Displaying items by tag: Belgium

Belgium: Holcim Belgium hopes to complete its Obourg cement plant’s Go4Zero oxyfuel kiln conversion and carbon capture installation project by 2025, in order to achieve carbon neutrality at the plant by 2030. The producer says that the plans involves establishing a new 135m-high cooling tower, instead of a 145m-high tower as previously planned.

In an effort to rally local support, Holcim Belgium will begin offering virtual reality (VR) tours of the upgraded plant plans in September 2022.

Chief executive officer Bart Daneels said “We would like to start this project, which will be a world premiere in the cement industry.”

France: Logistics software provider Everysens says that its Transport & Visibility Management System (TVMS) product has helped Ciments Calcia to improve its use of railway transportation. Philippe Labbé, the logistics director for the subsidiary of Germany-based Heidelberg Cement, said that the company had been using the software for three years. During which time it increased its productivity and saved time on the operational management of rail logistics. Labbé added that he thought the product would help the company meet its decarbonisation commitments by switching more trucks to rail.

Ciments Calcia originally chose Everysens to digitise of use of railway transport, to bring all the relevant data on to one platform and to improve its management of it. The building materials manufacturer sells around 5.3Mt/yr of cement and it operates 10 production sites. It uses over 400 railway wagons in France and Belgium.

Italy: Cementir’s revenue rose by 21% year-on-year to Euro362m in the first quarter of 2022 from Euro301m in the same period in 2021. It attributed this to higher prices linked to the increase in the costs of fuels, electricity, raw materials, transport and services. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 26% to Euro60.7m from Euro48.1m. Grey, white and clinker sales volumes increased by 1.8% to 2.4Mt and ready-mixed concrete sales volume remained stable at 1.13Mm³. Cement sales volumes grew in Belgium, Denmark and the US but fell in Turkey. Concrete sales volumes grew in Belgium and Norway but fell in Turkey, Sweden and Denmark.

Belgium: CBR has successfully completed an upgrade of systems connected to the kiln of its 0.8Mt/yr Antoing cement plant. The company says that it has modernised the kiln gas cycle, reducing the plant’s power consumption by 2.5%.

The Antoing cement plant previously underwent a capacity expansion and alternative fuels (AF) substitution-increasing upgrade to its kiln line in late 2020.

From the Nordics to the Mediterranean, European countries lead the field in reduced-clinker cement production using supplementary cementitious materials (SCMs). While consumers, faced with ever-greater choice, continue to opt for sustainability, projects to improve existing SCMs and develop new ones have won government backing and have become a matter of serious investment for other heavy industries beside cement. European cement producers’ decisions are steering the course to a world beyond CEM I. Yet, even in Europe, great untapped potential remains.

Companies generated a good deal of marketing buzz around their latest reduced-CO₂ cement ranges in 2021 and the first quarter of 2022: Buzzi Unicem’s CGreen in Germany and Italy, Holcim’s EcoPlanet in six markets from Romania to Spain, Cementir Holding’s Futurecem in Denmark and Benelux, and Cemex’s Vertua in Spain and several other countries. All boast reduced clinker factors through the use of alternative raw materials. This, however, is really a rebranding of a long-established norm in Europe.

Since 2010, cements other than CEM I have constituted over 75% of average annual cement deliveries across Cembureau member countries (all cement-producing EU member states, plus Norway, Serbia, Switzerland, Turkey, the UK and Ukraine). This statistic breaks down differently from country to country. CEM II is the norm in Austria, Finland, Portugal and Switzerland, with deliveries in the region of 90%. Portland limestone cement (PLC) makes up a majority of deliveries in all four. It has been central to Switzerland’s transition to 89% (3.72Mt) of CEM II deliveries out of a total 4.18Mt of cement despatched in 2021. There, the main types of cement were CEM II/B-M (T-LL) Portland composite cement, with 1.38Mt (33%), and two different classifications of PLC: CEM II/A-LL PLC, with 1.28Mt (31%), and CEM II/B-LL PLC, with 888,000t (21%).

A second approach is that of the Netherlands, where CEM III blast furnace slag cement with a clinker factor below 65% predominates, favoured for its sulphate resistance and the protection it offers against chloride-initiated corrosion of steel reinforcement in marine settings. By contrast, the UK has traditionally maintained a higher reliance on CEM I cement. This can be partly explained by the preference of builders there for adding fly ash or ground granulated blast furnace slag (GGBFS) at the mixing stage. Nonetheless, CEM II Portland fly ash cement held a 14% (1.43Mt) market share in the UK’s 10.2Mt of cement consumption in 2021.

