Displaying items by tag: Alternative Fuels

US: Continental Cement has ordered a Fuelflex Pyrolyzer alternative fuels combustion system from Denmark-based FLSmidth for installation at its Davenport plant in Buffalo, Iowa. The supplier says that its product offers a lower capital expenditure compared to competing systems, can control NO_x emissions without the need for ammonia water and can be installed without a long shutdown period. This is the first commercial installation of the Fuelflex Pyrolyzer system following a pre-commercial installation at the Mannok cement plant in Northern Ireland, UK, in 2022.

David Loomes, the president of Continental Cement, said “We’re very excited about what the Fuelflex Pyrolyzer will do for our process.” He added, “We’re planning to achieve 55% fossil fuel replacement across the plant, utilising non-hazardous waste that would otherwise go to landfill or incinerators. The economic and environmental benefits of this technology are very significant and a key element of executing our carbon reduction commitment.” Continental Cement, a subsidiary of Summit Materials, has been incorporating waste materials as fuels for more than 30 years.

Jens Jonas Skov Larsen, Head of Capital Sales at FLSmidth, said “Mannok has called the Fuelflex Pyrolyzer a game-changer for the cement industry.” He continued, “This system effectively rearranges the order of the combustion process to make use of hot preheater meal, which is the heat source for the waste fuel pyrolysis. It’s a more efficient way of burning alternative fuels and it comes with a host of benefits, including reduced emissions and a more stable process.”

The installation at Davenport cement plant is expected to start operation in 2024. The full commercial launch for the system is scheduled by 2025. No value for the order has been disclosed.

Finland: Tana Oy has appointed Kalle Saarimaa as its chief executive officer with effect from 1 June 2023.

Saarimaa is currently working as the Senior Vice President for Circular Solutions at Fortum Oyj. However, he has been a member of the board of Tana Oy since 2021. Prior to working for Fortum Oyj he held posts with Ekokem and Walki Oy. He is also active in Finnish and European waste management organisations and as a board member of circular economy companies.

Tana sells products to the recycling and landfill sectors such as shredders, compactors, screeners, sifters and more.

Mexico: Cemex's waste management subsidiary Regenera has signed a deal with the municipal council of Huajuapan de León to receive the latter's sorted non-recyclable municipal solid waste (MSW). Under the deal, Regenera will receive up to 6000t/yr of MSW, which it will supply to Cemex's Tepeaca cement plant in Puebla.

India: Ambuja Cements has placed orders with equipment suppliers for an 8Mt/yr clinker capacity expansion across two of its cement plants. The plants in question are the 2.9Mt/yr Bhatapara cement plant in Chhattisgarh and the 4.5Mt/yr Maratha cement plant in Maharashtra. Ambuja Cements will also build 42MW-worth of waste heat recovery (WHR) power capacity. The new cement capacity will be able to operate on renewable energy and use 50% alternative fuel (AF). As such, upon completion of the project, the plants will together produce 14Mt/yr of Ambuja Cements' reduced-CO₂ Blended Green Cement. The producer will fund the work through internal accruals, and expects to complete it in May 2025.

CEO Ajay Kapur said "These brownfield expansion projects are part of our strategy to double our production capacity over the next five years from the current capacity of 67.5Mt/yr. Our ongoing investments in capacity expansion and sustainability will enable us to achieve our long-term objectives, as we remain committed to delivering sustainable growth and value to our stakeholders."

India: Nuvoco Vistas’ sales rose by 14% year-on-year during the 2023 financial year, to US$1.29bn. The group’s cement sales volumes were 18.8Mt, up by 5%. It recorded a profit after tax of US$1.95bn.

In 2023, Nuvoco Vistas achieved a cement alternative fuel (AF) substitution rate of 12%. Its emphasis on developing blended cements enabled it to achieve an industry-leading cement to clinker factor of 55%. It operations during the year relied on over 20% renewable energy.

India: ACC has blamed a drop in earnings in the fourth quarter of its financial year on higher fuel prices. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 15% year-on-year to US$71.9m in the quarter that ended in March 2023 from US$64.7m in the same period in 2022. However, it said that fuel prices were expected to drop due to synergies with other subsidiaries within Adani Group. It is also working on reducing operational costs by reducing its clinker factor, logistics costs and growing sales of blended cement products. It added that it had reduced its kiln fuel cost by 10% in the fourth quarter by taking the measures mentioned above and by increasing its use of alternative fuels.

