Displaying items by tag: Alternative Fuels

US: Chemical distributor Univar has shipped 379,000M^₃ (100 million gallons) of fuel-quality waste from its waste chemical business, ChemCare, to Systech Environmental, a subsidiary of Lafarge. The two companies have been in partnership in waste management since 1989.

"We are committed to responsible waste management for our ChemCare customers, including the recycling of materials wherever possible. Our 25 year partnership with Systech has been an outstanding reflection of this, enabling the responsible disposal of waste while providing an alternative fuel source for cement kilns," said Greg Vas Nunes, vice president of ChemCare. Systech Environmental added that the arrangement had prevented the generation of 800,000t of CO₂.

ChemCare provides waste management service that collects both hazardous and non-hazardous waste products at customer locations in the US and Canada. It then works with partners in the waste disposal business to transport these materials to licensed third-party treatment, storage and disposal facilities.

Systech Environmental processes hazardous and non-hazardous industrial waste for use as fuel in cement kilns. It is actively processing or marketing fuels at 16 cement plants in the US.

Malaysia: Cement Industries of Malaysia Bhd (CIMA), a wholly-owned subsidiary of UEM Group Bhd, is set to be the first cement manufacturer in the country to use tyres and biomass waste as an alternative source of fuel.

CIMA managing director Mohd Yusri Md Yusof said that the company has installed an alternative fuel combustion system from Japan's Taiheiyo Engineering Corporation, which will allow the company to use tyres and biomass waste such as palm kernel shell and empty fruit bunch (EFB) as an alternative source of fuel.

"The move makes CIMA the first cement manufacturer in the country with this technology," said Yusof. He added that using waste as alternative fuel for cement production ensures that waste materials are reused in a responsible manner instead of being disposed of in landfills.

"With this state-of-the-art technology in place, we can reduce energy costs through the utilisation of tyres and biomass up to a maximum of 30%, while at the same time playing an active role in reducing our carbon footprint," said Yusof.

Meanwhile, Plantation Industries and Commodities minister, Douglas Uggah Embas, said that the Malaysian government has identified biomass as one of the growth areas towards creating wealth from waste. "The National Biomass Strategy 2020 outlines the framework and the potential of the biomass in creating higher value-added economic activities. The National Biomass strategy envisages a potential contribution of Gross National Income of US$9.16bn by 2020," said Embas.

Pakistan: The All Pakistan Cement Manufacturers Association (APCMA) has asked the Federal Board of Revenue (FBR) to exclude cement from the 'Third schedule' of the Sales Tax act or to fix the maximum retail price (MRP) on the basis of two different zones in the upcoming budget of 2014 - 2015.

In a letter to the FMR chairman the APCMA said, that as the dynamics of every province and region are different, collection of sales tax on the basis of a single MRP across the country would force producers to restrict sales to nearby markets. It added that this would restrict sales to further-away markets reducing the potential revenues the FBR could collect.

The APCMA has proposed a zone-based MRP to protect both local consumers from paying excess prices and producers from paying more to sell cement in outlying markets. It also asked the FBR to introduce a uniform tax rate for the corporate sector.

Cement in Pakistan is subject to various taxes including: Corporate Income Tax - 34% of taxable income; Minimum tax – 1% of turnover; Federal excise duty (FED) – US$3.8/t; and Sales Tax 17% of the MRP. The APCMA has also proposed removing the FED and reducing the duty on alternative fuels to zero. Further suggestions included restoring the initial allowance on plants and machinery to 50% (from 25% at present) to encourage production capacity development and reducing import taxes on raw materials and capital goods for industrial development from 5 to 1%.

Slovenia: A local environmental non-government organisation (NGO), Eko Krog, which has been fighting Lafarge in the city of Trbovlje for years, has launched a challenge to the environmental permit issued to Lafarge in January 2014.

Eko Krog stated that that the basis for issuing the environmental permit for the operations of the cement factory was flawed and that the permit will result in new pollution in the Trbovlje valley. It has appealed to the Ministry of Agriculture and the Environment, which will now have to review the Environment Agency's (ARSO) decision to issue the permit.

