Displaying items by tag: CO2

Philippines: Cemex subsidiary Solid Cement is installing a new US$356m, 1.5Mt/yr line at its Antipolo cement plant. When operational in April 2024, the line will increase the plant’s capacity by 79% to 3.4Mt/yr. Over the first four months of the project since March 2022, Solid Cement invested US$197m in silos and mechanical installation. The new 1.5Mt/yr line will use Low Temperature Clinker technology to reduce its CO₂ emissions, and will also recycle waste hot gases for raw materials drying.

Solid Cement is building the plant using 6000t of its own Vertua reduced-CO2 cement, which it says will further reduce its net carbon footprint by 564t.

Philippines president and CEO Luis Franco said “We will maintain our active role in supporting the development of this nation, as we have done in the past 25 years.”

Canada: The provincial government of Alberta has signed a contribution agreement for US$3.87m in funding towards Lafarge Canada’s planned carbon capture installation at its Exshaw cement plant. The cost of the system is US$20.9m. Offshore Energy News has reported that it is one of 11 carbon capture projects in the province which Alberta Minister of Energy Sonya Savage said will be operational by 2030. Ultimately, project partners plan to establish a CO₂ sequestration hub and transport network connecting the capture sites of various industry partners.

Colombia: Federación Interamericana del Cemento (FICEM) and the Global Cement and Concrete Association (GCCA) have announced their next steps to accelerate the decarbonisation of cement production in Latin America and the Caribbean. The partners have named Colombia as the region’s first Net Zero Accelerator host country. The initiative works to identify barriers to decarbonisation and to recommend policy changes to make an immediate impact. Along with fellow Net Zero Accelerator host countries Egypt, India and Thailand, Colombia brings the total coverage of the initiative to 10% of global cement capacity.

GCCA chief executive officer Thomas Guillot said “The urgency of addressing climate change becomes clearer every day. Last year, our industry made a breakthrough Net Zero global commitment to reduce our carbon footprint, and we are now driving action in Latin America to make real change in one of the regions predicted to use the most concrete and cement in the coming decades. Our Roadmap Accelerator programme, previewed today by our members and affiliate (FICEM) at Latin America and the Caribbean Climate Week, highlights the tailored policies and tools we will use to ensure that Net Zero concrete and cement is achieved by 2050.”

It’s been a good week for carbon capture projects in Europe with the announcement of who the European Union (EU) has selected for a grant from its Innovation Fund. 17 large-scale projects have been pre-selected for the Euro1.8bn being doled out in the second round of awards. On the cement and lime sector side there are four projects. These include projects at Holcim’s Lägerdorf cement plant in Germany, HeidelbergCement’s Devnya Cement plant in Bulgaria, Holcim’s Kujawy plant in Poland and Lhoist’s Chaux et Dolomites du Boulonnais lime plant in France. Large-scale in this instance means projects with capital costs over Euro7.5m. To give readers some sense of the scale of the projects that the EU has agreed to pay for, if the funding was shared out equally between the current bunch, it would be a little over Euro100m per project. This is serious money.

Devnya Cement’s ANRAV carbon capture, utilisation and storage (CCUS) project in Bulgaria has received little public attention so far so we’ll look a little more closely at this one first. No obvious information is available on what capture technology might be in consideration at the plant. HeidelbergCement’s leading experience in carbon capture technology at cement plants gives it a variety of methods it could use from a solvent scrubbing route to something less common. What the company has said is that, subject to regulatory approval and permitting, the project could start to capture 0.8Mt/yr of CO₂ from 2028.

What has also been revealed is that the project is linking up via pipelines to a depleted part of the Galata gas field site in the Black Sea. Oil and gas company Petroceltic Bulgaria is a partner and the aim of the project is to start a CCUS cluster in Eastern Europe. with the potential for other capture sites in Romania and Egypt to join in. This is noteworthy because much of the focus for the burgeoning cement sector CCUS in Europe so far has been on usage on local industrial clusters or storage in the North Sea.

The other new one is the Go4ECOPlanet project at Holcim’s Kujawy plant in Poland. Lafarge Cement is working with Air Liquide on the project. The latter will be providing its Cryocap FG adsorption and cryogenics technology for direct capture of flue gas at the plant. The transportation of the CO₂ is also interesting here as it will be by train not pipeline. Liquid CO₂ will be despatched to a terminal in Gdańsk, then transferred to ships before being pumped down into a storage field under the North Sea.