The UK Mineral Products Association (MPA) has identified limestone as an underutilised resource in the country’s cement production. Together with HeidelbergCement subsidiary Hanson Cement, it has applied for a change to National Application standards to allow the production of Portland composite cement from fly ash and limestone or GGBFS and limestone. The association has forecast that Portland composite cement could easily rise to 30 – 40% of UK cement consumption, and that this has the potential to eliminate 8% of the sector’s 7.8Mt/yr-worth of CO₂ emissions.

Metallurgical waste streams have long flowed into European cement production, primarily as GGBFS, but also as bauxite residue. In 2021, alumina production in the EU alone generated 7Mt of bauxite residue, of which the bloc recycled just 100,000t (1.4%) that year. Two projects – the Holcim Innovation Center-led ReActiv project and Titan Cement and others’ REDMUD project – aim to produce new alternative cementitious materials from bauxite residue.

By collaborating with other industries, cement producers’ investments can most effectively reduce the overall cost of using these materials in cement production. In Germany, HeidelbergCement and ThyssenKrupp’s Save CO₂ project aims to develop new improved latent hydraulic binders or alternative pozzolan from GGBFS by producing slag from directly reduced iron (DRI). The Save CO₂ team believes that GGBFS substitution for clinker has the capacity to eliminite 200Mt/yr of CO₂ emissions from global cement production.

Meanwhile in the world of mining, ThyssenKrupp and others’ NEMO project is investigating the recovery of a useable mineral fraction for cement production from the extractive waste of the Luikonlahti and Sotkamo mines in Finland and the Tara mine in Ireland, through bioleaching and cleaned mineral residue upcycling. This may give cement producers full access to Europe’s 28Bnt stockpiles of sulphidic mining waste, of which mines generate an additional 600Mt each year.

Denmark-based CemGreen, which produces the calcined clay supplementary cementitious material CemShale, is developing a shale granule heat-treating technology called CemTower. This consists of three pieces of equipment vertically integrated into cement plants’ preheaters, kilns and coolers, and brings the processing of waste materials – here oil shale – to the cement plant.

Lastly, cement producers are exploring the possible uses of waste made of cement itself. In Wallonia, HeidelbergCement subsidiary CBR’s CosmoCem project is investigating the production of alternative cement additives from large available flows of local demolition, soil remediation and industrial waste. Similarly, the Greece-based C2inCO₂ project seeks to mineralise fines from concrete recycling for HeidelbergCement to use in the production of novel cements in its Greek operations.

In Switzerland, ZND Portland composite cement (produced using fine mixed granulate from building demolitions) is the third largest cement type, with 178,000t (4.3%) of total deliveries – narrowly behind CEM I with 239,000t (5.7%).Holcim Schweiz developed its Susteno 4 ZND Portland composite cement with Switzerland’s lack of any ash or slag supply in mind, demonstrating the potential flexibility of a circular economic approach to cement production.

On 21 March 2022, the University of Trier reported that it is in the process of mapping mineral resources, waste deposits and usable residues ‘on a cross-border scale,’ in an effort to produce new materials for use in cement production. Industry participants include France-based Vicat, CBR, Buzzi Unicem subsidiary Cimalux and CRH subsidiary Eqiom. Vicat is preparing a kiln at its 1Mt/yr Xeuilley cement plant in Meurthe-et-Moselle to use in testing new alternative raw materials developed under the project.

For Cembureau and its members, work continues, with the goal of Net Zero by 2050 constantly in sight. This goal includes a reduction in members’ clinker-to-cement ratios to well below 65%. In this, the association and its members are working towards a world not just beyond CEM I, but beyond CEM II, too. What exactly this will mean remains to be seen.

