Concrete

LC3 cement

Published

4 years ago

March 5, 2021

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LC3 is a new type of cement that is based on a blend of limestone and calcined clay. LC3 can reduce CO2 emissions by up to 40 percent, is made using limestone and low-grade clays which are available in abundant quantities,is cost effective and does not require capital intensive modifications to existing cement plants.

The objective of the LC3-Project is, through research and testing, to make LC3 standard and mainstream general-use cement in the global cement market.

The main research activities focus not only on specific thematic areas of cement research but also on production, environmental sustainability and cost effectiveness of this new cement.

With funding from the Swiss Agency for Development and Cooperation through its Global Programme in Climate Change, that has been able to bring the idea of the LC3-technology from the lab in Switzerland to all parts of the world.

Difference between LC3 and conventional Portland cement

Traditional Portland cement consists of 95% clinker. The production of it is energy-intensive and responsible for most of the CO2 within the cement. By reducing the clinker-content with so called Supplementary Cementitious Materials (SCMs), large CO2-savings can be achieved.

LC3 is a new blend of two materials which have a synergetic effect. can reduce half of the clinker content and thereby cut up to 40% of the CO2-emissions. Furthermore, LC3 uses industrial waste materials which thereby increase the resource efficiency and reduce the utilization of the scarce raw materials that are necessary for producing clinker.

How to produce LC3?

To produce LC3, existing equipment can be used. The production line has to be adjusted since Limestone and Calcined Clay are added. The LC3-blend consists of the following materials:

Clinker that needs to be burnt at very high temperatures between 1400 and 1500?C.

Calcined clays are burnt at approximately 800?C.
Limestone is added without processing
Gypsum for workability

LC3-has been used in many different regions and different scales. Overall, more than 25 applications were already built with LC3. In Latin America, several applications have been built. They are mainly in Cuba but also in other countries. Among those applications are a LC3-house, testing sites in the sea, art sculptures and pavements.

In India, the most prominent project is the model Jhansi, India. This house is made 98% out of LC3 and it used 26.6 t of industrial waste (192 kg/sqm) and Saved 15.5 t of CO2 (114 kg/sqm). These CO2-savings are similar to the emissions of 10 passengers traveling by plane from Switzerland to South Africa.

Model house in Jhansi

But there are also numerous other projects in India. For example, the offices of the Swiss Agency for Development and Cooperation in the compound of the Swiss Embassy in Delhi were built with LC3-prefab materials. Furthermore, some roads, a check damn and pavements were built.You find a selection of these applications on the photos.

Swiss Embassy building in Delhi Check dam in Orchha CO2-savings LC3 saves up to 40% of CO2 as compared to Ordinary Portland Cement. Most of the CO2 comes from the clinkerisation process. Therefore, reducing the clinker factor and replacing it with SCMs is the fastest intervention to save high numbers of CO2.

Within the clinker production, there are two main sources of CO2. Firstly, clinker needs to be burnt at very high temperatures between 1400 and 1500?C. Secondly, CO2 embodied in limestone is released during production. Reducing the clinker content therefore means to save both energy-related and emobied CO2.

Resource-savings

Utilization of lower grade material for LC3. Clay waste e.g. ceramic or cosmetic industry Less purity of limestone required, e.g. dolomite presence Using existing deposits of waste materials Low prices for the raw materials. Avoiding creating waste. Avoiding cost (e.g. for landfill taxes)

High performance

For more than 10 years, the prestigious research institutes EPFL, IIT Delhi and Madras and CIDEM have tested LC3 in all different aspects and came to the result LC3 reaches OPC – CEM I performance.

Not only in lab conditions but also through industrial trials and applications these findings were confirmed. They are constantly monitored in existing LC3-applications in different parts of the world and environments (e.g. marine or high-altitude applications).

Globally scalable

The raw materials limestone and calcined clay are abundantly available worldwide. Other commonly used Supplementary Cementitious Materials like fly ash or slag are already fully used and cannot be scaled for the use in cement. Furthermore, with increasing focus on sustainability more and more coal power and steel production plants are expected to be closed. This will further cut the supply of these materials as SCMs. The only material largely available and in sufficient quantity are kaolinitic clays.

Cost-effective

Different scenarios of producing LC3 were analysed financially in a study by the cement market experts. Their results showed that with a cement plant, grinding plant or Greenfield scenario the production of LC3 is profitable. The main indicator for driving the profitability is the close access to suitable clays.

Overall, the production cost can be up to 25% lower for LC3 than for OPC due to savings for energy and material. This is without additional policy incentives, such as green funds or carbon certificates, which can further increase the attractiveness for cement producers.

Ready to be implemented

LC3 is a technology which is market-ready and it is already produced in several plants in the world. The sooner the technology is rolled out globally; the more CO2-emissions can be avoided.

The already existing readiness of the technology for the industrial uptake is an important distinction compared to other green technologies.

Furthermore, LC3 can be used without additional training by builders. In India, demo constructions were built without further providing training.

Source: LC3 website.

Concrete

ACC Q3 Net Profit at Rs 10.91 Bn, Revenue Reaches Rs 52.07 Bn

ACC attributed its performance to volume growth, cost optimization, and improved efficiency.

Published

2 days ago

January 28, 2025

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Cement manufacturer ACC reported a net profit of Rs 10.91 billion for the third quarter ending December 2024, a significant increase from the Rs 5.37 billion profit posted during the same period last year. The company’s revenue from operations reached Rs 52.07 billion in the current quarter, compared to Rs 48.55 billion a year ago.