Turning to the other two grant recipients, the Carbon2Business project plans to capture over 1Mt/yr of CO₂ using a second generation oxyfuel process at Holcim Deutschland’s Lägerdorf cement plant. This project is part of a larger regional hydrogen usage cluster so the captured CO₂ will be used to manufacture methanol in combination with the hydrogen. Finally, Lhoist’s project at a lime plant in France is another team-up with Air Liquide, again using the latter’s Cryocap technology. The capture CO₂ will be transported by shared pipeline to a hub near Dunkirk and then stored beneath the North Sea as part of the D'Artagnan initiative. Around 0.61Mt/yr of CO₂ is expected to be sequestered.

The key point to consider from all of the above is that all of these projects are clear about what is happening to the CO₂ after capture. The days of ‘carbon capture and something’ have thankfully been left behind. CO₂ transportation infrastructure is either being used or built and these cement plants will be feeding into it. This will inevitably lead to questions about whether all these new CO₂ networks can support themselves with or without EU funding but that is an argument for another day.

Finally, in other news, four residents from the Indonesian island of Pulau Pari started legal proceedings against Holcim last week for alleged damages caused by climate change. Industrial CO₂ emissions are unquestionably a cause of this along with other sources but what a court might think about this remains to be seen. Yet, it is intriguing that the plantiffs have decided to go after the 47th largest corporate emitter rather than, say, one of the top 10. Regardless of how far the islanders get this is likely not to be last such similar attempt. If the case does make it to court though it seems likely that Holcim will mention its work on CCUS such as the two projects above. Only another 200-odd cement plants in Europe to go.

Germany: Cemex Deutschland’s carbon capture partner Carbon Clean has hired US-based engineering company KBR to carry out installation of the planned 100t/day CycloneCC carbon capture system at the producer’s Rüdersdorf cement plant in Brandenburg. KBR will provide front-end engineering design (FEED) services for the project.

KBR global technology solutions president Jay Ibrahim said "Reaching net zero targets requires expertise from different industries to work together, and we make a powerful team. Hopefully, it will be the first of many such projects."

Germany: Holcim Deutschland announced a planned upgrade to its Lägerdorf cement plant’s kiln on 14 July 2022. The producer will install a second generation oxyfuel kiln, which uses an air separation unit to supply oxygen directly, emitting CO₂-rich flue gas. A new carbon capture system will supply captured CO₂ to a synthetic hydrocarbons plant, which will produce methanol for other industrial applications. The upgrade will result in the capture of 1.2Mt/yr
of CO₂ emissions and make Lägerdorf one of the world’s first carbon neutral cement plants, according to Holcim Deutschland.

The project, called Carbon2Business, was among four cement plant projects and 13 other EU-wide projects to win a share of a US$1.81bn EU Innovation Fund funding pot. CEO Thorsten Hahn acknowledged that the awarding of funds was ‘good news for Holcim and all partners working with us to decarbonise cement.’ He said “Climate change means cement change.”

Bulgaria/Poland: The EU Innovation Fund has awarded funding to Devnya Cement’s ANRAV carbon capture, utilisation and storage (CCUS) project in Bulgaria and Lafarge Polska’s Go4ECOPlanet CCUS project in Poland.

ANRAV is a full-chain CCUS project connecting Devnya Cement’s Devnya cement plant in Varna Province over 30km to the Black Sea for storage. Go4ECOPlanet applies a similar model to the capture and storage of CO₂ from Lafarge Polska’s Kujawy cement plant offshore in the North Sea. The Kujawy cement plant is situated 200km inland in Kuyavian-Pomeranian Voivodeship. The plan is part of Lafarge Polska’s strategy to realise carbon neutrality at the Kujawy cement plant by 2027.

Regarding the ANRAV project, Mihail Polendakov, Bulgaria, Greece and Albania managing director at Devnya Cement’s parent company HeidelbergCement said “Our vision in the ANRAV consortium is to realise an economically viable CCUS cluster for Bulgaria and the neighbouring regions.” He continued “Subject to regulatory and permissions aspects, it could start operation as early as 2028, with a capture capacity of 800,000t/yr of CO₂.

A trio of slag cement stories have been in the sector news this week with reports from Australia, France and Sri Lanka. Of note from the first two reports is a focus on supplies of slag.

The first concerns Hallett Group’s US$80m supplementary cementitious materials (SCM) project in South Australia. This will see the company process slag and fly ash sourced from sites in the region to manufacture blended cement products and standalone SCMs. These will be principally milled, blended and distributed from a site at Port Augusta. However, an additional distribution site at Port Adelaide is also planned that can both import and export the company’s products in a bid to cut down on supply chain risk, particular for its mining customers. The company says it will replace up to 1.15Mt/yr of cement when fully operational, although initial production looks set to be about a third of this based on local media reports. Commissioning of the Port Adelaide distribution hub is scheduled for May 2023, following by the Whyalla Granulator in January 2024 and the Port Augusta processing plant in June 2024. Pointedly, Hallett Group is explicit about where is plans to source its SCMs from: Nyrstar Port Pirie and, potentially, Liberty GFG.

