Displaying items by tag: Alternative Fuels

Lithuania: Scientists at Kaunas University of Technology (KTU) have developed methods to convert discarded textiles into alternative fuels and cement additives to reduce waste. Efforts focus on reducing the clinker content of cement and CO₂ output.

Dr Raimonda Kubiliute of the KTU Faculty of Chemical Technology said “The cement industry, especially clinker firing processes in rotary kilns, contributes significantly to environmental pollution. This is why researchers are actively seeking ways to reduce the amount of conventional cement in cement-based mixtures by replacing it with alternative binders or fillers.”

KTU found that polyester fibre from waste textiles, when added to concrete at 1.5%, increases compressive strength by 15-20% and improves freeze-thaw resistance. Ash from thermal treatment of textiles at 300°C in an inert atmosphere can replace up to 7.5% of ordinary Portland cement and increase strength by up to 16% under curing conditions. The findings are part of the ‘Production of Alternative Fuel from Textile Waste in Energy-Intensive Industries (Textifuel)’ project between KTU and the Lithuanian Energy Institute.

Dr Kubiliute said “This technological solution not only reduces CO₂ emissions during cement production but also provides an innovative and environmentally friendly approach to textile waste management.”

India: The Global Cement and Concrete Association (GCCA) India said that the cement industry has installed 1.8GW of renewable energy capacity and aims to add 5GW more by 2030, according to Platts via S&P Global. Around 3% of electricity used comes from renewables and 11% from waste heat recovery. GCCA India said that the average alternative fuel thermal substitution rate (TSR) in the sector is approximately 6%, although some plants have successfully achieved TSRs of more than 20%. It also said that there are developments in the installations of hybrid energy systems, which provide 24/7 electricity for the sector.

Blended cement accounts for 73% of production, and India has reportedly begun producing limestone calcined clay cement. Research is also underway into other low-clinker alternatives. According to a March 2025 report by GCCA India and The Energy and Resources Institute, the industry aims to achieve net-zero emissions by 2070. CRISIL forecasts that the sector will add 160-170Mt/yr of grinding capacity between the financial years 2026-2028, which run from April to March, driven by a healthy demand outlook and high capacity utilisation.

Global: The Global Cement and Concrete Association (GCCA) has launched its ‘Cement and Concrete Industry Net Zero Action and Progress Report 2025/6’, which reports a fall by 25% in CO₂ intensity of cementitious products since 1990 and sets out policy measures needed to accelerate decarbonisation. The report was launched at COP30 in Belem, Brazil.

The report highlights more than 60 decarbonisation projects across alternative fuels, alternative raw materials, carbon capture, renewable energy and recycled concrete. Examples include Fletcher’s Golden Bay plant and JSW’s Nandyal and Shiva plants. Publicly announced projects are collated and made available to see on the GCCA/LeadIT green cement technology tracker. The document also calls for policies enabling non-recyclable waste use in kilns, wider adoption of blended products, national carbon pricing mechanisms and the use of construction demolition waste as recycled raw materials.

GCCA president and Heidelberg Materials chair Dominik von Achten said “Our industry is collaborating and innovating across every aspect of our production - finding new ways to work and deploying exciting technologies that are already making a genuine step change. However, to achieve the industrial scale transformation that our world needs, we cannot do it by ourselves - our industry needs the support of governments, policymakers, stakeholders, and our allies across the built environment right now.”

GCCA chief executive Thomas Guillot said “The breadth of activity we are seeing across our membership is truly inspiring, with great examples of projects and work across all decarbonisation levers, where enabling policies exist. Cement and concrete are essential materials for the world, but we know they are also essential to decarbonise. Despite our progress, we know that firm policy action across the world is fundamental to enabling us to accelerate our reductions.”

Brazil: Cimento Apodi said that it has recorded a 20% thermal substitution rate (TSR), avoided 1500t/yr of CO₂ emissions and invested more than US$4.7m in a new 5MW solar park. The producer has targeted a 25% TSR by the end of 2025.

It says it will increase renewable energy use through its solar park and a waste heat recovery system. Together these will supply 25% of its electricity demand by the end of 2025. The implementation of the cement mill optimiser (CMO), an artificial intelligence-based system developed with the Federal University of Ceará and the Titan Group, has increased mill productivity by up to 13% and installed capacity by 10%. The company is also developing gasifiers that can reduce emissions by up to 10% per tonne of cement.

The integrated Quixeré cement plant coprocesses byproducts such as tyres, cashew nut shells, açaí seeds, carnauba stalks and industrial waste from other sectors. All materials undergo sorting and characterisation to meet the parameters of particle size, moisture and calorific value.

Philippines: Holcim Philippines has signed an agreement with Prime Infrastructure Capital for the supply of refuse-derived fuel (RDF) to its cement plants in Bulacan and La Union. Under the deal, Prime Infra’s subsidiary Prime Waste Solutions (PWS) Pampanga will provide RDF produced from plastic waste converted into alternative fuels through co-processing technology, helping Holcim to reduce its reliance on traditional fuels.

Cara Peralta, market sector lead for waste at Prime Infra, said “It is rare to find like-minded organisations such as Holcim willing to partner with us and make investments in sustainable practices like RDF consumption.”

Emir Adigüzel warned that cement prices in Europe could triple under current decarbonisation policies. The director of the World Cement Association (WCA) made the comments at a conference in Germany this week. He noted that most of these carbon-related costs will be passed to consumers. His view is that carbon pricing will force price rises across the industry.