ARSO said that the permit for unlimited cement production at the plant meets EU rules. However, Eko Krog has branded the decision was flawed, as key potential emissions were omitted, including those generated at the nearby quarry. Eko Krog also claimed that the documentation for the permit contains other flaws, including the failure to respect all of the recommendations of internationally-adopted standards for use of the best technology in the cement industry.

It is unclear how long the review of the permit by the relevant ministry will take, but Eko Krog has already once succeeded in having Lafarge stripped of the permit. Lafarge first received the permit in 2009, at which time it had invested Euro33m in upgrades, but its plans to use alternative fuels in its kiln subsequently prompted anger among locals and led to the successful challenge of the permit by Eko Krog in 2011. As a result, the plant had to scale down operations, making the January 2014 decision by the Environment Agency a major victory for Lafarge.

The plant responded to the decision by labelling it a first step in restarting cement production and obtaining a permit for the use of alternative fuels, which would be crucial for Lafarge's sustainability in Slovenia.

Ethiopia: A TEC has released progress information on contracts to provide an alternative fuel system, which can process sesame straw and stalks, and a cement big-bag filling station for Messebo Building Materials Production in Mekelle. Both commissions were awarded in the first quarter of 2013 and local manufacturing and the erection will be performed by Mesfin Industrial Engineering PLC, a sister company of Messebo.

Installation of the alternative fuels system will start in the fourth quarter of 2013 with a planned start-up in the first quarter of 2014. Collection and preparation of straw and the production of bales will take place at Kafta Humera. The first phase of the project includes building a baling capacity of 50t/hr and an alternative fuel feeding capacity to the calciner of 10t/hr at the cement plant in Mekelle. A future upgrade, phase two, will scale the system up to a baling capacity of 71t/hr and an alternative fuel feeding capacity of 20t/hr.

The new station for big-bag filling will be installed at the cement plant in Mekelle. The system will consist of three filling stations in modular design. Each station can handle 15 bags/hr. A total number of 45 big-bags/hr with an overall capacity of 90t/hr can be reached. The big-bag filling station will be installed and commissioned at the end of 2013.

ASEC Cement CEO Giorgio Bodo has cited security, fuel scarcity and general instability as the challenges facing cement producers in Egypt.

The comments came with the announcement that ASEC Minya had started clinker production at its 2Mt/yr Minya plant. In the news report ASEC congratulated itself on reaching clinker production within 28 months. Construction originally began in December 2010, just before the Egyptian Revolution of early 2011 occurred.

Bodo's comments will come as no surprise to delegates of the recent Global CemTrader conference which took place on 23 – 24 May 2013 in London, UK. In his presentation on current political unrest in the Arab countries and the implications for the cement industry, Bodo outlined seismic changes to the Egyptian cement market. As per his comments with the Minya announcement, challenges included the loss of fuel subsidies, fuel shortages, oversupply of cement and a decline in export prices. However, the overall picture was a mixed one. Bodo expected growth to be driven by growing political stability, increased government and private-sector spending, new development projects coming on-line, new export opportunities and other reasons.

Meanwhile, battles over the energy costs and supply in Egypt became public this week when Jose Maria Magrina, the CEO of Arabian Cement Company (ACC) implored the government to help cement producers move away from using natural gas, by removing operating licenses and speeding up the granting of environmental permits. Around the same time a member of the Federation of Egyptian Industries revealed that the government plans to increase the price of natural gas by over 75% for cement producers by 2016. Eventually the cement industry will be expected to source its energy needs independently.

Misr Cement announced in May 2013 that it too was preparing to use coal following a 14-hour shutdown of its kilns due to a shortage of mazot (heavy duty fuel oil). Figures with the ACC release stated that energy shortages have caused the cement industry in Egypt an effective loss of 20% (3.7Mt) of its production capacity since February 2013, with a 25% loss for ACC (350,000t). Suez Cement has also confirmed that it too has cut production by 20 - 30% so far in 2013. ¬

Unsurprisingly in this situation the alternative fuels sector has shown considerable interest in Egypt as Dirk Lechtenberg, MVW Lechtenberg & Partner, reports in the June 2013 issue of Global Cement Magazine [LINK]. Agricultural waste such as rice straw has shown potential as an alternative fuel for cement kilns. Refuse-derived fuels present a harder challenge given competition from the informal economy scavenging through rubbish tips.

