Displaying items by tag: CO2

France: UK-based Carbon8 Systems has announced plans for the commercial implementation of its carbon capture and use (CCU) system at Vicat’s Montalieu integrated cement plant in France. It follows successful demonstration projects at cement plants in the UK and Canada.

The company’s CO₂ntainer product will be deployed directly onsite at the plant and integrated into Vicat's existing industrial processes. It will capture CO₂ directly from the plant's flue gas emissions and use this as part of its Accelerated Carbonisation Technology (ACT) process. This accelerates the carbonation of cement bypass dust into lightweight aggregates. In its first phase of operation it will process and convert up to 12,000t of cement bypass dust.

Hydrogen and its use in cement production has been adding a dash of colour to the industry news in recent weeks. Last week, Lafarge Zementwerke, OMV, Verbund and Borealis signed a memorandum of understanding (MOU) to plan and build a full-scale unit at a cement plant in Austria to capture CO₂ and process it with hydrogen into synthetic fuels, plastics or other chemicals. This week, Air Products and ThyssenKrupp Uhde Chlorine Engineers (TUCE) signed a strategic agreement to work together in ‘key regions’ to develop projects supplying green hydrogen. Both of these developments follow the awarding of UK government funding in February 2020 to support a pilot project into studying a mix of hydrogen and biomass fuels at Hanson Cement’s Ribblesdale integrated plant.

As the title of this column suggests there is an environmental colour code to describe how hydrogen is made for industrial use. This is a bit more codified than when grey cement gets called ‘green’ but it pays to remember what the energy source is. So-called ‘green’ hydrogen is produced by the electrolysis of water using renewable energy sources such as hydroelectric or solar, ‘Grey’ hydrogen is made from steam reforming using fossil fuels and ‘Blue’ hydrogen is similar to grey but has the CO₂ emissions from the fuels captured and stored/utilised. Price is seen as the main obstacle to wider uptake of hydrogen usage as a fuel in industry although this is changing as CO₂ pricing mounts in some jurisdictions and the connected supply chain is developed. A study by BloombergNEF from March 2020 forecasted that green hydrogen prices could become cheaper than natural gas by 2050 in Brazil, China, India, Germany and Scandinavia but it conceded that many barriers would have to be overcome to get there. For example, hydrogen has to be manufactured making it more expensive than fossil fuels without government policy support and its, “lower energy density also makes it more expensive to handle.”

The three recent examples with respect to the cement industry are interesting because they are all exploring different directions. The Lafarge partnership in Austria wants to use hydrogen to aid the utilisation side of its carbon capture at a cement plant. The industrial suppliers, meanwhile, are positioning themselves in the equipment space for the technology required to use hydrogen on industrial plants. Secondly, ThyssenKrupp has alkaline water electrolysis technology that it says it has used at over 600 projects and electrochemical plants worldwide. Air Products works with industrial gas production, storage and handling.

Finally, the Hanson project in the UK will actually look at using hydrogen as a partial replacement for natural gas in the kiln combustion system. A Cembureau position paper in mid-2019 identified that the challenges to explore in using hydrogen in cement production included seeing how its use might affect the physical aspects of the kiln system, the fuel mass flows, temperature profile, heat transfer and the safety considerations for the plant. Later that year a feasibility study by the Mineral Products Association (MPA), Verein Deutscher Zementwerke (VDZ) and Cinar for the UK government department that is funding the Hanson project concluded that a hydrogen flame’s high heat in a burner alone might not make it suitable for clinker formation. However, the study did think that it could be used with biomass to address some of that alternative fuel’s “calorific limitations” at high levels. Hence the demonstration of a mixture of both hydrogen and biomass.

That’s all on hydrogen but, finally, if you didn’t log into yesterday’s Virtual Global CemProducer 2 Conference you missed a treat. One highlight was consultant John Kline’s presentation on using drones to inspect refractory in some hard to reach places. Flying a camera straight into a (cool) pyro-processing line was reminiscent of a science fiction film! Global Cement has encountered the deployment of unmanned aerial vehicles in quarry and stockpile surveys previously but this was a step beyond.

The proceedings pack - including video, presenter slides and delegate list - for the Virtual Global CemProducer 2 Conference 2020 is available to buy now

HeidelbergCement released their sustainability report for 2019 this week. Every large cement producer publishes one but this one is worth checking out because of the company’s ambition to become CO₂ neutral. Other companies are heading the same way but few of them have such developed and public plans.

Sustainability reports are often a hodgepodge of non-financial reporting bringing together environment, health and safety, community and other topics. Multinational companies cover a wide range of jurisdictions and combining reporting in these kinds of fields can be beneficial. Typically they are members of various bodies like the Global Reporting Initiative (GRI) or the Global Cement & Concrete Association (GCCA) that give various levels of conformity between reports. Yet, the wider focus of sustainability reports gives companies a chance to promote what they are doing well, away from balance sheets.

