Displaying items by tag: Emissions
Hanson's Ribblesdale cement plant carbonates recycled concrete paste with CO2 emissions
22 November 2022UK: Hanson has announced a 'carbon capture breakthrough' in its use of recycled concrete paste (RCP) in the wet scrubber of its Ribblesdale cement plant in Lancashire. In under 30 minutes, 15t of RCP was able to capture 1.5t of CO2 from the plant's flue emissions. Carbonated RCP is suitable to replace limestone in cement production.
Hanson's sustainability director Marian Garfield said “The trial was carried out with our parent company Heidelberg Materials’ research and development team, and marks another important milestone in our carbon capture journey."
Cemex announces raft of carbon capture projects
22 November 2022Mexico: Cemex has announced a raft of new carbon capture projects in Europe and North America. When commissioned, they will bring its total installed CO2 capture capacity to over 3Mt/yr. The projects consist of three front-end engineering (FEED) studies to scale installations of Australia-based Leilac’s direct separation technology at Cemex cement plants in Germany, Poland and the US; a fourth FEED study for 95% capture installation at the Balcones, Texas, cement plant using RTI International's solvent capture technology and a development partnership for the cement industry's most comprehensive carbon capture, utilisation and storage (CCUS) studies at eight further cement plants in Europe, Mexico and the US.
Chief executive officer Fernando González said “CCUS brings together the essence of our strategic priorities: sustainability and innovation. Our Future in Action programme to achieve sustainable excellence and become a net-zero company is all about measurable, verified progress towards the most ambitious decarbonisation pathway in the industry. Although CCUS technologies are not ready to be scaled quite yet, it will take relentless work and innovation to ensure their viability in time to avoid the most damaging effects of climate change.”
Holcim US fined US$100,000 for alleged dust emissions
21 November 2022US: The Alabama Department of Environmental Management (ADEM) has ordered Holcim US to pay a US$100,000 fine for alleged fugitive dust emissions from its Theodore cement plant in Mobile. Between February and August 2022, witnesses reported multiple dust plumes sighted above the plant, which is situated on the Theodore canal. AL.Com News has reported that, while neither admitting or denying the contentions, Holcim US said that it has taken actions affecting its raw materials unloading processes to ensure compliance.
Plant manager Clay Copeland said “We have worked closely with the ADEM to address concerns raised earlier this year."
KIMA Process Control to supply kiln cooling system for Cementa's Slite cement plant
17 November 2022Sweden: Germany-based KIMA Process Control has secured a contract for the supply of a kiln shell cooling system for Cementa's Slite cement plant in Gotland. 88 water jets will deliver centimetre-precision cooling for the 55m-long kiln, while IR pyrometers measure temperatures over areas of 10cm2. According to KIMA Process Control, the equipment can avoid unnecessary cooling of the kiln shell, conserving the heat energy supplied by the main burner.
The new cooling system will eliminate the use of energy intensive electric fans, slashing 1700t/yr in CO2 emissions, according to the supplier. It said that noise emissions will also 'drastically' decline as a result of the upgrade. The system's operating costs are reportedly 98% less than those of the plant's existing fan system.
The supplier said that the new equipment will 'bring the cement plant in Slite an economic benefit in the shortest possible time.' It said "For the cement industry, this project represents a new milestone in terms of best available technology in the operation of rotary kilns."
Singaporean parliament enacts tightened carbon credit scheme
17 November 2022Singapore: Parliament passed the Carbon Pricing (Amendment) Bill earlier in November 2022. Under the act, Singapore will raise the price of carbon credits to US$18.17/t from 2024, and to US$32.71/t from 2026. CNA News has reported that the government said that the new legislation will provide the basis for the realisation of carbon credit prices of over US$36.31/t by 2030, in line with the country's 2050 net zero CO2 emissions commitment.
Polluters which emit over 25,000t/yr of CO2 currently pay US$3.65/t for carbon credits.
Saudi Arabia: Yanbu Cement was among successful bidders in Saudi Arabia's largest carbon credit auction to date earlier in November 2022. The Saudi Public Investment Fund (PIF)’s Voluntary Carbon Market Initiative Auction sold 1.4Mt-worth of carbon credits to 15 different entities, of which Yanbu Cement was the only cement sector representative. The PIF said that the sale will support the country's Saudi Vision 2030 development goal, while also advancing its progress towards net zero CO2 emissions by 2060.
Slashing cement's CO2 emissions Down Under
02 November 2022In Australia and New Zealand, four producers operate a total of six integrated cement plants, with another 13 grinding plants situated in Australia. This relatively small regional cement industry has been on a decades-long trajectory towards ever-greater sustainability – hastened by some notable developments in recent weeks.