Sources

CemSuisse, ‘Lieferstatistik,’ 11 January 2022, https://www.cemsuisse.ch/app/uploads/2022/01/Lieferstatistik-4.-Quartal-2021.pdf

WSA, ‘December 2021 crude steel production and 2021 global crude steel production totals,’ 25 January 2022, https://worldsteel.org/media-centre/press-releases/2022/december-2021-crude-steel-production-and-2021-global-totals/

MPA, ‘Low carbon multi-component cements for UK concrete applications,’ July 2018, https://prod-drupal-files.storage.googleapis.com/documents/resource/public/Low%20carbon%20multi-component%20cements%20for%20UK%20concrete%20applications%20PDF.pdf

European Commission, ‘European Training Network for Zero-waste Valorisation of Bauxite Residue (Red Mud),’ 16 July 2020, https://cordis.europa.eu/project/id/636876

European Commission, ‘Industrial Residue Activation for sustainable cement production,’ 16 February 2022, https://cordis.europa.eu/project/id/958208

Recycling Portal, Zement der Zukunft – Forschungsprojekt „SAVE CO₂“ gestartet, 28 May 2021, https://recyclingportal.eu/Archive/65677

h2020-NEMO, ‘Project,’ https://h2020-nemo.eu/project-2/

European Commission, ‘Green cement of the future: CemShale + CemTower,’ 14 April 2021, https://cordis.europa.eu/project/id/101009382

CosmoCem, ‘Communiqué de Presse,’ https://cosmocem.org/

CO₂ Win, ‘C²inCO₂: Calcium Carbonation for industrial use of CO₂,’ https://co2-utilization.net/en/projects/co2-mineralization/c2inco2/

Les Echos, ‘Rendre le ciment moins gourmand en CO₂,’ 21 March 2022, https://www.lesechos.fr/pme-regions/innovateurs/des-substituts-au-clinker-rendent-le-ciment-moins-gourmand-en-co2-1395002

Türkçimento’s Volkan Bozay took to the airwaves last week to raise the issues that the war in Ukraine is causing for Turkey-based cement producers. The head of the Turkish Cement Manufacturers’ Association explained, to the local Bloomberg HT channel, that the dramatic jump in the price of Newcastle Coal posed a serious threat to the sector. The price jumped nearly US$100/t in a single day in early March 2022. Bozay said that the cost of cement from a plant using imported coal would consequently rise by around US$15/t. He added that the association’s members had an average of 15 – 20 days of coal stocks.

Graph 1: Price of coal, March 2020 – March 2021. Source: Trading Economics.

In a separate press release Türkçimento revealed that Turkey, as a whole, imported approximately US$1.5bn of coal from Russia in 2021. The cement industry imported about 5Mt of coal in 2021, from all sources, although the majority of this came from Russia. Coal shipments from Russia since the start of the war were reported as ‘very limited or even not possible.’ It was further explained that each US$10/t increase in the price of coal put up plant production costs by US$1.5/t of cement.

Naturally Bozay’s appearance on a television news show carried a lobbying aspect. He called for government import standards – such as the sulphur ratio, lower heating values and volatile matter limits - to be relaxed to allow coal to be imported more freely from sources such as Colombia, Indonesia and South Africa. There was also a push to let in more alternative fuels such as tyres and waste-derived fuels. The bit that Bozay didn’t mention though was how many of his members had long term coal supply contracts in place to cushion them, from short term price inflation at least. Yet, if coal shipments from Russia have simply stopped, then the price is irrelevant. A cement kiln configured to run on coal stops when it uses up its stocks.

Turkey was the world’s fifth largest cement producer in 2021 according to the United States Geological Survey (USGS). Türkçimento data shows that in 2020 it exported 145,000t of cement to Russia by sea. Overall it exported 16.3Mt of cement and 13.5Mt of clinker. The US, Israel, Syria, Haiti and Libya were the top destinations for cement. Notably, Ukraine was the sixth largest recipients of cement, with 752,000t imported, although anti-dumping legislation introduced in mid-2021 looked set to reduce it until the war started. Ghana, Ivory Coast, Guinea, Cameroon and Belgium were the principal recipients of clinker. Cumulative cement exports for the year to October 2021 were up by 3% year-on-year compared to the first 10 months of 2020. Clinker exports were down by 27% though. Overall domestic production and sales in Turkey rose by 9.5%, suggested an estimated production figure of 79Mt for 2021.

Other fallout in the cement sector from the war in Ukraine this week included Ireland-based CRH’s decision to quit the Russian market. It entered the region in 1998 through a subsidiary based in Finland and was operating seven ready-mixed concrete plants via its LujaBetomix joint venture. CRH says that all operations in Russia have now stopped. In 2021 it sold its lime business in Russia, Fels Izvest, to Russia-based Bonolit. Although selling concrete plants is not trivial, these are far cheaper assets than clinker production lines. Germany-based HeidelbergCement, Italy-based Buzzi Unicem and Switzerland-based Holcim each operate at least one integrated cement plant in Russia. So far these companies have publicly expressed dismay at the humanitarian crisis unfolding in Ukraine and made donations to the Red Cross.

