Displaying items by tag: Alternative Fuels

Encouraging news from Egypt with the announcement that Lafarge Ecocem has taken on two refuse-derived fuels (RDF) contracts in Suez and Qalyubeya. The RDF plants will have production capacities of 42,000t/yr and 280,000t/yr respectively, after upgrades are built.

The move follows a deal Lafarge struck with Orascom in March 2015 to develop a waste management framework of municipal and agricultural waste. The plan is to achieve an average fuel substitution rate of 25% by the end of 2015. Around the same time Ecocem also signed a cooperation agreement with the German Development Cooperation (GIZ) and the Qalyubeya Governorate to upgrade a recycling plant in Qalyubeya to produce RDF. Part of the deal was intended to reinvest some of the revenue from RDF sales back into the region's waste collection infrastructure.

These production levels compare to SITA UK's new RDF plants in the UK, which has a more mature RDF market. There, the newly opened Malpass Farm plant is planned to produce 200,000t/yr and the Tilbury plant will have an output capacity of 500,000t/yr when it opens. However, the Malpass Farm plant mainly feeds one cement plant, the 1.3Mt/yr Cemex Rugby plant with a mean substitution rate of 61% in 2013. By contrast, Lafarge Cement Egypt runs the massive 10.6Mt/yr El Sokhna plant.

Co-processing at El Sokhna by Lafarge is of particular interest given the links with Egypt's unofficial household waste collectors, the Zabbaleen. Lafarge Egypt recruited and trained 140 Zabbaleen to gather waste material for RDF production. The strategy enabled Lafarge to gather continuous supplies of RDF and strengthen local stakeholder relations, as Lafarge's 2013 sustainability report puts it. Lafarge Egypt's substitution rate was 2.2% in 2012 with significant improvements made since then. The current target of 25% for the end of 2015 shows how much progress Lafarge has made.

Hisham Sherif of the Egyptian Company for Solid Waste Recycling (Ecaru) placed Egypt's municipal solid waste level at 20Mt/yr at a presentation given at the Global CemFuels Conference earlier in 2015. From this 4Mt/yr of RDF could be produced. Together with biomass derived fuel (BDF) Sherif reckoned that the country's cement plants could reach substitution rates of 30 – 40%. Problems though with increasing RDF rates in Egypt include legal complexities, institutional issues, poor services and monitoring and centralised planning with little regard for the country's unofficial waste pickers, such as the Zabaleen.

Lafarge Ecocem appears to be tackling each of these problems in turn as the deals with Orascom and the Qalyubeya Governorate show. However, spare a thought for Egypt's unofficial waste sector workers who are likely to lose their livelihoods as waste management becomes more formalised and personnel rates per tonne of waste collected tumble.

For more information on the Zabaleen, check out the documentary made about them in 2009, called 'Garbage Dreams'.

Paraguay: Industria Nacional del Cemento (INC) is looking to diversify its fuels mixture to include other types of oils and possibly biofuels. The company has signed an agreement with the engineering faculty at Asuncion National University (FIUNA) to certify the use of biofuels. INC's president Jorge Mendez believes that, from 2016, INC may start using a variety of fuels, following a US$50m investment in its furnace. This could save US$22m/yr, but it will not necessarily mean that biofuel will be used.

Egypt: Lafarge Industrial Ecology (Ecocem) has signed two major contracts to manage and operate existing refuse-derived fuel (RDF) platforms in Suez and Qalyubeya in Egypt.

In an effort to continue its efficient waste management processes, the company has signed a year agreement to renovate and upgrade the platforms in Suez and another separate 10-year agreement to manage and operate the existing platforms in Qalyubeya. Lafarge Ecocem has already added a new production line to the Suez platform and plans an additional line within one year of signing its contract with the governorate. The plant will produce 42,000t/yr of RDF and the investment will total US$1.66m.

Ecocem has also already added an extra line to the Qalyubea plant, in addition to renovating one production line. The company's future investments in the governorate will increase the RDF production capacity by 32,000t/yr to 280,000t/yr. Both investments at the Qalyubeya plant were funded by GIZ and the Bill and Melinda Gates Foundation with a total Investment of US$1m.

