Displaying items by tag: Alternative Fuels

Poland: Lafarge Poland has laid the foundation stone for the Euro100m new kiln line at its Małogoszcz cement plant. The replacement of the three existing kilns and installation of an alternative fuel (AF) line aims to reduce the plant’s CO₂ emissions by 20% and its energy consumption by 33%. The company, a subsidiary of Switzerland-based Holcim, aims to make the cement plant into one of the European Union’s most modern. China National Building Material (CNBM) subsidiary Nanjing Kisen International Engineering will carry out the work, which is scheduled for completion in early 2023.

Project director Krzysztof Byczyński said “One of the three kilns has already been demolished and in its place a new kiln will be built with the necessary installations. Preparatory works for the construction of a new kiln are currently underway.”

Italy: The Italian cement association Federbeton has launched its comprehensive plan for cement industry decarbonisation in line with the EU’s European Green Deal target of a 55% reduction in CO₂ emissions between 1990 and 2030 and carbon neutrality by 2050. The strategy entails Euro4.2bn of total new investments andEuro1.4m/yr of extra operating costs across the industry. This will cover the adoption of transition technologies and the large-scale application of carbon capture and storage (CCS). The association says that while some such actions, such as alternative fuel (AF) substitution,are immediately available, others require further development. The sector’s primary fuel is petcoke, mainly imported from the Gulf of Mexico. As such, Federbeton has identified the 100% replacement of all fossil fuels with ‘low-carbon impact’ alternatives as a means of reducing the industry’s carbon footprint by 12% achievable in the short term. Renewable green hydrogen use can cut a further 3% of CO₂ emissions, an energy transition to renewable sources can cut 5%, clinker factor reduction can cut 10%, alternative raw materials in clinker can cut 6%, CCS can cut 43%, supply chain and logistics changes can cut 16% and the optimisation of construction can cut the remaining 5%.

President Roberto Callieri said “The cement and concrete supply chain wants to be one of the protagonists of the ecological transition.” He added “Only with adequate and immediate support tools will it be possible to prevent the impoverishment of the industrial fabric, preserve the competitiveness of the supply chain and prevent relocation. Last but not least, a new environmental culture must be shared, based on dialogue and no longer on the preconceived opposition to any choice of industry.”

Japan: Sumitomo Osaka Cement subsidiary Hachinohe Cement has announced that it will be receiving heavy oil and woodchips from cargo washed ashore from the wreck of a ship at Hachinohe port on 11 August 2021. The company plans to use the waste as refuse-derived fuel (RDF) for cement production at its cement Hachinohe cement plant. The company said that the oil spill from the incident has had a great impact on the region. It added “In the future, we would like to actively promote the acceptance of wreckage with heavy oil attached and cooperate in the early resolution of the situation.”

South Korea: Sampyo Group has announced a planned investment of US$171m before 2030 to reduce Scope 1 and 2 CO₂ emissions by 35% over the period from an August 2021 baseline. The parent company of Sampyo Cement plans to achieve this in the first phase by increased its use of alternative fuels, improving energy efficiency, introducing low-carbon raw materials such as fly ash and developing sustainable products. The company is targeting net zero CO₂ production by 2050.

Philippines: Holcim Philippines plans to invest US$4.18m in upgrades to its cement plants at La Union, Bacnotan, and Lugait, Misamis Oriental to improve business and sustainability performance.

The subsidiary of Switzerland-based Holcim held a ceremonial signing ceremony on 7 July 2021 to award the contract to Sinoma CBMIPH Construction to install a drying facility at the La Union plant. The project is intended to reduce the fuel consumption of the unit by reusing hot gases from operations to dry materials. The integrated plant was recently awarded an ISO 45001:2018 for Occupational Health and Safety Management System and recertified for ISO 9001:2015 (Quality Management System) and ISO 14001:2015 (Environmental Management System) by certification body TÜV Rheinland. Holcim Philippines has also contracted Sinoma CBMIPH to install a drying facility at its Lugait plant that will reduce moisture of raw materials to improve grinding operations. The La Union and Lugait projects are scheduled to be completed in the first quarter of 2022 and by the end of October 2021 respectively.

In January 2021, Holcim Philippines also started projects worth US$2.42m to raise the efficiency of converting qualified waste materials to alternative fuels of its cement plant in Bulacan, Norzagaray. These will enable its Geocycle subsidiary to support the Bulacan plant to increase its thermal substitution rate by using more post-consumer and municipal solid wastes as alternative fuels.

South Korea: Korea Cement Association (KCA) members have agreed to reduce their net CO₂ emissions to zero by 2050. To help them achieve this target, the state-owned Korea Development Bank has pledged US876m in investments in emissions reduction and green production upgrades by 2025, according to the Maeil Business Newspaper. The KCA says that 90% of local cement producers have increased their environmental, social and corporate governance investment and reduced their use of coal.