Despite the many problems facing local cement producers, Egypt's compound annual growth rate in expected to be 3% for the next five years. In addition it was recently announced by the Minister of investments that Brazilian investors intend to invest US$2bn into the local cement sector.

Egpyt: The Mexican cement giant Cemex has said it plans to invest US$100m to expand its operations in Egypt. The planned investments were discussed in a meeting between Sergio Menendez, President of Cemex in Egypt, and Yehia Hamed, Egyptian Minister of Investment.

The investment will allow Cemex to 'significantly improve its operations in Egypt and continue supporting the country's housing, commercial and infrastructure development, according to the company.

New environmental equipment will be installed to reduce emissions of pollutants and increase the use of alternative fuels. "Cemex is constantly providing industry-leading building solutions that help improve the well-being of the people of Egypt," said Menendez. "This investment is expected to support the sustainable development of Egypt for many generations."

Cemex said that more than 250,000t of waste have been processed into alternative fuels in Egypt since 2000. "In 2010 Cemex inaugurated a new US$12m dust filter equipped with the latest technology to reduce emissions in its Assiut cement plant," said Cemex.

India: The Goa State Pollution Control Board (GSPCB) has signed a memorandum of understanding (MoU) with a cement company to use the plastic waste generated across the state as fuel for its manufacturing plant. Vasavadatta Cement, a company with its plant in Karnataka, would procure the plastic waste collected by the state agencies and villages in Goa.

State Environment Minister Alina Saldanha said that the plastic waste collected from the highways and other internal roads would be baled before being handed over to the cement company. Goa State Infrastructure Development Corporation, a state run agency, has already taken up the task of collecting garbage from the highways, while villages would be asked to clean up their own roads.

"Two baling machines have already been installed one each in North and South Goa to treat the plastic before handing it over to the cement company," said GSPCB Chairman Jose Manuel Noronha. "The state requires six such machines to bale all of its plastic waste."

Congratulations to Cemex for their work on alternative fuels in Germany. In April 2013 Cemex reached an alternative fuels substitution rate of over 80% at its German cement plants, with the Kollenbach plant beating 90%. Impressive stuff.

The German cement industry as a whole is already one of the leaders in the industry for alternative fuels use, reaching levels above 60% in 2010. This compares favourably with, for example, the UK's (high) rate of 40% in 2011 and the Cembureau average rate of 28% for its 27 European member states in 2009.

To show how fast the change in alternative fuels usage has been in Germany, in 2000 the rate was around 25%. For Cembureau members it was about 10.5% in 2000. Cemex's achievement at Kollenbach even surpasses HeidelbergCement's alternative fuels rate of 85% that it achieved across the border in 2011, at its Eerste Nederlandse Cement Industrie (ENCI) plant in the Netherlands.

Globally, Cemex seems likely to meet its 2015 target of 35% alternative fuels substitution rate. The other large multinational cement producers have similar plans in place. For example, Lafarge intends to reach 50% usage by 2020.

For more information on the German cement industry, read our feature 'Germany: A modern force in cement' in the May 2013 issue of Global Cement Magazine.

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Germany: Cemex achieved an alternative fuels substitution rate of 82.6% for its cement plants in Germany in April 2012. According to a press release, this is the first country that the Mexico-based multinational cement producer operates in to reach this level. Its Kollenbach cement plant in Beckum, Germany, averaged a 90.9% substitution rate for the month.

"Beyond significantly reducing fuel costs, our expanding use of alternative fuels fosters the sustainable management of our earth's natural resources," said Eric Wittman, president of Cemex in Germany. "In April 2012, our Kollenbach plant replaced 12,000t of coal with refuse-derived fuel, bone meal and old tires."

In 2012, Cemex reached an alternative fuel substitution rate of 27.1%. Overall, the company's alternative fuel strategy enabled it to avoid the use of 2.3Mt of coal and the emission of 1.8Mt of CO₂.