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Increasing Use of Supplementary Cementitious Materials to Achieve Carbon Reduction Targets

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Jens Mose and John Terembula, Product Line Management, FLSmidth A/S, discuss why Vertical Roller Mills (VRM) are the best grinding solution for SCMs, in this second part of a three-part series looking at how Supplementary Cementitious Materials (SCM) can help cement manufacturers reduce carbon emissions.

Current examples of SCM adoption
India is a successful adopter of SCMs, with an average clinker factor of 0.71 in 2017. This is largely thanks to the introduction of standards for composite cements in 2015, as well as the widespread availability of fly ash from thermal power plants. Portland Pozzolanic Cement (PPC) had approximately 65 per cent market share in 2017, and the clinker factor of PPC was also improved from 0.68 in 2010 to 0.65 in 2017. Portland Slag Cement (PSC) makes up about 10 per cent of the market and also reduced clinker content in that time from 0.55 to 0.40. Meanwhile, ACC has achieved a clinker factor as low as 44 per cent through the use of fly ash from power plants and slag from steel production.
In the sub-continental India region, FLSmidth has supplied grinding systems with all types of mills. The most common grinding systems installed over the last 10 years are VRM or HRP with ball mill in semi-finish arrangement. One example is the Guinness World Record holder, the largest VRM for cement grinding at Shah Cement in Bangladesh. That mill regularly produces both PPC and PSC Cements.
Throughout Asia, a wide range of blended cements are made encompassing many different additive materials including trass, which is very hard-to-grind overburden from the quarry. Stable/reliable operation has been proven in the OK Mill even with this difficult material.
In other parts of the world, the uptake of SCMs varies. For example, in Brazil the nationwide average clinker-to-cement ratio is below 70 per cent , with blast furnace slag from steel mills the most widely used SCM . The country is targeting reductions in clinker content to 59 per cent in 2030 and 52 per cent in 2050 and will need to increase the use of limestone filler and calcined clays to meet these targets.
In Brazil, the VRM has been the standard for new cement grinding for the last 10+ years, with OK Mills accounting for 28 per cent of the country’s total cement production in 2015.
Meanwhile, in the US, the use of SCMs by cement manufacturers is on the rise , as more cement plants adopt ASTM C595 Standard (American Society for Testing and Materials), which allows up to 15 per cent limestone within Type 1L or Portland Limestone Cement (PLC). PLC is currently seeing a dramatic upward trend, thanks to widespread acceptance by end users like the Department of Transportation and the Federal Aviation Administration.

Which mills are best for SCMs?
The grinding operation is critical to the success of SCMs, to achieve the necessary particle size distribution. Some materials can be ground together with the rest of your cement mix (so-called ‘intergrinding’), while others may benefit from a separate grinding operation. Likewise, water demand (to increase workability) can present another sustainability concern.
In terms of the best mill type, the answer is almost always VRM. Over the last few decades, the industry has been gradually moving towards the use of VRM for both raw and cement grinding, due largely to the reduced energy consumption compared to ball mills: a saving of between 30 and 50 per cent. This transition will prove crucial as the adoption of SCMs increases, from a practical as well as economic and environmental perspective. VRM provides much greater flexibility to grind several different materials, to switch between different cement mixes, and to adjust to changing material characteristics – all while protecting quality.
For example, FLSmidth has a customer using the OK Mill to grind 100 per cent slag with raw feed containing more than 20 per cent moisture to produce moisture levels less than 1 per cent. This is only possible thanks to the drying capacity of the VRM. This level of flexibility is imperative to SCM adoption.
Ultimately, product quality is defined by cement strength development and setting times. To achieve the best result, you need optimal particle size distribution and dehydration of the gypsum within the cement. And for that, the precise operational controls of the VRM are a clear advantage over other mill types, enabling you to optimise the system’s temperature profile, mill airflow, separator speed and grinding pressure for optimum efficiency and productivity.

1- https://docs.wbcsd.org/2018/11/WBCSD_CSI_India_Review.pdf
2- Weston, J. ‘Brazil gives OK to VRM’, International Cement Review, 20 June 2016
3-https://www.mckinsey.com/~/media/mckinsey/dotcom/client_service/infrastructure/pdfs/pathways_low_carbon_economy_brazil.ashx
4- http://snic.org.br/assets/pdf/roadmap/roadmap-tecnologico-do-cimento-brasil.pdf
5- https://pubs.usgs.gov/of/2005/1152/2005-1152.pdf p.10

You can find part one in the August issue of Indian Cement Review and part 3 in the upcoming October issue.

(Communication by the management of the company)

Concrete

Cortec named key player in concrete admixture market

The 2023 admixture market was valued at $20.26 billion USD.

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Cortec® is proud to be listed as a key market player in the 2024 Concrete Admixture Market: Global Forecast 2024-2030 published by 360iResearch. The report offers insight into important market drivers and opportunities that harmonize with Cortec’s trajectory in the field of MCI® (Migrating Corrosion Inhibitor™) admixtures and signal exciting opportunities for continued growth.