"In line with our 'Building Egypt 2030' campaign, Lafarge is committed to help solve the issue of waste in Egypt and to continue taking the necessary steps towards sustainable development," said Hussein Mansi, CEO of Lafarge Egypt. "At Lafarge Egypt, we feel it is our responsibility as a leader in building solutions to be the major proponents in waste management and plan to continue finding many opportunities to make a difference."

Building on its waste management strategy, Lafarge Ecocem is committing to several additional long-term contracts with different governorates to help convert municipal solid wastes to alternative fuels. In addition, in March 2015, Lafarge Egypt and Orascom Telecom Media and Technology Holding S A E signed a memorandum of understanding to develop a waste management framework of municipal and agricultural waste.

Lafarge Egypt and Ecocem have implemented many projects over the past three years in order to increase the use of alternative fuels and aim to achieve an average fuel substitution rate of 25% by the end of 2015. More than 260,000t of waste have been processed and fired in Lafarge's Sokhna plant since 2013, an equivalent of 100,000t of fossil fuels.

UK: Mid UK Recycling Limited plans to extend its Wilsford Heath waste management facility at Ancaster, South Kesteven in Lincolnshire. If its plans are approved, the plant would recycle up to 350,000t/yr of waste mattresses and plastics.

Chris Mountain, managing director, said that the investment could run into 'multiple millions' of Euros. "We are an existing business, we employ 350 people in Sleaford, Caythorpe and the Ancaster site," said Mountain. "We will put in the main planning proposal in the next three months and as soon as we get the green light we'll start straight away." He said that initially the company wants to start by the end of December 2015, although it may take three years to complete the expansion. "We have been four years developing the site next-door, which is full to capacity now," he said. "The range of products we produce is getting wider and wider. It makes no sense to export those jobs out of the county."

There would be a building for machinery that could break down mattresses into resalable parts. Leftovers would form solid recovered fuel (SRF) products, which could by cement plants and power stations. Another building would be created for packing and storing gypsum from recycled wallboard, which would be sold to supermarkets as cat litter. The business would also bring in a new way of recycling rigid plastics, breaking them down into granules to sell to Lincolnshire manufacturers of drainage pipes, water pipes and car parts.

Mexico: Cemex has presented the results of its sustainable development report from 2014, stressing that it has responded to growing challenges in urban development, while highlighting the need for investments in long-lasting infrastructure, energy-efficient buildings and accessible housing.

Cemex's achievements include 600 infrastructure projects, amounting to more than 8Mm² of concrete for motorways, runways and streets in 14 countries, while it contributed towards the construction of 3150 affordable homes, covering more than 180,000m² in 12 nations. Since 1998, Cemex social programmes, including Patrimonio Hoy, ConstruApoyo and Centros Productivos de Autoempleo, have benefited more than 7m people, including 550,000 families. In 2014, Cemex substituted about 28% of its fuels for alternative fuels. Cemex also avoided the emission of more than 8Mt of CO₂ and lowered worker accident rates by 33%, as well as contract worker accidents by 23%, during 2014.

UK: Saxlund International has collaborated with Hope Construction Materials to install and commission a new waste-derived fuel solution for Hope Construction Materials' cement plant in Derbyshire, UK. The solution has been designed to provide storage, transportation, weighing and injection of solid waste fuel (SWF) to the two kilns. The goal is to increase the rate at which Hope can replace fossil fuels with waste-derived alternatives to more than 50%, a key part of its long-term sustainability targets.

The project incorporates a fuel reception and push-floor storage solution, reclaim conveyors, process tower with drum magnet and star screen, together with a weighing and pneumatic injection system to the main burners. The system facilitates stable and reliable process conditions to help minimise build-up in the pre-heater tower. It also offers a 'future-proof' solution with the flexibility to handle changing fuel characteristics and different types of waste-derived fuels, should suppliers change in the future.

"This is a flagship project for us. Once fully operational, the new solid waste fuel (SWF) system will run on a 24/7 basis delivering fuel at a rate of up to 5t/hr to each kiln," said Matt Drew, managing director Saxlund International. "It means that Hope Works will soon be operating with a significantly larger proportion of waste-derived fuels, in the process diverting up to 80,000t/yr of bulk solid waste from landfill and representing significant carbon savings to the business."

