Portland cement concrete is the most heavily used manufactured material on the planet after clean water, and it is integral to modern life. However, the production of 4 billion tonnes of Portland cement per year is responsible for 8% of global man-made greenhouse gas emissions. With the growing threat of climate change, there is an urgent need to decarbonise cement production. Currently, the most viable approach to reduce cement's carbon footprint involve the widespread use of supplementary cementitious materials (SCMs), such as fly ash from electricity generation and ground granulated blast furnace slag from steel manufacture. However, with decarbonisation of electricity and the decline of UK steel manufacture, these materials are becoming increasingly scarce. Therefore, we need to develop low-carbon alternatives, without disrupting construction practice nor compromising on long-term performance. This is the ultimate goal of this project. Recently, there has been growing interest in using clays as cementitious materials in the production of low-carbon concrete because they are practical, affordable, and scalable. The UK has abundant clay resources that can be easily obtained from overburdens of existing quarries and infrastructure development projects, where they are currently regarded as wastes. However, most of the clay in the UK and globally are low grade and are less reactive compared to high purity kaolinite clays. Therefore, there is a need to develop focussed solutions based on these low-grade clay deposits, rather than to depend on the importation of alternatives from thousands of miles. This project is timely since increased infrastructure activity, e.g. Crossrail, HS2, as well as driving increased demand for cement and concrete, will also lead to higher production of construction spoils that contain waste clays. Thus, we will develop new low-carbon cements from locally sourced clay-bearing construction and mining spoils. Using these in concrete production is a highly sustainable and circular solution; turning waste clays into valuable resources. The development of low-carbon cements is vital, but if these new materials are not translated from the laboratory to the construction site, then the necessary change will not arise. To achieve this, we will examine the performance of these new low-carbon cements from manufacture, through site practice to understanding long-term durability. The research team will work with industry from all along the supply chain to ensure that the newly developed materials satisfy industry requirements and are adopted as wide as possible to maximise carbon reductions of our built environment. In summary, the research team and their industrial partners will develop new cements from locally sourced low-grade waste clays to significantly reduce the carbon footprint of concrete and ensure performance along the entire lifetime of infrastructure. This will help the UK to deliver on its plans to decarbonise and achieve a net-zero economy.

The Transforming the Foundation Industries Challenge has set out the background of the six foundation industries; cement, ceramics, chemicals, glass, metals and paper, which produce 28 Mt pa (75% of all materials in our economy) with a value of £52Bn but also create 10% of UK CO2 emissions. These materials industries are the root of all supply chains providing fundamental products into the industrial sector, often in vertically-integrated fashion. They have a number of common factors: they are water, resource and energy-intensive, often needing high temperature processing; they share processes such as grinding, heating and cooling; they produce high-volume, often pernicious waste streams, including heat; and they have low profit margins, making them vulnerable to energy cost changes and to foreign competition. Our Vision is to build a proactive, multidisciplinary research and practice driven Research and Innovation Hub that optimises the flows of all resources within and between the FIs. The Hub will work with communities where the industries are located to assist the UK in achieving its Net Zero 2050 targets, and transform these industries into modern manufactories which are non-polluting, resource efficient and attractive places to be employed. TransFIRe is a consortium of 20 investigators from 12 institutions, 49 companies and 14 NGO and government organisations related to the sectors, with expertise across the FIs as well as energy mapping, life cycle and sustainability, industrial symbiosis, computer science, AI and digital manufacturing, management, social science and technology transfer. TransFIRe will initially focus on three major challenges: 1 Transferring best practice - applying "Gentani": Across the FIs there are many processes that are similar, e.g. comminution, granulation, drying, cooling, heat exchange, materials transportation and handling. Using the philosophy Gentani (minimum resource needed to carry out a process) this research would benchmark and identify best practices considering resource efficiencies (energy, water etc.) and environmental impacts (dust, emissions etc.) across sectors and share information horizontally. 2 Where there's muck there's brass - creating new materials and process opportunities. Key to the transformation of our Foundation Industries will be development of smart, new materials and processes that enable cheaper, lower-energy and lower-carbon products. Through supporting a combination of fundamental research and focused technology development, the Hub will directly address these needs. For example, all sectors have material waste streams that could be used as raw materials for other sectors in the industrial landscape with little or no further processing. There is great potential to add more value by "upcycling" waste by further processes to develop new materials and alternative by-products from innovative processing technologies with less environmental impact. This requires novel industrial symbioses and relationships, sustainable and circular business models and governance arrangements. 3 Working with communities - co-development of new business and social enterprises. Large volumes of warm air and water are produced across the sectors, providing opportunities for low grade energy capture. Collaboratively with communities around FIs, we will identify the potential for co-located initiatives (district heating, market gardening etc.). This research will highlight issues of equality, diversity and inclusiveness, investigating the potential from societal, environmental, technical, business and governance perspectives. Added value to the project comes from the £3.5 M in-kind support of materials and equipment and use of manufacturing sites for real-life testing as well as a number of linked and aligned PhDs/EngDs from HEIs and partners This in-kind support will offer even greater return on investment and strongly embed the findings and operationalise them within the sector.

