A First for Europe

Calcined clay at Xeuilley

Unlike the kaolinitic clays typically used in calcined clay applications, the raw material at Xeuilley also contains higher quantities of smectitic clays with notably high iron content. Smectitic clays are generally more difficult to activate than kaolinitic clays, requiring precise process control to achieve adequate activation and avoid sintering. Meanwhile, the elevated iron levels require sophisticated color control to prevent an unwelcome red coloration of the product.

Extensive pilot-scale testing using Xeuilley clay was conducted at Fuller’s Dania laboratory in Denmark, confirming the company’s technology could deliver the required reactivity and color control and comply with French emission regulation by applying proper abatement design. This testing phase proved critical in demonstrating technical feasibility before committing to full-scale implementation.

Clearing regulatory hurdles

Despite the long-known published advantages of calcined clay as a supplementary cementitious material (SCMs), its pathway to commercial adoption in Europe has been slowed by the region’s restrictive cement standards. These have traditionally adopted a prescriptive approach to cement recipe design, with limits on the amount and type of SCMs a cement could contain. Although standards are now being adapted to allow alternative blends with lower clinker contents, market adoption is slow as the building materials market remains relatively conservative.

Achieving certification for Vicat’s calcined clay cement in France was thus a significant undertaking and required navigating a rigorous testing and approval process. As part of this, about 600 t of calcined clay were produced for certification, with the approval process taking about 6-8 months.

Conclusion and future outlook

The Xeuilley installation is set to demonstrate that calcined clay production can operate successfully at an industrial scale in the EU. With a capacity to produce 525 tpd calcined clay enabling up to 16% CO₂ reduction at the plant cement dispatch level—equivalent to 48,500 metric tonnes per year—the project establishes a new benchmark for sustainable cement manufacturing in Europe. It demonstrates that Fuller’s technology can successfully navigate the continent's demanding regulatory environment, even when dealing with non-kaolinitic clays, stringent emissions standards, and requirements for integrating alternative fuels.

The collaboration between Vicat and Fuller Technologies proved essential to the project's success. Vicat's commitment to innovation and sustainability was the foundation and impetus to pursue this groundbreaking project, while Fuller's technical expertise and technology enabled it to achieve its ambitious objectives.

The Xeuilley project precedes Fuller’s successful flash calcination installation at CBI Ghana, which holds the distinction of being the world's largest clay flash calciner with a capacity exceeding 1200 tpd. Together, these projects establish the company as a leader in industrial-scale calcined clay production, with proven capabilities across diverse geographical, regulatory, and geological contexts.

Looking forward, expectations for calcined clay projects remain strong. As carbon regulations continue to tighten and market demand for lower-carbon cement products grows, calcined clay technology offers cement producers a viable pathway to reduce emissions while maintaining (or even improving) product performance and reducing operating costs. Success at Xeuilley provides a blueprint for future European installations, demonstrating that technical challenges can be overcome and regulatory requirements can be met. With clay deposits widely available across many cement-producing regions, the potential for further deployment of this technology is substantial.

"The successful startup of our Xeuilley calcined clay plant represents just the beginning of Vicat's journey toward carbon-neutral cement production,” concluded Eric. “We're now evaluating opportunities to deploy calcined clay technology at additional sites within our network. We see significant potential to expand our low-carbon cement portfolio and help our customers meet their own sustainability objectives. Calcined clay will play a central role in achieving our 2030 and 2050 decarbonization targets."