Displaying items by tag: geopolymer cement

India: A Bangalore-based startup formed at the Indian Institute of Science (IISc) has developed an ‘eco-friendly’ cement alternative using geopolymer technology. The product claims to reduce CO₂ emissions by 21.5kg/m² of pavers produced compared to ordinary Portland cement, according to The Economic Times. It also claims to eliminate water use and offer a 15-20% cost advantage. The product achieves full strength in just three days, compared to the 28 days required for Portland cement.

Nanjunda Rao, one of four cofounders of Novacret and chief research scientist at IISc, said “The benefits are significant, geopolymer-based materials achieve full strength in just three days in tropical climates like India, compared to the 28 days required for Portland cement.”

Indonesia: Suvo Strategic Minerals has reached a non-binding agreement to form a joint venture (JV) with PT Huadi Bantaeng Industry Park (PT HBIP) to commercialise and manufacture low-carbon cement and concrete products that contains nickel slag and other byproducts. The JV will produce geopolymer cement and related products in Indonesia.

PT HBIP will supply nickel slag and other raw materials from its stockpiles at Bantaeng Industry Park and provide infrastructure, including land, port facilities and utilities like power and water. Suvo’s subsidiary, Climate Tech Cement, will deliver the low carbon cement formulations.

Aaron Banks, Suvo’s executive chair, said “The formation of this partnership is a key milestone for the company as it adds significant scale for potential future operations. The consumption of Portland cement within the broader region is around 300 - 400Mt/yr. Huadi, in alliance with other smelters, produce around 15Mt/yr of nickel slag. This partnership has the potential to lock in the necessary supply chains and give the company the best chance for success in delivering this low carbon cement to market.”

Banks also confirmed that Suvo has started preliminary offtake discussions for its low carbon cement product with ‘large users’ in Indonesia and Southeast Asia.

UK: Material Evolution has launched its 'ultra-low carbon' cement production plant, Mevo A1, in Wrexham. The facility was commissioned in October 2024 and operates on an industrial scale with a capacity to produce 120,000t/yr of its MevoCem product, which the company claims can achieve up to 85% emissions reductions compared to ordinary Portland cement. The plant uses Material Evolution's alkali-fusion process that doesn’t require heat or a kiln, producing a cement capable of undergoing geopolymerisation.

Sam Clark, co-founder and chief operating officer said "This launch takes us one step closer to achieving our goal of removing one gigaton of CO₂ by 2040."

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.

Australia: Alternative cement and concrete producers have welcomed a new Australian civil engineering standard that allows builders to use reduced-CO₂ geopolymer concrete in infrastructure projects. Wagners, which produces Earth Friendly Concrete (EFC), said that the revision has removed on if its key barriers to wider market acceptance. EFC replaces 100% of cement with supplementary cementitious materials, including ground granulated blast furnace slag (GGBFS) and pulverised fly ash, by virtue of its binder technology. Wagners previously supplied EFC for the London Power Tunnels project in the UK, based on local technical approval-based building codes. The producer now expects a new standard like the Australian one to follow in the EU.

US: SLB has launched EcoShield, a geopolymer-based well cement product. The company, also known as Schlumberger, says that the product cuts out up to 85% of embodied CO₂ emissions compared with conventional well cementing systems because it does not use ordinary Portland cement (OPC). It also reduces transport related emissions by using locally-sourced natural materials and industrial waste streams in its composition. The company says that the cement-free system can be deployed throughout various phases of the well life cycle, including abandonment. It can also be deployed across a range of field applications, including corrosive environments.

Jesus Lamas, SLB’s president of Well Construction, said “Decarbonising the well construction process while ensuring safety and performance standards is critical to our industry’s pathway to net zero.” He added “The cement-free EcoShield system is a breakthrough that delivers industry-standard zonal isolation capabilities while significantly minimising impacts from upstream oil and gas production.”

EcoShield has been tested by Pioneer Natural Resources in the Permian Basin on an 18-well field testing campaign and its use is ongoing.

UK: Karbonite UK has developed a new supplementary cementitious material consisting of mineral feedstock, geopolymers and waste biomass. The process also involves CO₂ sequestration and liquid-infused CO₂ absorption within the mineral structure. The material, called Karbonite, is activated at 750 – 850°C, releasing water, which is captured for recycling. Its CO2 emissions are 2.7kg/t, according to Karbonite UK. The developer says that Karbonite ground with 50% clinker yields a cement of equal compressive strength to ordinary Portland cement (OPC).

Karbonite UK is currently preparing a final report on the product for a major cement producer.

Managing director Rajeev Sood said “Karbonite offers a wealth of potential to an industry targeting net zero. We are excited to talk to cement and concrete producers about how they could integrate Karbonite technology into their existing process.”

World: Market Research Future has forecast a 15% composite annual growth rate (CAGR) in global green cement demand between 2018 and 2023, where green cement is defined as fly ash cement, slag cement, geopolymer cement and other cements produced using alternative raw materials. Market Research Future predicts that fly ash cement’s global growth will be the sharpest due to its abundant availability. Its report concluded that cement sector strategies in response to the growth would include mergers, joint ventures and acquisitions.

Mexico: Cemex plans to launch its net-zero CO₂ Vertua concrete product worldwide following its release in Europe. It said that customers in several European countries are using Vertua in infrastructure projects and climate-friendly building projects.
“We believe that climate change is one of the biggest challenges of our time, and we are committed to doing our part to address it. Vertua is clear evidence that we can transition to a carbon-neutral economy, where concrete is an essential component in the development of climate-friendly urban projects, sustainable buildings, and resilient infrastructure,” said Fernando A Gonzalez, chief executive officer (CEO) of Cemex.

Vertua uses a geopolymer binder solution created by Cemex’s Research and Development Center in Switzerland. This solution has a reduced carbon footprint of up to 70%, The compensation of the remaining CO₂ is achieved by participating in reforestation projects, among other initiatives.

Mexico: Cement has announced the launch of a range of carbon neutral concretes called Vertua. By offsetting, Cemex has eliminated Vertua’s remaining carbon footprint following a 70% reduction in embodied emissions compared to Ordinary Portland Cement (OPC) through use of a geopolymer cement mixture. The concretes will become available on different markets globally in 2020 and 2021.