Oceania is among the regions most exposed to the impacts of climate change. In Australia, which ranked 16th on the GermanWatch Global Climate Risk Index 2021, destructive changes are already playing out in diverse ways.1 Boral reported 'significant disruption' to its operations in New South Wales and southeast Queensland due to wet weather earlier in 2022. This time, the operational impact was US$17.1m; in future, such events are expected to come more often and at a higher cost.
Both the Australian cement industry and the sole New Zealand cement producer, Golden Bay Cement, have strategies aimed at restricting climate change to below the 2° scenario. Golden Bay Cement, which reduced its total CO2 emissions by 12% over the four-year period between its 2018 and 2022 financial years, aims to achieve a 30% reduction by 2030 from the same baseline. The Australian Cement Industry Federation (CIF)'s 2050 net zero cement and concrete production roadmap consists of the following pathways: alternative cements – 7%; green hydrogen and alternative fuels substitution – 6%; carbon capture – 33%; renewable energy, transport and construction innovations – 35% and alternative concretes – 13%, with the remaining 6% accounted for by the recarbonation of set concrete.
Australia produces 5.2Mt/yr of clinker, with specific CO2 emissions of 791kg/t of clinker, 4% below the global average of 824kg/t.2 Calcination generates 55% of cement’s CO2 emissions in the country, and fuel combustion 26%. Of the remainder, electricity (comprising 21% renewables) accounted for 12%, and distribution 7%. Australian cement production has a clinker factor of 84%, which the industry aims to reduce to 70% by 2030 and 60% by 2050. In New Zealand, Golden Bay Cement's main cement, EverSure general-purpose cement, generates CO2 at 732kg/t of product.3 It has a clinker factor of 91%, and also contains 4% gypsum and 5% added limestone.
Alternative raw materials
Currently, Australian cement grinding mills process 3.3Mt/yr of fly ash and ground granulated blast furnace slag (GGBFS). In Southern Australia, Hallett Group plans to commission its upcoming US$13.4m Port Augusta slag cement grinding plant in 2023. The plant will use local GGBFS from refineries in nearby Port Pirie and Whyalla, and fly ash from the site of the former Port Augusta power plant, as well as being 100% renewably powered. Upon commissioning, the facility will eliminate regional CO2 emissions of 300,000t/yr, subsequently rising to 1Mt/yr following planned expansions. Elsewhere, an Australian importer holds an exclusive licencing agreement for UK-based Innovative Ash Solutions' novel air pollution control residue (APCR)-based supplementary cementitious material, an alternative to pulverised fly ash (PFA), while Australian Graphene producer First Graphene is involved in a UK project to develop reduced-CO2 graphene-enhanced cement.
Golden Bay Cement is investigating the introduction of New Zealand's abundant volcanic ash in its cement production.
Fuels and more
Alternative fuel (AF) substitution in Australian cement production surpassed 18% in 2020, and is set to rise to 30% by 2030 and 50% by 2050, or 60% including 10% green hydrogen. In its recent report on Australian cement industry decarbonisation, the German Cement Works Association (VDZ) noted the difficulty that Australia's cement plants face in competing against landfill sites for waste streams. It described current policy as inadequate to incentivise AF use.
Cement producer Adbri is among eight members of an all-Australian consortium currently building a green hydrogen plant at AGL Energy’s Torrens Island gas-fired power plant in South Australia.
Across the Tasman Sea, Golden Bay Cement expects to attain a 60% AF substitution rate through on-going developments in its use of waste tyres and construction wood waste at its Portland cement plant in Northland. The producer will launch its new EcoSure reduced-CO2 (699kg/t) general-purpose cement in November 2022. In developing EcoSure cement, it co-processed 80,000t of waste, including 3m waste tyres. The company says that this has helped in its efforts to manage its costs amid high coal prices.
Carbon capture
As the largest single contributor in Australia's cement decarbonisation pathway, carbon capture is now beginning to realise its potential. Boral and carbon capture specialist Calix are due to complete a feasibility study for a commercial-scale carbon capture pilot at the Berrima, New South Wales, cement plant in June 2023.
At Cement Australia's Gladstone, Queensland, cement plant, carbon capture is set to combine with green hydrocarbon production in a US$150m circular carbon methanol production facility supplied by Mitsubishi Gas Chemical Company. From its commissioning in mid-2028, the installation will use the Gladstone plant's captured CO2 emissions and locally sourced green hydrogen to produce 100,000t/yr of methanol.
More Australian cement plant carbon capture installations may be in the offing. Heidelberg Materials, joint parent company of Cement Australia, obtained an indefinite global licence to Calix's LEILAC technology on 28 October 2022. The Germany-based group said that the method offers effective capture with minimal operational impact.