The company changed its financial year to one ending in March 2023 during the reporting period. Its calculated net revenue rose by 10% year-on-year to US$2.16bn for its 2023 financial year that ended on 31 March 2023 compared to US$1.97bn in the previous 12 months. Its cement and clinker sale volumes grew by 6% to 31Mt from 29Mt.

Ajay Kapur, the chief executive officer of ACC, said “Our transformation journey fuelled by sizeable operational efficiencies, improved synergies and business excellence has led to substantial improvement in our financial performance and overall business indicators. We have a detailed blueprint on each of the cost factors and initiatives to reduce and improve.”

Lithuania: Arturas Zaremba, the head of Akmenes Cementas, has warned that government proposals to increase the import tax on coal in 2024 and the abolition of subsidies for the fuel will affect the company. The country’s parliament is also proposing scaling the import tax based on a CO₂ scale, according to the Baltic Business Daily newspaper. Zaremba said that the cement producer uses 130,000t/yr of coal. However, it is currently investing Euro22m on an upgrade to its Akmenes integrated plant to allow it to switch to using a higher proportion of solid-recovered fuel. It currently has a 10% alternative fuels substitution rate using dried sewage sludge and tyres.

Zaremba said "There will be some impact because we will still have some of that coal left, but not as much as we would have had without the investment. I have not followed how much they plan to increase the excise duty, but we need to look into how much that would be in the financial terms. Any increase has an impact."

France: Ciments Calcia has announced an investment of Euro86m to further decarbonise cement production at its integrated Beaucaire plant. The subsidiary of Germany-based Heidelberg Materials has allocated a total of Euro600m towards reducing CO₂ emissions from all of its operations in the country in response to a government initiative, according to The Tribune newspaper.

The current funding follows a spend of just under Euro7m on upgrades at the site, including installing a new clinker cooler that will allow for greater recovery of waste heat, and the addition of a new computer control system. Following this work, the single production line plant was restarted in early April 2023.

The next stage of investment has started with a feasibility study. If successful, a tendering process could start in the second half of 2023 with work planned to start in 2025. The company intends to renovate the plant’s electricity network, modernise the production line with a preheater and a pre-crusher and make further changes to target an alternative fuels thermal substitution rate of 75%. A third stage, involving carbon capture and utilisation and/or storage, is tentatively planned to start in 2030.

Portugal: The first batch of clinker has been manufactured on the new upgraded production line at Secil’s Outão plant. Construction and start-up teams from ThyssenKrupp Polysius reached the milestone in mid-April 2023 after a heating period of 72 hours. Germany-based ThyssenKrupp Industrial Solutions was appointed by Secil to work on the Clean Cement Line project in 2020. It said it was going to modify the existing rotary kiln and preheater tower, install a new calciner and add a new grate cooler. Once finished it will produce Portland limestone cement (PLC). It is scheduled for commissioning in mid-2023.

Italy-based CTP Team was contracted in mid-2020 to supply and install a 29MW waste heat recovery (WHR) unit for the project. It planned to use an organic rankine cycle (ORC) unit using a 7.2MW turbine supplied by Turboden.

Italy-based Bedeschi also revealed in early April 2023 that it was in the cold commissioning phase for a new pipe conveyor at the plant to handle different kinds of alternative fuels. The conveyor has a diameter of 250mm and conveying length of 350m and will transport alternative fuels at a rate of 300m³/hr.

Philippines: Cemex Philippines (CHP) says it has reduced the CO₂ emissions from its subsidiaries, Solid Cement Corporation and APO Cement Corporation, by 50% between 1990 and 2022. From 2020 to 2022 CHP reduced its net CO₂ emissions by 18%. The company claims this is the highest CO₂ emissions reduction in the sector based on publicly released information.

Luis Franco, the president and chief executive officer of CHP, said "This milestone CO₂ reduction was possible because of our team's high commitment to achieve net zero. We are on track to meet our ambition of less than 430kg of net CO₂ per tonne of cement by 2030 and deliver net-zero CO₂ concrete by 2050." He added that the company is confident it can reach a 67% reduction by 2030 through the continued used of alternative fuels and decarbonated raw materials.