At the 24th AFCM Technical Symposium in April 2015, Nguyen Quoc Thang, plant manager at Vicem's Binh Phuoc cement plant, delivered an outstanding presentation. He explained the sourcing and processing methods for using cashew nut shells as an alternative fuel to replace coal at the plant.

Around 300,000t/yr of cashews are grown and harvested in the south-east of Vietnam, the equivalent of about 130,000t/yr of cashew nut shell, 85% of which remains after processing. According to Nguyen Quoc Thang, the plant uses cashew nut shells to replace 35% of its fuel and has significantly reduced its CO2 emissions and fuel costs by doing so.

Cashew nuts are grown in large quantities in Brazil, India, Nigeria, Vietnam, the Ivory Coast, Pakistan and Indonesia, among others. In 2012, some 4.15Mt of cashew nuts were grown. Cashew nut demand has risen greatly in both the long-term and the more recent past. New (and delicious) products are being designed to meet the demands of health-conscious people and vegans, including cashew nut butters, cashew milks, cashew cream, cashew ice cream, cashew cheese and cashew cooking sauces. All at premium prices, of course, and all driving cashew nut demand ever-higher.

Cashew nuts are always sold pre-shelled, as the shell is toxic if consumed. Their growing production volumes and the necessity that they always be pre-shelled for sale or further processing makes cashew nuts an ideal alternative fuel for cement production, with reliable supplies guaranteed for the foreseeable future, subject to good crop yields. Moreover, cashew nuts are mainly grown in regions that currently have low cement plant alternative fuel substitution rates, providing an instant solution to some of the cement industry's environmental challenges.

Cement producers in cashew nut-growing (and other types of nut) countries would do well to note the example that Vicem's Binh Phuoc cement plant has presented. In addition to saving costs and tackling environmental restrictions, the highly-profitable nut industries could provide extra economic value to their home countries through partnership with local cement plants.

Egypt: Tourah Cement plans to invest US$39.4m to convert its plant to alternative fuels to recover production ability and profitability. Tourah did not make a profit in 2014.

Egypt: Lafarge Egypt and Egyptian holding company Orascom Telecom Media (OTMT) and Technology Holding SAE have signed a memorandum of understanding (MOU) to develop a waste management framework of municipal and agricultural waste.

The memorandum, signed by Lafarge Egypt CEO Hussein Mansi and OTMT deputy CEO and COO Tamer el Mahdy, was created in an effort to process large volumes of municipal and agricultural waste into alternative fuels to be used in the Lafarge plant in Egypt and other companies.

The MOU represents a step towards sustainable development in the country and will begin the creation of a circular economy through the reduction of waste burning and dumping. The agreement will also create new employment opportunities and reduce the dependency on fossil fuels in the country.

Lafarge Cement Egypt has been providing thermal treatment solutions in Egypt for around three years in collaboration with its subsidiary Ecocem Industrial Ecology Egypt, which develops, sources and pre-treats solutions to facilitate the recovery of wastes into alternative fuels. Lafarge Egypt and Ecocem aim to achieve an average fuel substitution rate of 25% by the end of 2015.

UK: Environment minister Mark H Durkan and Devendra Mody, industrial director at Lafarge Tarmac, have signed an agreement allowing the use of waste-derived fuels (WDF) at Lafarge Tarmac's cement plant in Cookstown, Northern Ireland. The plant, which employs 86 people, currently uses coal for approximately 95% of its fuel. The agreement will see Lafarge Tarmac substitute up to 35% of its coal with WDF.

"The agreement will turn environment issues from barriers to business into economic growth opportunities. The deal is that the Northern Ireland Environment Agency (NIEA) firmly regulates and reduces red tape. In turn, partner companies invest heavily in the environment," said Durkan. "Lafarge Tarmac is committing significant investment in the environment. In addition to many environmental benefits, it will reduce its carbon emissions from production by a minimum of 10%, equivalent to taking 6500 cars off the road. It will look at ways to reduce emissions from its transportation chain and has also committed to improving public access to rare geological features found in the Ballysudden Area of Sepcial Scientific Interest (ASSI), located in its Cookstown quarry and to work with key stakeholders to develop a renewable energy strategy and examine options for reducing packaging."