A Growing Market
According to 360iResearch, the 2023 admixture market was valued at $20.26 billion USD. It is expected to reach $33.23 billion by 2030 with an estimated CAGR of 7.31%. This market covers all admixtures, including corrosion inhibitors, set retarders, superplasticizers, and water-reducers. While growth is expected across the globe, the largest market will continue to be Asia, which is experiencing escalating urbanization and spending on infrastructure. 360iResearch identifies increased construction and the demand for durability, performance, and sustainability as key drivers of the admixture market. Not only is the market asking for structures that last longer and theoretically reduce the need to create more new concrete (a process with high-CO2 emissions); there is also rising interest in using biobased admixtures to leave behind a better environmental footprint.

Cortec’s Place in the Admixture Market
The 360iResearch report identifies Cortec® as both a key player and a “Pathfinder” in the admixture market. These designations are significant in a market that comprises a wide variety of admixtures and relegates 60% of the players into the category of “Others” that go unnamed. Understandably, large public chemical companies such as DOW, which offer a broad general selection of admixtures, take the largest market share, making it even more impactful to know that Cortec®, a private specialty admixture company, stands out among chemical and construction material giants. While the report suggests that Pathfinders stand to benefit from more business strategy development, it also notes that they serve as potential challengers to “Forefront vendors” because of their innovative products. The report also draws attention to Cortec’s many MCI® DOT approvals.

Ready to Meet Demands
Cortec® is well-poised to meet the demands of today’s construction market as outlined in the admixtures report. In terms of sustainability, the main purpose of MCI® admixtures is to extend the service life of reinforced concrete structures by mitigating corrosion, one of the primary enemies of concrete longevity. Furthermore, while other biobased admixtures have recently emerged on the market, Cortec® remains the leader in biobased corrosion inhibiting admixtures, offering the only USDA Certified Biobased Product (MCI®-2005) of its kind.

MCI® admixtures also stand out in terms of compatibility and ease of use. As noted in the admixture report, the former is a major challenge because admixtures often change the workability, set time, and strength gain of concrete. However, contractors typically find that MCI® admixtures do not negatively affect concrete properties and do leave mixes very easy to work with. Moreover, with Cortec® distribution centers located in all major regions of the world, end users are well-equipped to source MCI® for construction projects in the Asia-Pacific, Europe, the Middle East, Africa, and the Americas.

Get Involved in the Admixture Market
The admixture market is on the brink of exciting opportunities that call for sustainability and durability features like those offered by MCI®. Cortec® is therefore uniquely positioned to continue making its mark among all key players, both large and small. Contact Cortec® today to learn more about taking advantage of Migrating Corrosion Inhibitors in this dynamic construction market.

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Concrete

Japan Considers Response to Steel Imports

China’s steel exports prompt potential action.

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Japan is contemplating measures to address the increasing influx of steel exports from China, as concerns rise regarding the impact on the domestic market. A senior official from Japan’s Ministry of Economy highlighted that the government is evaluating the situation and may implement trade policies to protect its steel industry from potential harm caused by cheaper Chinese imports.

The surge in Chinese steel exports is attributed to various factors, including government subsidies and lower production costs, allowing China to dominate global steel markets. This development has raised alarms among Japanese manufacturers, who face heightened competition and pressure on pricing and profitability.

Japan’s steel sector is vital to its economy, contributing significantly to industrial activities and job creation. Thus, safeguarding this industry is crucial for maintaining economic stability. The ministry’s official indicated that Japan may consider imposing tariffs or other import restrictions to counteract the challenges posed by China’s market practices.

In response to the growing concerns, the Japanese government aims to strike a balance between fostering a competitive market and ensuring the sustainability of its domestic steel industry. Collaborative efforts with international partners may also be explored to address the broader implications of Chinese steel exports on global trade dynamics.

As Japan assesses its options, the decision will likely reflect its commitment to maintaining industrial competitiveness while navigating the complexities of international trade relations. The outcome of these considerations could significantly influence the future landscape of Japan’s steel industry and its positioning in the global market, ensuring that it remains resilient in the face of external pressures.

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Concrete

India’s Steel Production to Surge by 32.9%

Decarbonization relies on ferrous scrap usage.

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India’s steel production is projected to experience a remarkable surge of 32.9% by 2030, with the increasing utilization of ferrous scrap playing a pivotal role in this growth and the broader decarbonization efforts in the industry. As the demand for steel rises, the focus is shifting towards more sustainable practices that reduce carbon emissions and promote circular economy principles.

The growing reliance on ferrous scrap, which is derived from recycled steel products, is seen as a critical strategy to minimize the carbon footprint of steel manufacturing. This shift not only helps in conserving natural resources but also significantly reduces energy consumption and greenhouse gas emissions associated with traditional steel production methods. By integrating recycled materials into the production process, India aims to create a more resilient and environmentally friendly steel industry.

Industry experts emphasize that adopting innovative technologies and efficient recycling processes will be essential for achieving these ambitious targets. The Indian government is actively promoting policies that support the steel sector’s transition towards greener practices, which includes investments in advanced recycling facilities and research into low-carbon production methods.

Additionally, the surge in steel production is expected to drive economic growth, creating jobs and enhancing the overall industrial landscape in India. As the country continues to modernize its infrastructure and urbanize rapidly, the demand for steel is set to increase, further underscoring the importance of sustainable production practices.

Overall, India’s strategy to leverage ferrous scrap in steel production not only addresses immediate economic needs but also aligns with global efforts to combat climate change, positioning the country as a leader in sustainable industrial practices. This approach is anticipated to pave the way for a greener, more efficient steel industry, contributing to both national growth and global sustainability goals.

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