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."

India: The Adani family has increased its stake in Ambuja Cements by 3.6% to 66.7% following an investment of just under US$800m. The move follows an investment of around US$600m that the board of the company approved in October 2022. The cement producer intends to use the additional finance to meet its target of reaching a cement production capacity of 140Mt/yr by 2028.

Ajay Kapur, the CEO of Ambuja Cements, said "This infusion of funds provides flexibility for fast-tracked growth, capital management initiatives and best-in-class balance sheet strength. It is not only the testament to steadfast belief in our vision and business model but also reinforces our commitment to delivering long-term sustainable value creation to our stakeholders and this shall propel us towards setting new benchmarks accelerating our growth and continue to deliver on operational excellence, business synergies and cost leadership."

Adani Group acquired Ambuja Cements and ACC from Switzerland-based Holcim in September 2022.

India: UltraTech Cement has increased its cement production capacity by 2.4Mt/yr through debottlenecking at integrated and grinding plants in Gujarat, Rajasthan and West Bengal. Following the improvement exercise its total domestic capacity is 141Mt/yr and worldwide it is 146Mt/yr. The improvements were made at the Pali integrated plant in Rajasthan and grinding plants at Magdall in Gujarat, Sonar Bangla in West Bengal and Neem ka Thana in Rajasthan.

India: UltraTech Cement plans to acquire a 26% stake in O2 Renewable Energy for around US$2m. It is making the purchase to support the energy requirements of its plants from renewable sources, according to the Times of India newspaper. O2 Renewable Energy is currently building a solar power plant in Karnataka that is expected to generate 35 – 48MW.

Kyrgyzstan: The Terek-Tash cement plant in the Kemin district is expected to commence operations in August 2024. Akylbek Japarov, the chair of the country’s Cabinet of Ministers, made the announcement as part of a tour of the Chuy region, according to the Trend News Agency. The plant will have a production capacity of over 1Mt/yr and has had an investment of US$160m. The Russian-Kyrgyz Development Fund has contributed US$45m to the project. Once completed the plant is expected to be one of the country’s largest industrial units. It will also use ash from the Bishkek thermal power plant.

UAE: Fujairah Cement’s revenue fell by 8% year-on-year to US$93.6m in 2023 from US$102m in 2022. It reported a net loss of US$72.3m, up by 85% from a loss of US$39.2m. The company blamed the situation on higher production costs due to rising coal and fuel prices. It said that it plans to increase its cement sales volumes domestically and internationally to improve its capacity utilisation rate. It operates an integrated cement plant at Dibba in Fujairah Emirate.

South Africa: PPC’s revenue grew strongly in the 10 month period to 31 January 2024 mainly due to sales growth from its subsidiary in Zimbabwe. Revenue also mounted in the group’s South African and Botswana cement business, where prices rises offset falling sales volumes. Earnings grew across the business. The company said that sales volumes in the coastal region of South Africa “experienced a sharper decline than in the inland region, mainly due to a weaker retail market and a lack of infrastructure projects in the area.” It added that the performance in group’s South Africa and Botswana units had further deteriorated in February and March 2024. In Zimbabwe sales benefitted from both residential construction and government funded infrastructure projects, constrained imports and a low base in the previous reporting period.

PPC completed the sale of its 51% stake in Rwanda-based Cimerwa to Kenya-based Devki Group subsidiary National Cement in late January 2024.

Netherlands: Ireland-based Ecocem has agreed a deal with Overslagbedrijf Moerdijk (OBM) to expand production and storage capacity at the company’s Moerdijk slag cement grinding plant. The project is intended to allow the unit to both produce and store the company’s advanced cement technology (ACT) product. It will quadruple the storage capacity for key materials at the site up to 40,000t. Ecocem has signed a long-term agreement to lease the site from OBM, who will manage the handling and storing materials on Ecocem’s behalf.

This expansion of the Moerdijk plant is part of Ecocem’s plans to expand its manufacturing and storage capacity to support the commercialisation of ACT across all its plants. It follows the expansion of its Dunkirk plant in France, which was announced in June 2023. These expansion plans will be supported by licencing and partnership strategies to accelerate availability and adoption of scalable low clinker cement at speed.

Conor O’Riain, Managing Director (Europe), at Ecocem, said: “We are increasing our capacity at all of our locations and our deal with OBM is a hugely important aspect of our expansion strategy. It will accelerate our ability to manufacture ACT our low clinker cement technology and make it available commercially by 2026. At the same time, we are actively pursuing licensing and partnership agreements in the construction industry to ensure the benefits of this technology are shared widely and we accelerate progress to Net Zero.”

In February 2024 Ecocem said that its ACT technology received an ETA (European Technical Assessment), which provides the technology with a route to full commercialisation by 2026.

UK: Over 450 people have signed a petition opposing plans to expand the quarry at Heidelberg Materials’ Ketton cement plant. The company has submitted a planning application for the extension to Rutland County Council, according to the Rutland Times newspaper. Residents including those at the nearby village of Empingham, cited negative effects upon air quality, lighting, noise, dust, sustainability, ecology and economic impacts in their criticism of the plans.

The 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).

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.