New research from the United Kingdom has added to the growing intrigue around alternative materials to be used in concrete and cement mixes.
The UK Quality Ash Association (UKQAA) collaborated with Coventry-based Atritor and Titan-owned US-based company ST Equipment & Technology (STET) to demonstrate the capabilities of Coal Derived Fly Ash (CDFA).
CDFA is well known in the UK. After years of electricity generation at coal-fired power stations, it is estimated that there are substantial reserves of this legacy product stockpiled and ready for use. Some estimate the reserves to be over 100 million tonnes due to the prevalence of power stations and blast furnaces in the UK.
Working together, the group showed that the CDFA material could be processed to the standards for concrete and cement in the UK and Europe. The material exhibits pozzolanic properties, enabling it to be used in low-carbon cement mixes and added directly to the ready-mix concrete production process.
The group used a multi-stage production process using Atritor’s and STET’s processing plants. At the Atritor plant, finer stockpiles of CDFA were created before being fed into STET’s pilot plant to remove the unburned coal.
UKQAA director Dr Nigel Cooke said the research could be a major breakthrough for sustainable materials.
As it stands, the UK mainly imports its Supplementary Cementitious Materials (SCMs) which can be used in lower carbon cement mixes or readymix concrete. This new testing could unlock the UK’s own SCM reserves and boost its self-reliance. The potential reserves already have the sector talking, with two major projects underway in the UK which could shape this emerging sector further.
TITAN Group has confirmed plans to commence a new facility in 2027 that will convert fly ash into SCMs using an innovative processing technology. The site, located in Chesire, could see its reserves support construction materials in infrastructure projects in the UK.
The facility is expected to be able to process 300,000 tonnes of wet fly ash annually with further scope to double production capacity in the future. TITAN Group has already confirmed through testing that this material will be able to meet the BS EN 450 standard as a pozzolanic addition to cement or concrete mixtures. The company said that the fly ash deposits could be processed for a wide range of applications including cement, concrete, and autoclaved aerated concrete blocks.
In fact, when the deal between TITAN Group and PEEL NRE, part of PEEL Group, a privately held UK infrastructure and property investment company, was announced, SCMs seem to have a key role in TITAN’s future plans.
“Expanding our alternative cementitious business, we are enhancing the sustainability of the construction sector. We are also meeting the growing demand for innovative, high-performance building materials, leveraging the proprietary technology of our company, ST Equipment & Technology. We are very pleased with our long-term partnership with PEEL, which will deliver value to the environment, our customers, and the neighbouring communities,” TITAN Group head of cementitious Jean-Philippe Benard said.
Drax is also a key player in this space after signing a 20-year joint venture with Power Minerals Limited. The agreement will see a new, modern facility developed to process “legacy ash” into SCMs. The site is expected to be operational by the end of next year.
“Following significant investment in testing, we’re now in a position to demonstrate to the government that we have solutions which fit in with its ambitions for a low-carbon economy. These new projects will create high-quality jobs and offer careers in a business that was considered to be obsolete. The UK can lead the world in unlocking the benefits of legacy stockpiles of CDFA,” Cooke said.
“It’s exciting to see these two huge projects underway, because they illustrate the acceptance of fly ash development in the UK. For many years, we’ve talked about the potential of fly ash, but now we’re seeing things coming to fruition. Construction companies and civil engineers are able to see that this is becoming a reality and can now plan projects around it.”
According to UKQAA, CDFA tonnes that are used to replace cement could save close to around 760kg of CO2 and around 1.6 tonnes of virgin materials. Cooke said this material could play a role in decarbonising the UK’s construction materials sector and also promoting internal production.
“By accessing these CDFA deposits, much of the risk of having to import SCMs is removed, such as exposure to exchange rates, shipping costs, and supply-demand balance,” he said,
“Processing legacy stockpiles could potentially contribute up to 50 per cent of our material needs for SCMs for decades to come. Indeed, this figure could be even higher depending on the level of investment in processing capacity.
“We have the designs, the investment, and the resource, but planning delays are the single biggest barrier to getting started. Every extra study or appeal adds months, sometimes years, and only the largest companies can afford to wait.