That cement prices will rise due to decarbonisation policies is not in itself news. This debate is really about how much and who pays. The WCA's latest analysis asserts that the cement sector will require investment of US$200bn by 2050 to fully decarbonise. Some progress has been achieved so far. Major cement companies reduced carbon intensity from an average of 700kg CO₂/t in 2019 to 640kg CO₂/t in 2023. Adigüzel’s argument is that carbon capture (CCUS) in the cement sector has its place only “if applied correctly.” His view is that these technologies will have a limited effect on global industry decarbonisation as the required investment per cement plant exceeds the capital cost of an entire cement plant. The WCA prefers to promote decarbonisation instead via energy efficiency, alternative fuels, reduced clinker factor and new technologies. That last one includes CCUS but is not limited to it also covering things such as electrification and heat storage. Note today’s news that India-based Adani Cement has ordered a RotoDynamic Heater from Coolbrook. Adigüzel also criticised the European Union’s Carbon Border Adjustment Mechanism (CBAM) in incentivising non-scheme exporters to reduce their carbon footprint, particularly given the expensive investments required.

Decarbonisation is going to be expensive and CCUS is the priciest part of this. Hence, cement producers are likely to consider taking as many measures as possible before implementing CCUS. That cement companies would pass on these costs to consumers also seems likely. The other obvious outcome is that consumers will simply use less cement where possible. Yet Adigüzel doesn’t address how net zero can be achieved with continuing clinker production without using CCUS. His pricing for CCUS is at the right scale though. As Boston Consulting Group (BCG) pointed out in 2024, the cost of CCUS looks set to increase cement prices from US$90 – 130/t to at least US$160 – 240/t by 2050. As well as the capital costs to build a CCUS unit, this includes the additional energy costs required and the price of transporting the CO₂ to a sequestration site. The first two large-scale Heidelberg Materials CCUS projects in Europe, for example, both connect to government-backed transport and sequestration schemes. BCG went on to posit that decarbonisation trends would create five archetypes of cement plants: export hubs and larger plants close to CO₂ storage sites; former export sites far from storage; import grinding hubs; and stranded assets.

Finally, Carbon Brief reported this week that CO₂ emissions in China continued to stay flat in the third quarter of 2025, suggesting a stable or falling trend since early 2024. The adoption of electric vehicles and declines from cement and steel production contributed to the picture in the latest quarter. Emissions from the production of cement and other building materials fell by 7% year-on-year in the third quarter of 2025. This was attributed to the ongoing real-estate contraction. Note that this decarbonisation trend in China has been created by market trends.

Expect plenty more sustainability stories everywhere over the next few weeks as the 2025 United Nations Climate Change Conference (COP30) started this week in Belém, Brazil. The GCCA will be present at a number of events including an update to the Brazil Cement Industry Roadmap on Saturday 15 November 2025

The Global FutureCem Conference on cement industry decarbonisation will take place on 21 - 22 January 2026 in Munich, Germany

Netherlands: N+P Group has appointed Stijn Jennissen as CEO. He has worked for N+P Group since 2009 when he started as a trainee. He became Chief Commercial Officer in 2017 and joined the board of director in 2019. Jennissen holds a business degree from the Business School Notenboom.

N+P Group specialises in the production and supply of waste derived alternative materials for various industries. It was founded in 1992 by Karel and Karin Jennissen.

Egypt: Titan Egypt, a subsidiary of Greece-based Titan Group, plans to invest US$63.5m over the next two years to expand production capacity and increase the use of alternative fuels to reduce costs, according to CEO Amr Reda.

The company operates two cement plants in Beni Suef and Alexandria with a combined capacity of 4.5Mt/yr, which will rise to 5.5Mt/yr following the planned expansions. Titan Egypt currently exports 30% of its production. Exports were 550,000t in 2024, with targets of 850,000t by the end of 2025 and 1Mt in 2026. Key export markets include Libya, Syria, Europe, the US and West Africa, alongside reconstruction projects in Gaza and Sudan.

UK: N+P Group announced that investment has been approved for its new 5t/hr research and development pilot line at its Hartlepool site. The installation will separate biogenic fractions from hard-to-process waste, including municipal solid waste and material from materials recovery facilities and other processing sites. The output will be a cleaned, high-biogenic alternative fuel, with biogenic content expected to exceed 70%. N+P aims to deliver the first volumes from its facility in the first quarter of 2026.

Italy: Federbeton, which represents the cement and concrete industry, has signed a memorandum of understanding with Assocarta, the association of paper, cardboard and pulp producers, to develop synergies in circular economy and decarbonisation initiatives.

The agreement aims to recover paper industry waste as a resource for reducing CO₂ emissions in cement production. Recycled waste and sludge will be used to produce solid fuel recovered (SRF). The protocol includes joint technical discussions to identify suitable recovery conditions, cooperation in securing national and EU funding and engagement with public authorities to improve regulatory frameworks.

Federbeton president Stefano Gallini said “If decarbonisation is a systemic challenge, achieving this goal necessarily requires collaboration and shared commitment. The agreement with Assocarta stems precisely from this awareness and is a concrete tool to accelerate the path towards carbon neutrality. Replacing fossil fuels with solutions like SRF represents an immediate opportunity for the environment, the community and the country's energy independence. It is a lever already widely adopted in Europe, where the average substitution rate is 56%. In Italy, we still stand at 26%, due to inconsistent application of regulations and cultural mistrust.”