Displaying items by tag: US
Türkiye: Exports of cement products from Türkiye to the US have decreased by 12% year-on-year to US$165m from January - March 2024, according to the Türkiye Trade Ministry. The ministry also reported that in March 2024, cement exports to the US fell to US$57.5m, representing a 28% year-on-year decrease. Overall, Türkiye's global cement product exports dropped 7.4% to US$1.1bn in the first quarter of 2024. In March 2024, exports were down 11% at US$390m. Despite these declines, Türkiye achieved cement product exports totalling US$4.5bn from March 2023 - March 2024.
Fortera opens new ‘green’ cement plant in California
15 April 2024US: Fortera has inaugurated its first ‘green’ cement production facility in North America, located in Redding, California. The 2787m2 ReCarb plant operates alongside the existing CalPortland cement plant, capturing CO₂ emissions and mineralising the CO₂ into calcium carbonate for production of the company’s low-carbon ReAct cement. The process reportedly reduces emissions by 70% compared to traditional methods, yielding a tonne of ‘green’ cement for every tonne of limestone input. The facility aims to capture 6600t/yr of CO₂ and to produce 15,000t/yr of ‘green’ cement.
According to Fortera CEO Ryan Gilliam, Fortera currently has 20 upcoming projects with various cement producers, which will cost US$150m each. This includes a plant in the Midwest that will be a 25-fold capacity increase compared to the Redding plant, producing 400,000t/yr of ‘green’ cement.
Cemex's Lyons cement plant operations may be terminated
11 April 2024US: Boulder County has initiated action to terminate the operating licence of the Cemex cement plant near Lyons, Colorado, citing improper expansion of use. Dale Case, director of Boulder County Community Planning and Permitting, sent a notice to the company, motivated by a ‘significant’ rise in traffic. The letter said that the increased traffic created a need for new traffic construction and infrastructure, and requires a new access permit from the Colorado Department of Transportation (CDOT).
The plant has been operational since 1965, but faced changes in 1994 when Boulder County amended its land use code, necessitating special use approval for open mining at the Dowe Flats Quarry. The special use approval for the quarry expired on 30 September 2022, leading to termination of all mining operations and multiple complaints alleging the cement plant's non-compliance with county code and traffic congestion. A CDOT study revealed an increase in truck traffic since the quarry's closure, with daily trips increasing by 50% year-on-year.
Cemex now has a 30-day window to contest the director's determination, reduce plant use, or appeal to the Boulder County Board of Commissioners. The plant will continue operating under existing conditions until a final decision is reached.
New slag cement facility in Houston
10 April 2024US: Eagle Materials and Heidelberg Materials North America, through their joint venture Texas Lehigh Cement Company, will start up a new slag cement facility. The facility will be located in Houston, Texas and will start production in the summer of 2024. When completed, it will have a production capacity of 500,000t/yr. This is in addition to Texas Lehigh’s cement plant in Buda, Texas.
US/Austria: RHI Magnesita (RHIM) plans to acquire Resco Group for US$430m. The acquisition of Resco will add fireclay and pyrophyllite-andalusite mining operations in the US to its existing magnesite and dolomite operations across Europe, the US, Brazil and China. Furthermore, RHIM aims to transfer ‘significant’ production volumes from non-US plants to Resco's US facilities. The completion of the acquisition is anticipated in the second half of 2024.
Holcim US invests in Midwest operations
05 April 2024US: Holcim US has announced an investment of US$20.5m in its Midwest operations. A key component of the investment is the new 35m-high cement storage dome in Fremont, Nebraska, which will increase its production capacity of ECOPlanet low-carbon cement. The dome has the capacity to store 50,000t of cement. Construction of the dome, which began in 2021, has contributed to local economic development and job creation at the terminal.
In line with the Nebraska Department of Transportation's blended cement requirement, the cement blended and distributed at the terminal incorporates natural pozzolan, a binding agent, to produce a lower carbon product compared to ordinary Portland cement.
US fully adopts portland-limestone cement
04 April 2024US: The Portland Cement Association (PCA) has commended the Connecticut Department of Transportation's approval of Portland-limestone cement (PLC), marking its acceptance in all US states and the District of Columbia. PLC, with increased limestone content, maintains traditional portland cement's efficacy but reduces CO₂ emissions by up to 10%. The US avoided more than 4Mt of CO₂ emissions in 2023 by using PLC and other blended cements. This achievement coincides with growing cement consumption by state transportation departments, fuelled by the Bipartisan Infrastructure Law.
Mike Ireland, president and CEO of PCA, said "This milestone is a huge step forward for sustainable American construction. Switching to PLC promises to save millions of tonnes of CO₂. Using a lower-emission product that meets all the performance requirements of traditional cement means the construction sector can build with durability, safety and sustainability in mind."
