Grinding and calcination technologies reduce clinker factor

 
At EnviroTech London 2026, held March 15–18 at Park Plaza London Riverbank in London, Fives is set to showcase process technologies aimed at reducing clinker content in cement through energy-efficient grinding, optimized classification, and clay activation. The systems target cement producers seeking measurable CO₂ reductions and improved process performance within industrial decarbonization strategies.

Clinker reduction as a decarbonization lever
Clinker production accounts for the majority of CO₂ emissions in cement manufacturing due to limestone calcination and kiln fuel combustion. Reducing the clinker factor by substituting supplementary cementitious materials (SCMs) such as activated clays remains one of the most effective pathways to lower embodied carbon while maintaining mechanical performance in concrete applications.

Fives’ portfolio presented at the event addresses this challenge across multiple stages of the production process, from raw material activation to final cement grinding.
 
High-efficiency grinding and classification
A central technology highlighted is the FCB Horomill, a horizontal grinding mill designed for high-efficiency cement production. Compared with conventional ball mills, the Horomill configuration reduces specific electrical energy consumption through bed compression grinding, limiting overgrinding and improving particle size distribution control. Lower grinding energy directly contributes to reduced indirect CO₂ emissions per tonne of cement.

Performance is complemented by the FCB TSV Classifier, which provides sharp particle size separation even under high material loads. High-efficiency classification improves fineness control, enabling the production of very fine cements and composite cements with optimized reactivity. In practical terms, this supports the integration of alternative materials without compromising strength development profiles required in structural concrete applications.

Clay activation for alternative binders
To enable substantial clinker substitution, Fives is also presenting the FCB Flash Calciner, a system engineered for the thermal activation of clays. The flash calcination process rapidly heats fine clay particles in a controlled environment, transforming kaolinite and other clay minerals into reactive phases suitable for use as SCMs.

Activated clays can replace a significant proportion of clinker in blended cements, depending on local standards and formulation requirements. The process is compatible with a range of clay types, increasing raw material flexibility for producers operating in regions without access to traditional SCMs such as granulated blast furnace slag or fly ash.

By integrating clay activation into the production line, manufacturers can develop low clinker cement formulations that meet performance standards while lowering process emissions.

Recycling concrete for circular cement production
Circularity is addressed through the FCB Rhodax system, a compression-based crushing technology designed for selective separation of demolition concrete. Unlike impact crushers, the system applies interparticle compression, enabling improved liberation of cement paste from aggregates.

This selective separation facilitates the recovery of reusable aggregates and fine fractions that can be reintroduced into new cement or concrete production streams. By increasing the recovery rate of valuable mineral components, producers can reduce dependence on virgin raw materials and lower the overall carbon footprint of construction materials.

Integrated approach to process optimization
Fives positions these technologies as part of a broader engineering offering that covers plant design, retrofits, and production line optimization. Integration across grinding, calcination, and material recovery stages allows producers to adapt existing assets to evolving environmental and regulatory constraints.

EnviroTech London 2026, organized by World Cement, provided a platform for discussing technical pathways toward low clinker cement. Through the combination of energy-efficient grinding, high-precision classification, clay activation, and material recycling, Fives demonstrated process-based solutions aligned with industrial decarbonization objectives in the cement and minerals sector.