Displaying items by tag: circular economy

Sweden: Cemvision has developed a patent-pending beneficiation process to upcycle electric arc furnace (EAF) and basic oxygen furnace (BOF) slags into high-performance supplementary cementitious material (SCM), while recovering valuable metals.

Third-party testing found the material performs as well as or better than ground granulated blast-furnace slag (GGBS). Cemvision recovers 99% of the iron oxide content from EAF slag for reuse in steelmaking, as well as other metals like chromium.

The output will support Cemvision’s Re-Ment Massive and Rapid products as clinker-replacing SCMs. The process was piloted with metallurgical research institute Swerim.

Cemvision CEO Oscar Hållén said “This is a game-changer not only for the cement industry but for steel producers as well. Our process enables high-performing cement products from materials that would otherwise be treated as waste. With this innovation, we're proving that decarbonisation and circularity can go hand in hand, and at scale.”

Portugal: Cimpor will invest €155m in establishing a new research and development centre focused on sustainable construction, CO₂ reduction and digital transformation. The investment will also cover the modernisation of Kiln 7 at the producer’s Alhandra cement plant. The new centre will focus on technologies such as low-clinker cement development, carbon capture and alternative fuels, using recycled concrete and 3D printing. The building itself will incorporate calcined clay-based cement and recycled aggregates.

The new centre will create over 100 jobs and serve as a hub for collaboration with universities and startups, as well as serve as a location for conferences and workshops. The building will operate as a ‘living lab’, with real-time monitoring of its thermal and structural performance and energy consumption.

The chair of Cimpor Global Holdings, Suat Çalbiyik, said “In 2018, we operated only in Portugal and Cape Verde with around 1800 employees. Today, we are the world’s third-largest cement group… with 8000 employees in 14 countries and a production capacity of 112.5Mt/yr of cement.”

Azerbaijan: The Global Cement and Concrete Association (GCCA) has called on governments at the COP29 climate conference to support the decarbonisation of the cement industry. The association published its Net Zero Progress Report 2024/25 to coincide with the conference. The report details the ‘extensive decarbonisation work’ currently underway in the industry, including accelerating carbon capture, utilisation and storage (CCUS), switching to renewable energy sources, advancing the circular economy and reducing cement’s clinker factor. The sector expects to commission its first net zero cement plant, following a carbon capture upgrade to Heidelberg Materials’ Brevik plant in Norway, later in 2024.

GCCA president Fernando González said “Our industry is engaged in the most significant transformation in its history. To fully unlock our decarbonisation progress in this crucial Decade to Deliver, we urgently need effective policy support."

UK: Heidelberg Materials UK has launched evoBuild, a global brand for low-carbon and circular cement, ready-mixed concrete, aggregates and asphalt products, in line with its parent company's sustainability strategy. According to the company, EvoBuild products either reduce CO₂ emissions by at least 30% or incorporate at least 30% recycled content.

This launch complements evoZero, the ‘world's first carbon-captured net-zero cement’, launched by Heidelberg Materials in November 2023. All eligible products from Heidelberg Materials UK will be integrated into the evoBuild portfolio ‘over the coming years.’

One unusual thing about coverage of cement in the media is the way that discussions often centre precisely on its absence – that is, on alternatives to cement. These alternatives boast unique chemistries and performance characteristics, but are all produced without Portland cement clinker. They are generally called ‘alternative cements,’ perhaps because ‘cement-free cement’ does not have such a commercially viable ring to it. This contradictory tendency reached a new high in the past week, with developments in alternative cement across Asia, Europe, the Middle East and North America. Together, they hint at a more diverse future for the ‘cement’ industry than the one we know today.

Asia

In Indonesia, Suvo Strategic Minerals has concluded tests with Makassar State University of a novel nickel-slag-based cement. Huadi Nickel-Alloy Indonesia supplied raw materials, and tests showed a seven-day compressive strength of 37.5MPa. Suvo Strategic Minerals says that a partnership with Huadi Nickel-Alloy Indonesia for commercial production is a likely next step.