Cement Australia said “The Gladstone region is the ideal location for growing a diverse green hydrogen sector, with abundant renewable energy sources, existing infrastructure, including port facilities, and a highly skilled workforce." It added "The green hydrogen economy is a priority for the Queensland government under the Queensland Hydrogen Industry Strategy.”
Logistics
Australian and New Zealand cement facilities' remoteness makes logistics an important area of CO2 emissions reduction. In Australia, cement production uses a 60:40 mix of Australian and imported clinker, while imported cement accounts for 5 – 10% of local cement sales of 11.7Mt/yr.
Fremantle Ports recently broke ground on construction of its US$35.1m Kwinana, Western Australia, clinker terminal. It will supply clinker to grinding plants in the state from its commissioning in 2024. Besides increasing the speed and safety of cement production, the state government said that the facility presents 'very significant environmental benefits.'
Conclusion
Antipodean cement production is undergoing a sustainability transformation, characterised by international collaboration and alliances across industries. The current structure of industrial and energy policy makes it an uphill journey, but for Australia and New Zealand's innovating cement industries, clear goals are in sight and ever nearer within reach.
References
1. Eckstein, Künzel and Schäfer, 'Global Climate Risk Index 2021,' 25 January 2021, https://www.germanwatch.org/en/19777
2. VDZ, 'Decarbonisation Pathways for the Australian Cement and Concrete Sector,' November 2021, https://cement.org.au/wp-content/uploads/2021/11/Full_Report_Decarbonisation_Pathways_web_single_page.pdf
3. Golden Bay Cement, 'Environmental Product Declaration,' 12 May 2019, https://www.goldenbay.co.nz/assets/Uploads/d310c4f72a/GoldenBayCement_EPD_2019_HighRes.pdf
Suez Cement to undertake US$14.4m solar project at Suez cement plant
02 November 2022Egypt: Suez Cement has partnered with Intro Power and Utilities for the construction of a 20MW solar power plant at its Suez cement plant. From its commissioning in early-mid-2023, the installation will provide the plant with 45GWh of energy annually, 20% of its annual consumption. Suez Cement says that this will eliminate 22,000t/yr-worth of CO2 emissions. Construction is expected to cost US$350m and commence in 2023.
Suez cement aims to achieve specific CO2 emissions of 400kg/t of cementitious product by 2030, down by 47% from 1990 levels.
Managing director Mohamed Hegazy said “Through transitioning to renewable solar energy, we are looking at long-term economic benefits, laying the foundation for a low-carbon business and energy security, without jeopardising the health of our environment. We are proud about this new milestone and to be one of the few cement players in Egypt taking this step towards using a more affordable and cleaner energy."
Cemex increases nine-month 2022 sales and income
27 October 2022Mexico: Cemex sold 47.8Mt of cement in the first nine months of 2022, down by 5.3% year-on-year from 40.5Mt in the same period of 2021. Despite this, its consolidated revenues rose by 8%, to US$11.7bn from US$10.8bn. The group's cost of sales grew by 12% to US$8.09bn from US$7.25bn, and its operating earnings before interest, depreciation, taxation, depreciation and amortisation (EBITDA) dropped by 6.6%. Nonetheless, contributions from discontinued operations led to net income growth of 72%, to US$987m from US$574m.
Cemex said that higher prices in local currency terms drove sales growth across all of its regions. As a percentage of sales, costs grew to 70% from 68%, mainly on account of energy price rises. Operating EBITDA fell across all regions apart from Europe, the Middle East, Africa and Asia (EMEAA), where it rose by 2.5% to US$524m from US$511m. Cemex noted Europe's 'remarkable resilience' in implementing 'double-digit' price increases to increase earnings, while also crossing a threshold of 40% in CO2 emissions reduction from its 1990 baseline.
Titan Group tightens emissions reduction commitments
27 October 2022Greece: Titan Group has set new CO2 reduction targets by adding Scope 3 emissions. Titan Group had previously committed to a 21% Scope 1 emissions reduction and a 42% Scope 2 emissions reduction per tonne of cementitious material between 2020 and 2030. Titan Group reduced its total CO2 emissions by 20% between 1990 and 2021, and by 5.5% year-on-year in the third quarter of 2022. Its latest targets are currently under review by the Science-Based Targets Initiative (SBTi).
Titan Group chair Marcel Cobuz said “The initiatives in our decarbonisation roadmap offer significant business growth opportunities. Our technology and sales teams across all our markets are focused on decarbonising our operations more quickly and offering our customers more and more sustainable and circular solutions.”