The cement and steel sectors are foundational to the UK, are the largest manufacturing industries (by mass), and are essential to construct our infrastructure. Cement manufacture is intensive in resources, carbon, and energy, and needs radical transformation to achieve sustainability. The steel industry produces up to 1M tonnes of steel making by-products annually, and into the foreseeable future. These waste materials need to be managed properly to improve resource efficiency, and to avoid landfill and subsequent ecotoxicity. Although effective utilisation of steel slags is ~80%, a large portion is unutilised. Moreover, the majority of slag utilisation is for low-value products, e.g. aggregate, but their chemistry and mineralogy are variable, making their effects on material properties unpredictable, in the absence of further processing. Additionally, more than 190 Mt of legacy iron and steel slag are present across the country. The UK's cement industry is set to cut 4.2 MtCO2 emissions per year by 2050, about half of which is to be gained by resource efficiency in cement plants. Every year, the UK cement sector consumes ~12.5 Mt of natural raw materials, which can potentially be substituted with by-products that the steel sector produces. These materials contain the key elements that are essential to cement making, but they also have an unusually high amount of iron. FeRICH aims to replace the natural raw materials used in Portland cement making by valorising and upcycling iron-rich waste materials from the steel industry. This leads to cements containing an unprecedented level of [calcium] ferrites; however, our understanding of ferrite chemistry is still incomplete, and we need to establish what happens to this phase both during cement production and after use. These side streams also constitute other minor elements that are likely to alter the cement chemistry. Therefore, we need to develop the knowledge underpinning the interdependency between the role of minor elements in ferrite chemistry, what controls the reaction of ferrite with water over time alone or in mixture with other phases occurring in cement, and importantly, the long-term durability of ferrite-rich cement. Along with this, we also need to develop modelling tools to be able to predict the relationship between these factors - FeRICH relies on thermodynamics as a powerful technique here. We also recognise that ferrite-rich cements are ferromagnetic, and this property can add functional properties to cement (or subsequently to concrete) which may be exploited throughout the materials lifetime: form manufacturing to both their service life and end of life. FeRICH will develop and validate data-for-manufacturing of ferrite rich Portland cement. From reactions at high temperature in kilns to reaction with water at ambient temperatures, we will establish the best cement making conditions and materials compositions to achieve maximum process, energy and resource efficiency in kilns and cement performance upon reaction with water. For the first time, we will also examine the electromagnetic properties of ferrites related to cement, laying down the foundation for building intelligent systems in the future infrastructure. The findings and data developed in this project will be assimilated into tools that will accelerate the uptake of iron rich wastes in cement making. FeRICH will reduce the environmental burden of the cement industry and drive the steel industry towards zero-waste through implementation of the circular economy strategy. This will help alleviate the current crisis in the UK steel industry whose competitiveness in the global market is inhibited by a higher overhead costs than other countries. The results will allow for the use of other iron-rich materials for cement making, in the UK and worldwide.

The cement and steel sectors are foundational to the UK, are the largest manufacturing industries (by mass), and are essential to construct our infrastructure. Cement manufacture is intensive in resources, carbon, and energy, and needs radical transformation to achieve sustainability. The steel industry produces up to 1M tonnes of steel making by-products annually, and into the foreseeable future. These waste materials need to be managed properly to improve resource efficiency, and to avoid landfill and subsequent ecotoxicity. Although effective utilisation of steel slags is ~80%, a large portion is unutilised. Moreover, the majority of slag utilisation is for low-value products, e.g. aggregate, but their chemistry and mineralogy are variable, making their effects on material properties unpredictable, in the absence of further processing. Additionally, more than 190 Mt of legacy iron and steel slag are present across the country. The UK's cement industry is set to cut 4.2 MtCO2 emissions per year by 2050, about half of which is to be gained by resource efficiency in cement plants. Every year, the UK cement sector consumes ~12.5 Mt of natural raw materials, which can potentially be substituted with by-products that the steel sector produces. These materials contain the key elements that are essential to cement making, but they also have an unusually high amount of iron. FeRICH aims to replace the natural raw materials used in Portland cement making by valorising and upcycling iron-rich waste materials from the steel industry. This leads to cements containing an unprecedented level of [calcium] ferrites; however, our understanding of ferrite chemistry is still incomplete, and we need to establish what happens to this phase both during cement production and after use. These side streams also constitute other minor elements that are likely to alter the cement chemistry. Therefore, we need to develop the knowledge underpinning the interdependency between the role of minor elements in ferrite chemistry, what controls the reaction of ferrite with water over time alone or in mixture with other phases occurring in cement, and importantly, the long-term durability of ferrite-rich cement. Along with this, we also need to develop modelling tools to be able to predict the relationship between these factors - FeRICH relies on thermodynamics as a powerful technique here. We also recognise that ferrite-rich cements are ferromagnetic, and this property can add functional properties to cement (or subsequently to concrete) which may be exploited throughout the materials lifetime: form manufacturing to both their service life and end of life. FeRICH will develop and validate data-for-manufacturing of ferrite rich Portland cement. From reactions at high temperature in kilns to reaction with water at ambient temperatures, we will establish the best cement making conditions and materials compositions to achieve maximum process, energy and resource efficiency in kilns and cement performance upon reaction with water. For the first time, we will also examine the electromagnetic properties of ferrites related to cement, laying down the foundation for building intelligent systems in the future infrastructure. The findings and data developed in this project will be assimilated into tools that will accelerate the uptake of iron rich wastes in cement making. FeRICH will reduce the environmental burden of the cement industry and drive the steel industry towards zero-waste through implementation of the circular economy strategy. This will help alleviate the current crisis in the UK steel industry whose competitiveness in the global market is inhibited by a higher overhead costs than other countries. The results will allow for the use of other iron-rich materials for cement making, in the UK and worldwide.