Europe

Cement producer Mannok and minerals company Boliden partnered with the South Eastern Applied Materials (SEAM) research centre in Ireland to launch a project to develop supplementary cementitious materials (SCMs) from shale on 7 October 2024. The project will additionally investigate CO₂-curing of cement paste backfill for use in mines. Irish state-owned global commerce agency Enterprise Ireland has contributed €700,000 in funding.

UK-based SCM developer Karbonite expects to launch trial production of its olivine-based SCM with a concrete company in 2025. The start-up launched Karbonite Group Holding BV, with offices in the Netherlands, to facilitate this new phase. Karbonite’s SCM is activated at 750 – 850°C and sequesters CO₂ in the activation process, resulting in over 56% lower CO₂ emissions than ordinary Portland cement (OPC). Managing director Rajeev Sood told Global Cement that talks are already underway for subsequent expansions into the UAE and India.

Back in the UK, contractor John Sisk & Son has received €597,000 from national innovation agency Innovate UK. John Sisk & Son is testing fellow Ireland-based company Ecocem’s <25% clinker cement technology in concrete for use in its on-going construction of the Wembley Park mixed development in London.

At the same time, Innovate UK granted a further €3.23m to other companies for concrete decarbonisation. Recipients included a calcined clay being developed by Cemcor, an SCM being developed from electric arc furnace byproducts by Cocoon, a geopolymer cement technology being developed by EFC Green Concrete Technology UK and an initiative to develop alternative cement from recycled concrete fines at the Materials Processing Institute in Middlesbrough. Also included was the Skanska Costain Strabag joint venture, which is working on the London stretch of the upcoming HS2 railway. The joint venture, along with partners including cement producer Tarmac and construction chemicals company Sika UK, will test low-kaolinite London clay as a raw material with which to produce calcined clay as a cement substitute in concrete structures in HS2’s rail tunnels.

Middle East

Talks are underway between UK-based calcined clay producer Next Generation SCM and City Cement subsidiary Nizak Mining Company over the possible launch of a joint venture in Riyadh, Saudi Arabia. The joint venture would build a 350,000t/yr reduced-CO₂ concrete plant, which would use alternative cement based on Next Generation SCM’s calcined clay.

North America

Texas-based SCM developer Solidia Technologies recently patented its carbonatable calcium silicate-based alternative cement, which sequesters CO₂ as it cures.

Meanwhile, C-Crete Technologies made its first commercial pour of its granite-based cement-free concrete in New York, US. C-Crete Technologies says that the product offers cost and performance parity with conventional cement, with net zero CO₂ emissions. Its raw material is globally more abundant than the limestone used as a raw material for clinker. Other abundantly available feedstocks successfully deployed within C-Crete Technologies’ repertoire include basalt and zeolite.

Across New York State, in Binghamton, KLAW Industries has succeeded in replacing 20% of concrete’s cement content with its powdered glass-based SCM, Pantheon. KLAW Industries has delivered samples to local municipalities and the New York State Department of Transportation. Its success expands the discussion of possible circular cement ingredients from the industrial sphere into post-consumer resources.

In Calgary, Canada, a novel SCM has drawn attention from one of the major cement incumbents: Germany-based Heidelberg Materials. It invested in local construction and demolition materials (CDM)-based SCM developer EnviCore on 9 October 2024. The companies plan to build a pilot plant at an existing Heidelberg Materials CDM recycling centre.

Conclusion

Alternative cement developers are still finding the words to talk about their products. They may be more than ‘supplementary’ up to the point of entirely supplanting 100% of clinker. Product webpages offer ‘hydraulic binder,’ ‘pozzolan’ and even ‘cement.’ As alternative ‘cements’ are developed, they build on the work of pioneers like Joseph Aspdin and Louis Vicat. Start-ups and their backers are now reaching commercial offerings, on a similar-but-different footing to cement itself. None of these novel materials positions itself as the sole, last-minute ‘super sub’ in the construction sector’s confrontation with climate change. Rather, they are a package of solutions which can combine into a net zero-emissions heavy building materials offering, hopefully before 2050.