France: Denmark-based FLSmidth has won a contract to supply a 400t/day calcined clay production line to Vicat’s Xeuilley integrated cement plant. The order includes flash calciner technology, an environmental control system and alternative fuel (AF) firing, handling and storage equipment. The line will have a design capacity of up to 525t/day and is scheduled for commissioning in 2023. It will enable clinker substitution in cement of up to 40%, according to the supplier. It says that cement produced using calcined clay will have a 16% smaller carbon footprint than its clinker-based equivalent. The value of the contract is Euro26.8m.

Vicat deputy chief executive officer Eric Bourdon said, “EU regulations and increasing demand for more sustainable cement has accelerated the decision to introduce clay as an environmental alternative to clinker in our production. With clay readily available in the area and positive results from pilots at FLSmidth’s test facilities in Denmark, we feel confident about the technology and hope to be able to expand further in the future.”

Croatia: Building materials producer Nexe Grupa invested a total of Euro15.3m in upgrades to its plants in 2020. This included subsidiary Našicecement’s capacity expansion at its Našice integrated cement plant. The producer also implemented alternative fuels substitution in the plant’s kiln line.

Germany: Data from HeidelbergCement’s Sustainability Report 2020 reveals that it reduced its specific net CO₂ emissions by 2% year-on-year to 576kg/t of cementious material in 2020 from 589 kg/t in 2019. This represents a 23% reduction since 1990. The company has a target of 30% by 2025. It has a number of carbon capture and utilisation/storage (CCU/S) projects in various stages of development to meet its goal of becoming carbon neutral by 2050. Other data shows that its alternative fuels substitution rate rose to 25.7% from 24% and its clinker ratio fell slightly to 74.3%.

During the reporting year, the group joined the climate lobbying group Foundation 2° and achieving a CDP climate protection rating of A. For water security it secured the second-highest rating of A-. The group’s specific water consumption for cement rose by 5% in 2020 to 271.9l/t of cement from 260l/t in 2019. However the company says it is continuing to improve water consumption reporting at its sites until 2025.

Another week and it’s another commodity story related to the effects of coronavirus. This time the Indian press and financial analysts have started to notice a shift in the fuel mix of some of the major producers from petcoke to coal. UltraTech Cement moved to 30% petcoke and 60% imported coal in the fourth quarter of its 2021 financial year that ended on 31 March 2021. This compares to a reported mix of 77% and 10% in the previous year according to Mint. Dalmia Bharat reduced its share of petcoke to 52% in the fourth quarter from 70% in the third quarter, while its coal mix was 35 - 40% in the fourth quarter.

Price is the driver here. UltraTech Cement’s chief financial officer Atul Daga summed the situation up in an earnings call in late January 2021. Essentially, he said that fuel represented about 13% of total costs for cement producers in India and that both the cost of coal and petcoke nearly doubled from June 2020 to January 2021. However, coal is seen as the cheaper option, hence the move towards it in the fuels mix ratio. The petcoke market meanwhile has suffered due to reduced oil refinery output due to, you guessed it, the effect of coronavirus on global markets in 2020. Scarcity in the US market has particularly affected the decisions on buyers for Indian cement companies since this is the key source of their imports. Demand for petcoke from Latin America and the Mediterranean hasn’t helped either. Both petcoke and coal markets are expected to stabilise in the second half of 2021. Diesel prices have also risen recently causing UltraTech Cement’s power and fuel costs to increase by 28% year-on-year to US$356m and logistics costs, including freight expenses, to rise by 25% to US$449m in the fourth quarter of its 2021 financial year.

With this in mind it’s interesting then, that for some analysts at least, fuel prices have been seen as more worrying for cement producer profits than the latest round of coronavirus-related lockdowns from India’s second wave of infection. Fitch Ratings for example, warned that the impact of mounting fuel costs would continue to be seen in the quarter to June 2021 but that it would subside due to the switch in fuel mix and price rises passed to end consumers. On the lockdowns, it forecast that localised restrictions, with cement plants being allowed to continue operating in most states, would cause a far less pronounced drop in cement demand than during the first national lockdown.

Graph 1: Monthly cement production in India, January 2019 – April 2021. Source: Office of the Economic Adviser.

Graph 1 above shows that the crisis the Indian cement sector faced during the first lockdown, when production crumbled by 85% year-on-year to 4.3Mt in April 2020. The following recovery saw production reach its second highest ever figure at 32.9Mt in March 2021. It’s too soon to tell what’s happening from the national figure but that dip in April 2021 is not looking good so far.

One benefit from unstable fuel prices is that it builds the economic case for cement producers to raise their alternative fuels substitution rates. UltraTech Cement, for example, reported that its ‘green’ energy rate grew to 13% in its 2021 financial year from 11% in 2020. With a target of 34% by its 2024 financial year, this is an ideal opportunity for a change for both UltraTech Cement and other producers.