The results for the quarter are not directly comparable to last year’s figures due to ACC’s acquisition of the remaining 55 per cent of Asian Concretes and Cements (ACCPL) and its step-down subsidiary, Asian Fine Cements. The consolidated financial results for this quarter include those of ACCPL.

Additionally, ACC received a Rs 7.20 billion refund from the government as an excise duty exemption on clinker consumption for the period from May 2005 to February 2013. This refund follows a ruling in ACC’s favour by the Customs, Excise, and Service Tax Appellate Tribunal. Of this amount, Rs 6.36 billion was recognised as income in the current quarter and the nine months ending December 31, 2024.

The company’s total expenses for the December quarter stood at Rs 50.99 billion, while its total income was Rs 65.75 billion. The revenue from the cement business was Rs 56.14 billion, and from Ready Mix Concrete, it was Rs 3.44 billion.

ACC attributed its performance to volume growth, cost optimization, and improved efficiency. The company expects continued growth, driven by demand for premium cement products and a focus on innovation and sustainability.

Looking ahead, ACC anticipates that the cement sector, which experienced modest growth of 1.5-2 per cent during the first half of FY25, will rebound in the fourth quarter as construction activity accelerates in the infrastructure and housing segments. The company projects cement demand growth of 4-5 per cent for FY25, supported by the pro-infrastructure and housing measures in the 2025 Budget and increased government spending on infrastructure projects.
News source: ET Energy

Concrete

Dalmia Bharat to Invest Rs 10 Bn in Capex During Q4

In the next six months, the company plans to release a roadmap for the second phase of its expansion, with a target production capacity of 75 million tonnes.

Published

3 days ago

January 28, 2025

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Dalmia Bharat plans to invest approximately Rs 10 billion in capital expenditure for the quarter ending in March, bringing its total expenditure for the current fiscal year to around Rs 30 billion.

As for the fiscal year 2025-26 (April-March), the company intends to spend between Rs 25 billion and Rs 30 billion on capital expenditure. Dalmia Bharat’s current annual production capacity is 46.6 million tonnes, which is set to increase to 49.5 million tonnes by the end of March.

India, being the second-largest cement producer globally, has seen domestic players aggressively expand capacities through both expansion and acquisitions to meet the anticipated demand driven by the government’s infrastructure push. It is projected that between 2024 and 2028, 150-160 million tonnes of capacity will be added, driven by a combination of organic and inorganic growth. This increase in supply, coupled with heightened competition, is expected to limit the growth of cement prices, as noted in a Crisil report from last year.

Dalmia also mentioned that while optimism surrounding cement prices has risen due to recent price recoveries, the intensifying competition may prevent any substantial price increases. He noted that the current market conditions are marked by aggressive market share pursuits, which, coupled with the lack of demand growth in the first nine months, have added strain to the industry. He pointed out that every industry goes through phases where the focus shifts from market share to prioritizing margins, as beyond a certain point, market share no longer delivers value.

He anticipates that competitive pressure, particularly in the southern markets of India, will persist, alongside ongoing consolidation within the industry.

News source: The Economic Times

Concrete

NUVOCO Vistas Sales Volume Grew by 16% YoY for Q3 FY25

Consolidated revenue from operations stood at Rs 24.09 billion

Published

4 days ago

January 27, 2025

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Nuvoco Vistas Corp, a leading building materials company in India, announced its unaudited financial results for the quarter ended December 31, 2024. With 25 MMTPA of combined installed capacity, Nuvoco Vistas Corp. Ltd. is the 5th largest cement group in India and amongst the leading cement players in East India. The company is on track to achieve 31 MMTPA cement capacity1 by Q3 FY27 after emerging as the Successful Resolution Applicant for Vadraj Cement (VCL). A Letter of Intent has already been issued. The VCL facility comprises of 3.5 MMTPA clinker unit in Kutch and a 6 MMTPA grinding unit in Surat and reflects the company’s drive for growth and diversification.

The company’s consolidated cement sales volume registered a strong growth of 16% YoY to 4.7 MMT in Q3 FY25. Consolidated revenue from operations stood at Rs 24.09 billion during the same period. Consolidated EBITDA for the quarter stood at Rs 2.58 billion.

The cement industry has witnessed a recovery following a challenging first half of FY25. After facing subdued demand, the industry is showing signs of improvement, supported by favourable market dynamics. In response, the Company undertook several initiatives to drive strong volume growth during the quarter. While cement prices remained muted for majority part of the quarter, they recovered toward the end. Meanwhile, the Company has continued to focus on operational excellence. The company has achieved the lowest blended fuel cost in the last 13 quarters, at Rs. 1.45 per Mcal. Nuvoco’s power & fuel cost continues to be amongst the lowest in the industry.

In the RMX business, “Concreto Uno Concrete”, launched during the year, is seeing volume traction across regions. The MBM business introduced “Tile Adhesive T5”, “Tile Glitter” and “Tile Bonder” under the brand ZERO M to strengthen the product portfolio. The company continues to strengthen its commitment to sustainability with lowest carbon emissions in the industry, with 457 kg CO2 per ton2 of cementitious materials.

Commenting on the company’s performance, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp. Ltd., stated, “The Company proactively seized demand opportunities to bolster its position in the market and delivered strong volume growth during the quarter. Price increases in the recent period continue to reflect a positive trend, while sustained improvements in demand should support prices as well. Strategic priorities for the company remain centered on driving premiumisation, optimising geo- mix, enhancing fuel mix efficiency, strengthening brand presence, and maintaining cost excellence. The company is confident in its expansion strategy and ability to execute on growth plans pertaining to Vadraj Cement, which will diversify its market footprints in the Western India, thereby supporting long-term growth ambitions and further consolidating its position as the 5th largest player in India.”