Graph 2: European Union Emission Trading Scheme price, 2020 – March 2022. Source: Sandbag.

Finally, one more surprise this week has been a crash in the European Union (EU) Emission Trading Scheme (ETS) carbon price from a high of Euro96/t in early February 2022 to Euro58/t on 7 March 2022. As other commentators have stated, normally the carbon price would be expected to follow the energy market, but this hasn’t happened. Instead investors have pulled out, possibly to maintain liquidity for other markets.

With the US set to ban Russian oil, gas and coal imports and phase-outs to varying degrees promised by the UK and the EU in 2022, we can expect more turbulence from energy markets in the coming days. As the Turkish example above shows, all of this can... and will... have effects on cement production.

Benelux/France: Cementir Holding has introduced its Futurecem limestone calcined clay cement into the Benelux and French cement markets. Futurecem cement applies Cementir Holding’s patented processes to substitute over 35% of clinker in cement with limestone and calcined clay, preserving the cement’s strength and quality while reducing its carbon footprint by 30% compared to ordinary Portland cement (OPC).

Cementir Holding previously rolled out Futurecem cement in Denmark in 2021. In 2022, it plans to launch InBind high performance concrete (HPC) and ReCover ultra-high performance concrete (UHPC) to expand its range of HPC and UHPCs using Futurecem technology.

Eddy Fostier, managing director of Cementir Holding’s Belgian subsidiary CCB, said “Thanks to the joint efforts of the group and CCB teams, Futurecem technology is the main pillar for CCB’s low carbon transition within the Group roadmap. This product technology is matching customer needs, highlighted through a specific survey carried out across the most relevant market areas and applications.” Fostier concluded “I’m fully convinced that Futurecem will play a relevant role in the decarbonisation of the construction industry, where cement and concrete are essential building materials both in the present and in the future.”

Italy: Cementir’s revenue grew by 11% year-on-year to Euro1.36bn in 2021 from Euro1.22bn in 2020. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 17.9% to Euro311m from Euro264m. Sales volumes of cement and concrete increased by 4.1% to 11.2Mt and 14.8% to 5.01Mm3 respectively.

“2021 marked for Cementir the year of the historic record of revenues and EBITDA despite the uncertainties related to the pandemic crisis, the substantial increase in energy costs, materials and services and the devaluation of the Turkish lira,” said Francesco Caltagirone Jr, chair and chief executive officer of Cementir.

The group also reviewed and approved the three-year Group Industrial Plan update for the period 2022 - 2024 and the 2022 budget. It has a target of reduce CO₂ emissions (scope 1) by 30% in 2030 compared to 1990 levels. It is also planning to invest Euro116m in the 2022 – 2025 to meet this goal and others. Some of this will go towards building a new production line at its integrated Gaurain cement plant in Belgium, where the work is intended to raise the unit’s alternative fuels substitution rate to 80% from 40%. The group noted that this project has been delayed to 2022 due to the coronavirus pandemic. Changes at other cement plants include switching to natural gas and biogas as well as energy efficiency projects. It is also said it was planning to ‘significantly’ increase the production of its FUTURECEM calcined clay cement and related sustainable products.

Belgium: Holcim has completed its acquisition of speciality building products company PTB-Compaktuna. The group said that the acquisition further expands its service-led offering in the repair and refurbishment market.

CEO Jan Jenisch said “I am excited to add PTB-Compaktuna to the Holcim family as another step in the expansion of solutions and products, advancing our Strategy 2025 – Accelerating Green Growth. This addition strengthens our presence in Europe in key markets like repair and refurbishment. Building on the entrepreneurial vision and legacy of the Smessaert family, I look forward to investing in this business’ next era of growth and warmly welcoming their employees into the Holcim family.”

Belgium: Environmental disclosure organisation CDP has listed Cemex, HeidelbergCement and Holcim among 200 companies on its 2021 Climate Change A List for actions to mitigate their CO2 emissions. Holcim’s Indian subsidiaries ACC and Ambuja Cements also received A ratings. Both ACC and Ambuja appeared on CDP’s 2021 Water Security A List, while Holcim scored an A-.

Chief executive officer Jan Jenisch said “Building on the launch of our nature-positive strategy this year, we set new and ambitious goals to achieve water security across our operations worldwide, with our colleagues from Ambuja in India leading the way. CDP’s rankings this year are a testimony to the tremendous work carried out by our 70,000 people around the world and a great encouragement for all of us to keep raising the bar.”