One highlight of HeidelbergCement’s report is its progress towards reducing its specific CO₂ emissions per tonne of cement and its recognition by the Science Based Targets (SBT) initiative towards this goal. So far it has achieved a reduction of around 22% from 1990 levels to 599kg CO₂/t (net) with a target of a 30% reduction or 520kg CO₂/t by 2030. There is a lot more going on in the report but it’s led by the vision, ‘to offer CO₂-neutral concrete by 2050 at the latest.’ It plans to achieve this by increasing the proportion of alternative CO2-neutral raw materials and fuels, developing lower clinker cement types and capturing and utilising CO₂ emissions. A focus on concrete is worth noting given the pivot by building materials manufactures towards concrete in recent years.

Back in the present, HeidelbergCement is roughly in the middle of the pack of major European multinational cement producers with its specific CO₂ emissions for cement in 2019. LafargeHolcim reported 561kg CO₂/t and Cemex reported 622kg CO₂/t. This is a bit of a moving target since corporate acquisitions and divestments can change both the starting point and the apparent current progress. HeidelbergCement’s acquisition of Italcementi in 2017 or CRH’s purchase of Ash Grove did exactly that. The other thing to consider is that these companies manufacture a lot of cement. The actual gross CO₂ emissions from a multinational cement producer are immense. LafargeHolcim, one of the world’s largest multinational producers, emitted 113Mt of CO₂ in 2019 from process and fuel sources whilst making cement. To put that into context, estimates for total global CO₂ emissions range from 33 – 36Gt for 2019. The cement industry’s entire share was estimated by the International Energy Agency (IEA) to be 4.1Gt in 2018.

Where this sustainability report starts to become really interesting is where it talks about CO₂ capture and utilisation. Its plans in this department are more mature than many of its competitors with various initiatives at different levels of development, mostly in Europe. Norcem, its Norwegian subsidiary, recently signed an agreement with Aker Solutions to order a CO₂ capture, liquification and intermediate storage plant at its integrated Brevik cement plant. The deal is dependent on government support but it’s a serious proposal. As reported previously from the Innovation in Industrial Carbon Capture Conference 2020, HeidelbergCement is actively preparing to hook up with CO₂ transport and storage infrastructure. The driver is CO₂ pricing from initiatives like the European Union (EU) Emissions Trading Scheme (ETS). With the EU preparing for the next phase of the ETS and talk of the European Green Deal gathering pace, before the coronavirus outbreak at least, CO₂ prices in Europe look set to rise. HeidelbergCement is positioning itself to benefit from being the first major cement producer to head into CO₂ capture and storage/utilisation with a variety of methods intended for different CO₂ prices and regional requirements.

HeidelbergCement doesn’t mention the coronavirus pandemic in its latest sustainability report. The report covers 2019 after all, before all of this happened. These reports do include health and safety information of employees, so this may be something to look out for next year. However, Cemex did mention the coronavirus in relation to its climate action plans this week. Essentially it wants to maintain its plans as a ‘fundamental component’ of its efforts to recover from the health crisis. This chimes with media talk around so-called ‘green-led’ government-backed relief programmes. Governments are the ones who are likely to be handing out the money, probably in the form of infrastructure projects. So it’s the perfect opportunity for them to encourage change from the companies bidding for this funding. Sustainability reports and the information behind them will be a useful tool in accessing this cash.

Mexico: Cemex says that the ongoing coronavirus pandemic will not delay its ‘Climate Action Strategy’ that was previously announced in February 2020. The building materials producer has developed a CO₂ reduction roadmap to help guide it towards a towards a targeted 35% reduction in net specific CO₂ emissions between 1990 and 2030.

The roadmap consists of: reduction of CO₂ emissions of clinker through “the production of novel clinkers with lower heat consumption”; use of “alternative decarbonated raw materials”; increased alternative fuel substitution; and increased substitution of clinker with “alternative cementitious materials, using admixtures to enhance strength, and adopting new grinding technologies to improve performance”; in addition to the increased use of renewable energy.

Cemex chief executive officer (CEO) Fernando Gonzalez said, “Climate change is one of the biggest challenges of our time, and we believe that we can continue to address it as a fundamental component of our efforts to recover from the Covid-19 pandemic.”

Germany: HeidelbergCement has published its sustainability report for 2019. The building materials producer says it decreased its specific gross CO₂ emissions per tonne of cement by 0.9% year-on-year to 622kg/t in 2019 from 628kg/t in 2018. Absolute net CO₂ emissions also fell, by 4.6% to 68.4Mt from 71.7Mt. Indirect CO₂ emission grew by 4.8% to 4.4Mt from 4.2Mt, though energy consumption in cement production fell by 3.5% to 364,000TJ from 377,000TJ.