Related to this is the need for ‘technology neutral’ standards, as championed this week by the Alliance for Low-Carbon Cement and Concrete (ALCCC), along with 23 other European industry associations, civil society organisations and think tanks. The term may sound new, but the concept is critical to the eventual uptake of alternative cements: standards, the ALCCC says, should be purely performance-based. They ought not attempt to define what technology, for example cement clinker, makes a suitable building material. According to the ALCCC, Europe’s building materials standards are not technology neutral, but instead ‘gatekeep’ market access, to the benefit of conventional cement and the exclusion of ‘proven and scalable low-carbon products.’

At the same time, cement itself is changing. Market research from USD Analytics showed an anticipated 5% composite annual growth rate in blended cement sales between 2024 and 2032, more than doubling throughout the period from US$253bn to US$369bn. If you can’t beat it, blend with it!

For a further discussion of alternative cement and binders in Europe, see Global Cement’s interview with ALCCC co-ordinator Joren Verschaeve in the forthcoming November issue of Global Cement Magazine on 17 October 2024.

Spain: Packaging and paper manufacturer Mondi has co-founded Paper Sacks Go Circular Spain, an alliance aimed at enhancing the circularity of used paper bags within the construction sector. The alliance consists of 12 European companies collaborating to eventually elevate recycling processes for construction materials like cement, plaster and insulation. The alliance will start with paper bags, then expanding to other streams such as construction and demolition materials. The initiative aligns with the goal of increasing the recovery rate of construction byproducts in Spain, currently at 48%, according to the latest data from the Spanish National Statistics Institute.

Circular economy manager at Mondi Flexible Packaging, Carlos Martinez Ezquerra, said "This initiative demonstrates Mondi’s commitment to collaborating with industry partners across the value chain to increase recycling rates for used paper bags. It creates a scalable approach for the rest of Europe and other industries, leading to a reduction in ‘waste’ management costs and a significant increase in the valorisation rate, and supports transparency and traceability of the circular economy. We are proud to be one of the founding initiators."

Egypt: Cemex has signed an agreement with Assiut Governorate to operate its second Regenera facility in Egypt. This facility processes about 7,000t/month of municipal solid refuse, treating it to generate alternative fuels before compost production, thereby ensuring minimal residual materials go to landfill. The Assiut agreement follows the first Regenera facility in Mahala, which began operations in May 2024. Cemex has invested over US$2.5m in an alternative fuel dryer at the Assiut plant.

Qatar: The Ministry of Environment and Climate Change has organised a symposium to launch a new ‘green’ cement made from sewage waste, with aims to support environmental sustainability and the circular economy in line with the Qatar National Vision 2030. The symposium highlighted the role of scientific research in transforming sewage into green cement. The cement is produced by treating sludge, resulting from solid sewage waste by burning, grinding and mixing it with catalysts, then is practically applied in the manufacture of building blocks and foam concrete. The amount of accumulated sewage waste is estimated at about 40,000t/yr, which can be used to produce 40 million bricks or 150,000m³/yr of foam concrete.

Germany: Cemex has acquired a majority stake in the Berlin-based recycling company RC-Baustoffe to enhance its circularity business Regenera. The company processes construction, demolition and excavation materials. The acquisition integrates RC-Baustoffe with Regenera, allowing the facility to process up to 400,000t/yr, which will be turned into repurposed aggregates for concrete production.

CEO of Cemex, Fernando González, said “With acquisitions such as this, Cemex continues to strengthen its commitment to circularity through Regenera as well as promoting the world’s transition to a more circular economy. Construction and demolition materials account for more than 30% of global ‘waste’ streams and reintegrating these materials into the construction value chain can reduce the use of virgin raw materials."

Colombia: Cemex Colombia has reported that 90% of the water used at its Santa Rosa grinding plant in 2024 to date came from non-fresh water sources, including rainwater harvesting and water recycling systems. Additionally, the plant operates with zero water discharges. UK-based Environmental Resources Management (ERM) supported the development of the current water management protocol for the plant.