“The government has recognised the value of this resource, now they must help us turn that recognition into action.”
Surge in interest
SCMs is not a new term to those in the quarrying and construction sector, but, the buzz around it is growing. And not just in the UK, other major markets, including the US and wider Europe, appear to be moving forward with research and testing for this material.
Earlier this year, Ecocem and TITAN Group signed a strategic partnership to collaborate on the development of low-carbon cements.
As part of the agreement, the roll-out of these products will initially be into the Greek market. This will see the development of a bespoke version of Ecocem’s low-carbon cement technology, which will also mark Ecocem’s first deal with a major cement producer and a step into working with diverse SCMs beyond slag materials.
“Signing this co-development and technology transfer agreement with a partner of TITAN Group’s size and calibre is a real demonstration of confidence in our ACT technology,” Ecocem founder and managing director Donal O’Riain said.
“It’s also a testament to the value of our focus on research and innovation and our ability to take pioneering new approaches for low-carbon cement from the lab to the construction site.
“ACT technology reduces emissions by using cement with much greater efficiency and without requiring a significant green premium. This partnership has the potential to accelerate the use of a range of SCMs with ACT technology and deliver rapid and low-cost decarbonisation of the cement industry globally.”
This announcement was immediately followed by confirmation that Ecocem achieved ASTM C1157 certification in the US. The standard highlights how Ecocem’s ACT solution delivers consistent performance, durability, and reliability, and meets or exceeds the industry benchmarks for strength. According to Ecocem, its ACT solution can reduce clinker content by up to 70 per cent and replace it with either limestone or SCMs.
The US, like the UK market, imports nearly a quarter of its cement with domestic production contributing the rest. O’Riain said SCMs could support the US to increase domestic production further.
“This is a significant moment for Ecocem and for low-carbon cement globally,” he said.
“Over the past 10 years, our solutions have seen significant traction across Europe. The US is one of the largest cement markets in the world, and this certification will support integration into existing supply chains and offer a pathway for the sector to rapidly decarbonise through improved efficiency and without increasing costs or complexity.”
Ecocem is pushing ahead with plans for its first North American production site which is likely to be a terminal and milling facility in the Port of Los Angeles. The project remains in the early stages, but if approved, it would enable the production of low-carbon cement in California.
Investing in the future
The US market has become something of a hotspot for investment in SCMs technology in recent months.
Ecocem’s announcements were closely followed by a double announcement from CRH, the global construction materials producer.
Firstly, CRH confirmed it had acquired SCMs supplier Eco Materials Technology for US$2.1 billion. The second was that Ash Grove, a CRH company, was breaking new ground with a commercial carbon capture and utilisation (CCU) facility, which also had the capacity to develop by-products into low-carbon SCMs.
The CCU facility is expected to be operational next year with a production capacity of up to 30,000 tonnes of SCMs annually. To date, the Carbon 1 Mississauga project has also been awarded up to $10 million in federal funding.
“This groundbreaking project is a powerful example of what happens when innovators, industry leaders, and governments come together with a shared vision,” head of CRH Ventures Eduardo Gomez said.
The Utah-based business, Eco Materials Technologies, has a production network which includes fresh and harvested fly ash, pozzolans, synthetic gypsum and green cement operations as well as production facilities and terminals.
When announcing the Eco Materials acquisition, CRH chief executive officer Jim Mintern said the company was eager to position itself as a SCMs leader.
“This strategic acquisition further positions CRH as a leading cementitious player in North America with both cement and SCM capabilities. This transaction demonstrates CRH’s disciplined approach to capital allocation, building market-leading positions in higher-growth markets with secular tailwinds and superior returns.
“As we continue to modernise North America’s infrastructure, this transaction secures the long-term supply of critical materials for future growth and puts CRH at the forefront of the transition to next-generation cement and concrete. With more than 1,100 Eco Material employees joining the CRH team, our combined operations create a more connected business to better serve our customers.”
It appears that SCMs are gaining popularity in the in-demand world of alternative materials. •
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