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."
Decarbonising the cement sector in the US, March 2024
27 March 2024The US Department of Energy (DOE) announced a US$1.6bn investment in the cement sector this week. The funding was part of a total of US$6bn for 33 projects in over 20 states to decarbonise energy-intensive industries also including chemicals and refining, iron and steel, aluminium and metals, food and beverages, glass, process heat applications and pulp and paper. The DOE was keen to link the money to “the President’s Bipartisan Infrastructure Law and Inflation Reduction Act.” Politics is never far away it seems! The projects are part of the Industrial Demonstrations Program, managed by DOE’s Office of Clean Energy Demonstrations (OCED).
Company | State | Funding | Scale | Method |
Heidelberg Materials US | Indiana | US$500m | Full | CCS |
National Cement | California | US$500m | Full | Alternative fuels, calcined clay, CCS |
Summit Materials | Georgia, Maryland, Texas | US$216m | Demonstration | Calcined clay |
Brimstone Energy | TBD | US$189m | Commercial | Raw material substitution |
Sublime Systems | Massachusetts | US$87m | Commercial | Raw material substitution |
Roanoke Cement | Virginia | US$62m | Demonstration | Calcined clay |
Table 1: Summary of US Department of Energy funding announced on March 2024 to decarbonise cement and concrete production
Table 1 above shows the main approaches each of the projects aim to use. The two most expensive ones involve carbon capture and sequestration (CCS) at Heidelberg Materials US’ Mitchell cement plant in Indiana and National Cement’s Lebec plant in California respectively. In a complimentary press release Chris Ward, the CEO of Heidelberg Materials North America, said “This substantial federal funding investment will help create the first full-scale deployment of carbon capture and storage on a cement plant in the US.” The proposed CCS unit at the plant will capture around 2Mt/yr of CO2 from 2030. If Ward’s forecast is accurate (and no one beats them to it), then Heidelberg Materials will likely have set up the first full-scale CCS units at cement plants in both North America and Europe. This will be a significant achievement. The National Cement project, by contrast, is a mixed bag of approaches to decarbonising cement production that follows the multi-lever approach advocated for in many of the industry net-zero roadmaps. It intends to use agricultural by-products such as pistachio shells, as alternatives fuels to lower the fuel-based emissions, calcined clay to lower the clinker factor and CCS to capture the remaining 950,000t/yr of CO2 emissions.
The other projects either involve using calcined clay or substituting limestone with calcium silicate. The Summit Materials proposal is noteworthy because it aims to build four clay calcination units in locations in Maryland, Georgia and Texas. None of these appear to be near Summit’s (or Cementos Argos’) cement plants. This suggests that the company may be intending to use calcined clay in ready-mixed concrete production. The Roanoke Cement Company calcined clay project will be baseEuropead at its cement plant in Troutville, Virginia.
The remaining two grant recipients, Brimstone and Sublime Systems, will both test the companies’ different methods of manufacturing cement by using calcium silicate instead of limestone. Brimstone’s method produces ordinary Portland cement (OPC) and supplementary cementitious materials (SCM). The company said in July 2023 that its OPC met the ASTM C150 standards. However, the company has released less information about its actual process. Sublime Systems’ uses an electrolysis approach to create its ASTM C1157-compliant cement. It calls this ‘ambient temperature electrochemical calcination.’
Investment on the same scale of the DOE has also been happening in Europe. In July 2023, for example, the European Commission announced an investment of Euro3.6bn in clean tech projects to be funded from the proceeds of the European Union emissions trading scheme (ETS). This was the third call for large-scale projects following previous announcements of recipients in 2021 and 2022. Euro1.6bn of the third call funding went towards cement and refining projects including five cement and lime projects in Belgium, Croatia, Germany and Greece. The money granted for each of these schemes was in the region of Euro115 - 235m.
Both the US and Europe are throwing serious finance at the cement industry to try and kickstart the various pathways towards net zero. They are also doing it in different ways, with the US aiming to boost its economy by onshoring sustainable industry, and Europe hoping to fund its approach via carbon taxation. Government-driven decarbonisation investment for cement in other large countries and regions around the world appears to be lagging behind the US and Europe but these may spring up as net zero targets are set, roadmaps drawn up and government policy formulated. These places could also benefit from watching what works and does not work elsewhere first. Back in the US and Europe the next tricky part of this process will be bridging the gap between government subsidy and commercial viability.
US: Summit Materials has appointed John Terembula as Senior Director, Grinding Technology. He previously worked for FLSmidth from 1994 to early 2024 in a variety of engineering and then product manager roles for grinding applications. His final position at FLSmidth was as Global Product Line Manager, Vertical Roller Mills. Terembula holds a degree in chemical engineering and materials from Lafayette College and an MBA from Temple University.