support for decarbonisation; a streamlined planning system; and better delivery of projects. This sounds familiar to priorities in other countries but one British spin on this includes the UK’s carbon border adjustment mechanism (CBAM).
Graph 1: Domestic cement sales and imports in the UK, 2017 – 2022. Source: MPA.
Edwin Trout’s feature on the UK cement sector in the June 2024 issue of Global Cement Magazine presents a good overview of the last 12 months. The general UK economy has faced shocks in recent years such as Brexit, Covid-19 and the war in Ukraine. However, this has been further compounded by a downturn and high interest rates since late 2022 when the then Prime Minister Liz Truss caused market turbulence in the wake of a badly received government financial statement. As Trout relates, sales of heavy building materials have been in relative decline since mid-2022 with more of the same expected in 2024. Production of cement in 2023 is currently uncertain given the reporting time lag from the MPA but up until 2022 domestic cement sales fell somewhat but imports grew. This has created a situation where overall cement sales in 2022 were 12Mt, not far behind the annual level in the early 2000s. However, the share of imports has nearly doubled since then. More recent MPA data on mortar and ready-mixed concrete sales throughout the first nine months of 2023 suggest that market activity has decreased and poor weather at the start of 2024 looks set to have made this worse.
Despite the apparent slowdown in building materials sales the cement companies have been conducting smaller-scale maintenance and upgrade projects at their facilities and supply chain schemes such as the cement storage unit for deep sea shipping lines that Aggregate Industries said in February 2024 it was going to build at the Port of Southampton. The news the cement companies want to show off has been a steady stream of information about ongoing decarbonisation projects in the cement sector. C-Capture started a carbon capture trial at Heidelberg Materials’ Ketton cement works in Rutland in May 2024, Capsol Technologies said in March 2024 that it had been selected to conduct a study on its carbon capture technology at Aggregate Industries Cauldon cement plant in Staffordshire, Heidelberg Materials' Ribblesdale cement plant in Lancashire announced in March 2024 that it was taking part in a study to assess the use of ammonia as a hydrogen source for fuelling cement kilns and Heidelberg Materials awarded Japan-based Mitsubishi Heavy Industries (MHI) a front end engineering design contract for a carbon capture installation at its Padeswood cement plant in Flintshire in February 2024. Finally, on the divestment front, CRH completed the sale of its UK-based lime business to SigmaRoc for €155m in March 2024. The business operates from sites in Tunstead and Hindlow with five permitted lime kilns.
That’s it for this short recap on the UK for now. For a longer look at the UK cement sector read Edwin Trout’s feature in June 2024 issue of Global Cement Magazine.
Hillhead 2024 runs until 27 June 2024
UK: Tarmac will utilise River Logic's Digital Planning Twin™ for enhanced supply chain capabilities in its cement division.
Jim Dutton, cement supply chain planning manager at Tarmac, said "We're pleased to have commissioned River Logic as a partner to work with our cement business in the UK. Working with River Logic means we have further support to simplify, connect, and optimise our supply chain efforts. With this third-generation system, we can look at CO2 emissions data in addition to supply and demand information which supports our planning."
Tarmac digitises its rail logistics with Everysens
15 January 2024UK: CRH subsidiary Tarmac has successfully deployed France-based software developer Everysens’ Transport Visibility & Management System (TVMS) in its total operations processing system (TOPS) for rail transport. The TVMS digitally tracks trains, enabling the customer to measure performance, analyse patterns and ensure smooth anticipation and collaboration between stakeholders. Tarmac expects the upgrade to streamline its delivery monitoring and also allow for proactive decision-making.
Tarmac head of rail Chris Swan said "Everysens' integration with TOPS has significantly supported Tarmac to digitise its rail freight operations. Tracking our freight trains has become a lot easier and more precise through digital solutions. With real-time ETA data, we can optimise routes, manage resources, and provide an even higher level of service to our customers. This integration underscores our commitment to staying ahead in technology and embracing digitisation for more efficient and streamlined operations."
