Research project
Green, Circular, and Smart Cement Manufacture
- Start date: 1 October 2021
- End date: 31 August 2026
- Funder: UKRI
- Value: £1,714,388
- Partners and collaborators: University of Sheffield, University of California, Los Angeles (UCLA), Severn Trent Water, CTS Cement Manufacturing Corporatio, Befesa Salt Slags Ltd, National Nuclear Laboratory, Mineral Products Association, United Utilities Group PLC
- Primary investigator: Prof. Theodore Hanein
- Postgraduate students: Wafaa Borja, Vaishnav Kumar Shenbagam
Cement is the most widely manufactured material globally and accounts for around 8% of anthropogenic CO₂ emissions. In the UK, over 8 million tonnes of Portland cement clinker are produced annually, contributing approximately 2% of national emissions.
Calcium sulfoaluminate (CSA) cements offer a promising alternative, with over 30% lower CO₂ emissions and improved performance in applications such as rapid infrastructure repair. However, their use in the UK is currently limited by the lack of a domestic alumina source.
This project focuses on developing new supply chains that connect cement producers with UK sources of alumina-containing industrial residues, reducing reliance on imported raw materials and lowering the carbon footprint of cement production. In parallel, the project will establish a UK centre for experimental thermodynamics, strengthening national capability in low-carbon cement research. Together, these activities aim to accelerate the adoption of circular, low-emission cement technologies and position the UK as a leader in sustainable construction materials.
Impact
This Fellowship will enable the valorisation of UK industrial waste streams, including aluminium water treatment sludge (aWTS) and aluminium oxide residue (AOR), supporting the development of a new sub-industry centred on the manufacture of high-performance, low-CO₂ calcium sulfoaluminate (CSA) cements. This will contribute to increased industrial sustainability through resource circularity, reduced reliance on imported raw materials, and lower carbon emissions from cement production.
A successful pilot kiln trial has already demonstrated the technical feasibility of producing bauxite-free CSA (BCSA) clinker at scale. The next phase will focus on validating performance and application through testing on real-world sized structural elements, enabling a level of assessment not possible at laboratory scale. This will provide critical evidence on mechanical performance, durability and constructability.
The project will culminate in a small-scale demonstration, using BCSA cement in a fast-track infrastructure application, such as an access ramp, designed to be operational within one to two days. This will provide a visible and practical proof-of-concept for industry, supporting confidence in the material and its applications.
By addressing key technical, supply chain and implementation barriers, this research will support the commercial adoption of CSA-based cements in the UK, with a target of enabling domestic manufacture by 2030. The outcomes will benefit UK cement producers, waste management sectors, policymakers and the construction industry more broadly, while contributing to national net zero targets and more resilient, circular construction systems.
Publications and outputs