HeidelbergCement chair Dominic von Achten said, “We have declared our express commitment to the United Nations (UN) Sustainable Development Goals. In particular, we will continue to intensify our commitment to tackling climate change in the coming years.”

France: LafargeHolcim France has said that all bagged cement will now bear a 360Score CO₂ emissions reduction rating, “to allow traders, artisans and homebuilders to know the precise carbon impact of their cement.” The rating, between ’A’ and ’D,’ corresponds to the factor of CO₂ compared to CEM-I Ordinary Portland Cement (OPC). ’A’ Class cement produces 75% – 100% less CO₂, while ’D’ class cement produces 0% – 25% less.

LafargeHolcim France chief executive officer (CEO) François Petry said, “By applying the 360Score rating scale to our bags of cements, we are continuing to implement our Lafarge 360 approach, which consists in supporting all builders to build in a more responsible manner.”

Austria: Lafarge Zementwerke, OMV, Verbund and Borealis have signed a memorandum of understanding (MOU) for the joint planning and construction of a full-scale plant by 2030 to capture CO₂ and process it into synthetic fuels, plastics or other chemicals. As part of the ‘Carbon2ProductAustria’ (C2PAT) project the companies intend to build the unit at the integrated Mannersdorf cement plant and capture all of the 0.7Mt/yr of CO₂ emitted.

"We are committed to leading the industry in reducing carbon emissions and shifting towards low-carbon construction. We have worked consistently and successfully on the reduction of the CO₂ footprint of our cement plants, products and solutions. Ultimately, CO₂-neutral cement production can only be possible with the implementation of breakthrough technologies, like carbon capture, which is why we have great expectations for the C2PAT project", said Lafarge’s local chief executive officer (CEO) José Antonio Primo.

The project aims to use hydrogen produced by Verbund to allow OMV to transform the captured CO₂ into a range of olefins, fuels and plastics. Borealis would then use some of these products as a feedstock to manufacture plastics. However, the companies say that, “taking the next steps towards a Zero CO₂ economy will require the right financial as well as favourable regulatory framework conditions. The success of C2PAT will largely depend on whether the right financial and regulatory framework conditions are created both at the European Union and Austrian national level.”

The joint project is designed in three phases. In phase one, the partners are currently evaluating and developing a joint strategy for project development, business modelling and process engineering. Based on the results of phase one, a cluster of industrial pilot plants in the Eastern part of Austria could be technically developed and built in the mid-2020s in phase two. Phase three entails building a full scale CO₂ capture and utilisation unit at a cement plant.

Lafarge Zementwerke is the Austrian subsidiary of building materials manufacturer LafargeHolcim. OMV produces and markets oil and gas, energy and other petrochemical products. Verbund is an Austrian-based electricity generator, with a focus on hydroelectric power. Borealis is a chemical company and a producer of polyolefins, base chemicals and fertilisers.

Germany: Schwenk Zement has announced plans for the production of sustainable aviation fuel (SAF) from cement kiln CO₂ emissions. The World Ethanol and Biofuels Report has reported that Schwenk Zement’s integrated 1.0Mt/yr Allmendingen, Baden-Württemberg plant will receive a pilot SAF plant in late 2020.

France: CRH subsidiary EQIOM has announced a 9000t/yr reduction in its transport-related CO₂ emissions, down by 5% to 171,000t/yr for the past three years from 180,000t in 2017. It achieved the reduction through its commitment to the FRET21 initiative, a sustainable development strategy of the Agence de l’Environnement et de la Maîtrise de l’Énergie (ADEME) and Association des Utilisateurs de Transport de Fret (AFAT).

The initiative is based on CO₂ reduction around four key activities: loading rate; distance travelled; means of transport; and responsible purchasing. EQIOM launched five initiatives, including increasing laden returns of trucks to reduce empty transport to 28%, commissioning four new natural gas and bioethanol-powered vehicles and increasing rail freight to 89%.

EQIOM logistics manager Jérôme Becamel said, "As in the rest of the country, our transport activity has been impacted by the social situation, particularly strikes on the roads and in the railways. However, we are delighted with the results obtained for this first challenge even if we were unable to reach our ambitions 100%. We are only more motivated and we will be stepping up our efforts over the next three years.”

Norway: Norcem, a subsidiary of HeidelbergCement, has signed an agreement with Aker Solutions to order a CO₂ capture, liquification and intermediate storage plant at its integrated Brevik cement plant. The final decision for the project depends on funding from the Norwegian government, which is expected to approve the unit in its national budget for 2021.

The project will use Aker Solutions’ Advanced Carbon Capture (ACC) technology and its S26 amine solvent. Once complete the unit will capture 0.4Mt/yr of CO₂. This will be transported to the Northern Lights project for permanent storage offshore beneath the North Sea.