Tarmac and Cambridge Electric Cement participate in trial melt of Cement 2 Zero carbon neutral cement project
03 October 2023UK: The Cement 2 Zero project has successfully concluded its first trial melt of recovered cement paste in an electric arc furnace at the Materials Processing Institute’s Teesside campus. The project uses the paste as flux for electric steel recycling. Cambridge Electric Cement (CEC) has demonstrated that the ‘slag’ from this process can be ground into fine clinker that, when mixed with gypsum and supplementary cementitious materials (SCMs), produces net zero CO2 cement. The Cement 2 Zero project to produce CEC’s cement at an industrial scale launched in March 2023, with US$7.85m in funding from UK Research and Innovation. Tarmac will grind the clinker from the project’s trial melts for testing in order to obtain certification and specification as a usable cement product.
UK: A court has fined CRH subsidiary Tarmac US$516,000 for failing to ensure the provision of moveable guards fitted to an interlocking device connected to a rotary mill at its Dunbar cement plant between January 2019 and April 2021. The East Lothian Courier newspaper has reported that the failure resulted in a worker’s loss of fingers after he came into contact with the unit’s rotary valve on 30 April 2021. The producer has until 20 September 2023 to pay the fine.
UK: Aggregate Industries, Breedon, Lhoist and Tarmac have announced the launch of the Peak Cluster, a carbon capture and storage cluster of cement and lime plants. The partners aim to eliminate 3Mt/yr of emissions from operations across their plants in Cheshire, Derbyshire and Staffordshire by capturing 100% of their CO2 emissions. Progressive Energy will oversee the capture and transportation of CO2 from the plants for storage below the Irish Sea. Possible storage partners for the cluster are Liverpool Bay CCS or the upcoming Morecambe Net Zero storage project. When operational, the Peak Cluster will eliminate 40% of emissions from UK cement and lime production. Participating cement plants are Aggregate Industries' 1Mt/yr Cauldon cement plant in Staffordshire, Breedon's 1.5Mt/yr Hope plant in Derbyshire and Tarmac's 0.8Mt/yr Tunstead plant in Derbyshire.
Mineral Products Association (MPA) energy and climate change director Diana Casey said “The launch of the Peak Cluster is an exciting and vital step forward in the journey of the cement and lime sectors towards net zero. The region is a historic heartland for cement and lime production providing highly skilled jobs for local communities, and a secure supply of essential materials to the UK economy." She concluded "The UK Concrete and Cement Industry Roadmap to Beyond Net Zero highlighted the importance of carbon capture for the decarbonisation of the cement and concrete supply chain, and the Peak Cluster is an essential part of that transition. This launch demonstrates the commitment of cement and lime producers to transition to net zero to secure the future of these important industries, and the vital products they produce, in a net zero world.”
Update on recycled concrete paste, February 2023
08 February 2023Cement 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.
UK: Tarmac has appointed Craig Kirkland as the plant manager of Tarmac’s integrated Dunbar plant in Scotland. Kirkland first started working for the subsidiary of Ireland-based CRH in the mid-1990s as its Landfill & Recycling Manager. He later became its Commercial Manager in 2015 before becoming the Head of Transformation at the Dunbar plant in 2021.
Tarmac’s Tunstead lime kiln uses hydrogen fuel
01 July 2022UK: Tarmac has successfully produced lime at its Tunstead, Derbyshire, plant using net zero hydrogen to fuel its kiln. The achievement was the culmination of a series of trials substituting various proportions of hydrogen for natural gas.
Tarmac’s lime director Graham Cooper said “Lime has been manufactured in the Peak District for centuries and this forward-thinking project aims to ensure the future of this nationally significant industry as the UK transitions to net zero.”
UK: Tarmac has supplied its Toptint Glow glow-in-the-dark concrete for a major mixed-use commercial development called The Glass Yard in Chesterfield, Derbyshire. Construction company Blue Deer used Toptint Glow in the main walkways and first-floor balconies of the office, restaurant and retail complex. France-based Chryso supplied its Lumintech glow-in-the-dark chippings for use in the concrete. The supplier said that the chippings are fully recycled. They are available in white, stone, light grey, agate and jade to match the colour of the concrete mix. Each has a corresponding glow colour of blue, green turquoise or blue turquoise. Tarmac says that glow-in-the-dark concrete helps to enhance the nighttime built environment.
Product development manager Glanville Norman said “Tarmac is always looking to develop new and exciting materials that can complement bold design. This is the first time that Toptint Glow has been used on a major commercial development and we were delighted to be able to propose a solution that not only has high aesthetic and environmental quality but also helped to improve safety and visibility.”