The second slag-themed story hails from France, where Hoffmann Green Cement has acquired ABC Broyage, which operates a slag grinding plant in North Dordogne. Like the project in Australia above, Hoffmann Green is focused on its supply chain. With this acquisition it will be able to grind its own blast furnace slag instead of buying it. Raw blast furnace slag will be imported via the port of La Rochelle where the company has storage silos. It will then be ground at the former ABC Broyage site and sent on to Hoffmann Green’s H1 and H2 production sites, located at Bournezeau in the Vendée region. Finally it will use it to manufacture its H-UKR and H-IONA cement products. There is no mention of how much the acquisition is costing Hoffman Green. Instead the emphasis, according to company founders Julien Blanchard and David Hoffmann, is very much to, “strengthen our control over our supply and secure our margins in the current highly inflationary context.”

Finally, the week’s third slag-themed cement story is from Sri Lanka, where local media reports that Insee Cement has started producing Portland Composite Cement, using SCMs such as slag, at its Ruhunu grinding plant. This story follows the trend of cement producers around the world switching to greater usage of blended cements, often for sustainability reasons. Unfortunately, political events in Sri Lanka are overshadowing everything else locally, with the president having fled amid social unrest provoked by the ongoing and severe economic crisis. To this end Insee Cement has astutely also donated medical supplies this week to the intensive care unit at the Colombo National Hospital.

These slag stories are important for the cement sector can be demonstrated by a recent update to the Center for International Climate and Environmental Research - Oslo’s (CICERO) research on global CO₂ emissions from cement production. When it published its estimate for 2021 it found that overall emissions were 2.6Bnt in 2021 or just over 7% of the world’s total CO₂ output. What is worse though, is that its data suggests that cement-based emissions have steadily grown year-on-year from 1.2Bnt in 2002. Apart from a dip in 2015 they have kept on rising! This can mostly be attributed to the growth of the Chinese cement industry in the early 2000s suggesting that a tipping point may be reached in the current decade as lowering cement production CO₂ intensity finally kicks in.

Slag and other SCM-based blended cements fit in here as they are one of the ‘easiest’ ways to reduce the clinker factor of cement and concrete and thereby reduce the sector’s CO₂ levels. Hence they keep popping up on the various roadmaps and reports for the cement industry to reach net zero. The flipside of this however is that slag is becoming harder to source as the demand for granulated blast furnace slag increases and less new steel plants get built, especially in North America and Europe. Hence the focus on the supply of slag in the first two news stories above. Blended cements may be the future but getting there will be far from simple.

Australia: Hallett Group plans to establish a slag cement grinding plant in Port Augusta, South Australia. Magnet News has reported the cost of the project as US$83.9m, towards which the producer has received US$13.4m in government funding. The plant will produce cement using South Australian ground granulated blast furnace slag (GGBFS) from Nyrstar’s Port Pirie and Liberty Primary Steel’s Whyalla steel refineries and fly ash from the site of the former Port Augusta power plant. Its operations will be 100% renewably powered. An accompanying new distribution facility at Port Adelaide will ship the cement to markets. The project will create 50 new jobs.

When the Port Augusta grinding plant becomes operational in 2023, its products will reduce regional CO₂ emissions by 300,000t/yr, subsequently rising to 1Mt/yr, according to the company’s expansion plans.

Hallett Group chief executive officer Kane Salisbury said "We're talking about 1% of the entire country's 2030 [CO₂ reduction] commitment, delivered through this project." Salisbury added "We're looking at turning South Australia into a global leader in manufacturing green cement."

France: Hoffmann Green Cement Technologies has acquired ABC Broyage, which operates a slag grinding plant in North Dordogne. The producer says that ABC Broyage will import granulated blast furnace slag (GBFS) via La Rochelle and supply ground GBFS to its H1 and H2 green cement plants in Bournezeau. This will give Hoffmann Green Cement Technologies self-sufficiency in its raw materials processing.

Co-founders Julien Blanchard and David Hoffmann said “Managing our supply chain has always been one of Hoffmann Green's strategic priorities. After securing our supplies of co-products and their storage, we are now focusing on optimising their processing through the acquisition of ABC Broyage and the development of vertical integration.” Blanchard and Hoffmann noted that, besides strengthening the company’s control over its raw materials supply, ABC Broyage’s slag grinding capacity also secures its margins in the ‘current highly inflationary context.’