Displaying items by tag: bauxite

India: ACC’s Chaibasa cement plant in Jharkhand has received its first instalment of fly ash for use in cement production from Vedanta Aluminium subsidiary Vedanta Jharsuguda. Global Cement News previously reported that Vedanta Aluminium had been seeking a cement industry fly ash and bauxite residue buyer for a long-term collaborative partnership in July 2021.

In the 2022 financial year, Vedanta Aluminium supplied 190,000t of fly ash to Indian cement producers.

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

Australia: Researchers from Murdoch University in Western Australia have developed a cement-free concrete called Colliecrete. ABC News has reported that the concrete comprises of 80 – 90% fly ash. Other ingredients are bauxite residue and recycled aggregates. Developer Ramon Skane said that customers can make Colliecrete ‘anywhere, at room temperature.’

Germany/Brazil: Researchers at the Martin Luther University Halle-Wittenberg in Saxony-Anhalt and the University of Pará in Pará have produced a cement alternative with 66% reduced CO₂ emissions. A type of calcium sulphoaluminate cement, it replaces up to 60% of limestone in clinker with overburden from bauxite mining. Researchers demonstrated that the resulting product conforms to all standards for commercial Ordinary Portland Cement. The results of the research have been published in ‘Sustainable Materials and Technologies.’

India: Vedanta Aluminium has expressed interest in a long-term collaborative partnership with a cement producer. The Economic Times newspaper has reported that, in such a partnership, Vedanta would supply the producer with fly ash and bauxite residue with which to produced reduced-CO₂ cement. The company said that a cement producer could be its ‘perfect circular economy partner.’

Chief executive officer Rahul Sharma said "We hope the Indian cement producers come forth to work with us on this innovative solution, which is a true win-win scenario for the industry and environment.”

US: Cemtech Materials will produce cement using bauxite residue supplied under a new contract signed with New Day Aluminium Holdings subsidiary Noranda Alumina. Noranda Alumina has executed a letter of intent with Cemtech to sell it 60,000t of bauxite residue starting in the fourth quarter of 2020. The bauxite will be used in the cement production process as the raw material for iron, replacing other current iron bearing raw materials.

Noranda Alumina chair and chief executive officer (CEO) David D’Addario said, “We are focused on continuously improving the sustainability of our business and reducing our environmental footprint on our path to a zero residue refinery, and look forward to helping our partners in the cement industry to achieve their aligned goals.”

The deal follows a beneficial use approval from the Louisiana Department of Environmental Quality. Noranda Alumina is located in Gramercy, Louisiana. It produces smelter grade alumina for the production of aluminium and chemical grade alumina for non-metallurgical applications.

India: Metals producer Hindalco has won a contract to supply fellow Aditya Birla subsidiary UltraTech Cement with 1.2Mt/yr of bauxite residue from its aluminium operations, up by 180% from 250,000t in the 2020 financial year, which ended on 31 March 2020. The Economic Times newspaper has reported that UltraTech Cement will use the bauxite residue – or ‘red mud’ – in cement production at 14 of its plants across seven states. As a result of the deal, Hindalco, the world’s largest producer of rolled aluminium, will have full bauxite residue utilisation across three of its refineries. Managing director Satish Pai said, “We have been working with producers to develop high-grade inputs for the cement industry.”

Brazil: Norway-based Norsk Hydro and the Federal University of Para (UFPA) have announced their collaboration on the development of a low-carbon cement from bauxite residue from Norsk Hydro subsidiary Alunorte’s bauxite mining and alumina refining operations in the state of Pará. Electronic News has reported that the research partnership hopes to develop a new cement for commercial production and sale by 2030. This will use an estimated 500,000t/yr of waste bauxite residue.

Norsk Hydro bauxite and alumina research and development senior manager Erik Araujo said, “Hydro seeks to be a benchmark in sustainability in the aluminium industry. The research is an opportunity to promote intersectional advances in our environmental management, with a reduction in carbon emissions for the cement industry.

Australia/Bangladesh: Australian Bauxite has negotiated a letter of intent with Bangladesh’s Aziz Group. As part of the agreement it will use Aziz Group as its agent to market cement-grade bauxite in the country. The deal will also see Australian Bauxite supply chemical-grade bauxite to Aziz Group for the manufacture of polyaluminum chloride to be used in the treatment of industrial waste water.

"There is a real opportunity for our well established trading and manufacturing relationships to be of significant support in the marketing of this specialised Australian Bauxite cement-grade bauxite. We look forward to jointly developing a good market base for real supply opportunities,” said Johnny Chowdhury, the chief executive officer (CEO) of Aziz Group

Australian Bauxite operates a bauxite mine in Tasmania. It also holds mining tenements in Queensland, New South Wales and Tasmania for future development.

Australia: Australian Bauxite has completed its second and largest shipment of cement-grade bauxite, comprising 35,913t, from its Bald Hill mine.

“We have now demonstrated to all our customers that we can load and ship large tonnage cargos of bauxite very efficiently from Bell Bay Port. It also demonstrates that our stockpiles of bauxite performs very well, having withstood the recent major floods in northern Tasmania, without degrading. This is another landmark step for the company,” said Australian Bauxite’s Chief Operating Officer, Leon Hawker.

The mining company intends to sell its bauxite products into three main markets including cement-grade bauxite for the production of high specification cement. It re-opened its Bald Hill Bauxite Project at Campbell Town in northern Tasmania in early August 2016 ahead of the scheduled date.