Displaying items by tag: Clinker factor

Colombia: The Science-Based Targets Initiative (SBTi) has validated Grupo Argos Subsidiary Cementos Argos’ CO₂ emissions reduction goals. Cementos Argos aims to reduce its Scope 1 and Scope 2 CO₂ emissions in line with a well-below 2°C climate change scenario by 2030. Its strategy includes increasing co-processing of alternative fuel (AF), reducing its cement’s clinker factor, optimising its heat and electricity consumption, investing in cleaner technologies, increasing the share of renewable power it uses and diversifying its product range to include more low-carbon products.

In Australia and New Zealand, four producers operate a total of six integrated cement plants, with another 13 grinding plants situated in Australia. This relatively small regional cement industry has been on a decades-long trajectory towards ever-greater sustainability – hastened by some notable developments in recent weeks.

Oceania is among the regions most exposed to the impacts of climate change. In Australia, which ranked 16th on the GermanWatch Global Climate Risk Index 2021, destructive changes are already playing out in diverse ways.¹ Boral reported 'significant disruption' to its operations in New South Wales and southeast Queensland due to wet weather earlier in 2022. This time, the operational impact was US$17.1m; in future, such events are expected to come more often and at a higher cost.

Both the Australian cement industry and the sole New Zealand cement producer, Golden Bay Cement, have strategies aimed at restricting climate change to below the 2° scenario. Golden Bay Cement, which reduced its total CO₂ emissions by 12% over the four-year period between its 2018 and 2022 financial years, aims to achieve a 30% reduction by 2030 from the same baseline. The Australian Cement Industry Federation (CIF)'s 2050 net zero cement and concrete production roadmap consists of the following pathways: alternative cements – 7%; green hydrogen and alternative fuels substitution – 6%; carbon capture – 33%; renewable energy, transport and construction innovations – 35% and alternative concretes – 13%, with the remaining 6% accounted for by the recarbonation of set concrete.

Australia produces 5.2Mt/yr of clinker, with specific CO₂ emissions of 791kg/t of clinker, 4% below the global average of 824kg/t.² Calcination generates 55% of cement’s CO₂ emissions in the country, and fuel combustion 26%. Of the remainder, electricity (comprising 21% renewables) accounted for 12%, and distribution 7%. Australian cement production has a clinker factor of 84%, which the industry aims to reduce to 70% by 2030 and 60% by 2050. In New Zealand, Golden Bay Cement's main cement, EverSure general-purpose cement, generates CO₂ at 732kg/t of product.³ It has a clinker factor of 91%, and also contains 4% gypsum and 5% added limestone.

Alternative raw materials

Currently, Australian cement grinding mills process 3.3Mt/yr of fly ash and ground granulated blast furnace slag (GGBFS). In Southern Australia, Hallett Group plans to commission its upcoming US$13.4m Port Augusta slag cement grinding plant in 2023. The plant will use local GGBFS from refineries in nearby Port Pirie and Whyalla, and fly ash from the site of the former Port Augusta power plant, as well as being 100% renewably powered. Upon commissioning, the facility will eliminate regional CO₂ emissions of 300,000t/yr, subsequently rising to 1Mt/yr following planned expansions. Elsewhere, an Australian importer holds an exclusive licencing agreement for UK-based Innovative Ash Solutions' novel air pollution control residue (APCR)-based supplementary cementitious material, an alternative to pulverised fly ash (PFA), while Australian Graphene producer First Graphene is involved in a UK project to develop reduced-CO₂ graphene-enhanced cement.

Golden Bay Cement is investigating the introduction of New Zealand's abundant volcanic ash in its cement production.

Fuels and more

Alternative fuel (AF) substitution in Australian cement production surpassed 18% in 2020, and is set to rise to 30% by 2030 and 50% by 2050, or 60% including 10% green hydrogen. In its recent report on Australian cement industry decarbonisation, the German Cement Works Association (VDZ) noted the difficulty that Australia's cement plants face in competing against landfill sites for waste streams. It described current policy as inadequate to incentivise AF use.

Cement producer Adbri is among eight members of an all-Australian consortium currently building a green hydrogen plant at AGL Energy’s Torrens Island gas-fired power plant in South Australia.

Across the Tasman Sea, Golden Bay Cement expects to attain a 60% AF substitution rate through on-going developments in its use of waste tyres and construction wood waste at its Portland cement plant in Northland. The producer will launch its new EcoSure reduced-CO₂ (699kg/t) general-purpose cement in November 2022. In developing EcoSure cement, it co-processed 80,000t of waste, including 3m waste tyres. The company says that this has helped in its efforts to manage its costs amid high coal prices.

Carbon capture

As the largest single contributor in Australia's cement decarbonisation pathway, carbon capture is now beginning to realise its potential. Boral and carbon capture specialist Calix are due to complete a feasibility study for a commercial-scale carbon capture pilot at the Berrima, New South Wales, cement plant in June 2023.

At Cement Australia's Gladstone, Queensland, cement plant, carbon capture is set to combine with green hydrocarbon production in a US$150m circular carbon methanol production facility supplied by Mitsubishi Gas Chemical Company. From its commissioning in mid-2028, the installation will use the Gladstone plant's captured CO₂ emissions and locally sourced green hydrogen to produce 100,000t/yr of methanol.

More Australian cement plant carbon capture installations may be in the offing. Heidelberg Materials, joint parent company of Cement Australia, obtained an indefinite global licence to Calix's LEILAC technology on 28 October 2022. The Germany-based group said that the method offers effective capture with minimal operational impact.

Cement Australia said “The Gladstone region is the ideal location for growing a diverse green hydrogen sector, with abundant renewable energy sources, existing infrastructure, including port facilities, and a highly skilled workforce." It added "The green hydrogen economy is a priority for the Queensland government under the Queensland Hydrogen Industry Strategy.”

Logistics

Australian and New Zealand cement facilities' remoteness makes logistics an important area of CO₂ emissions reduction. In Australia, cement production uses a 60:40 mix of Australian and imported clinker, while imported cement accounts for 5 – 10% of local cement sales of 11.7Mt/yr.

Fremantle Ports recently broke ground on construction of its US$35.1m Kwinana, Western Australia, clinker terminal. It will supply clinker to grinding plants in the state from its commissioning in 2024. Besides increasing the speed and safety of cement production, the state government said that the facility presents 'very significant environmental benefits.'

Conclusion

Antipodean cement production is undergoing a sustainability transformation, characterised by international collaboration and alliances across industries. The current structure of industrial and energy policy makes it an uphill journey, but for Australia and New Zealand's innovating cement industries, clear goals are in sight and ever nearer within reach.

References

1. Eckstein, Künzel and Schäfer, 'Global Climate Risk Index 2021,' 25 January 2021, https://www.germanwatch.org/en/19777

2. VDZ, 'Decarbonisation Pathways for the Australian Cement and Concrete Sector,' November 2021, https://cement.org.au/wp-content/uploads/2021/11/Full_Report_Decarbonisation_Pathways_web_single_page.pdf

3. Golden Bay Cement, 'Environmental Product Declaration,' 12 May 2019, https://www.goldenbay.co.nz/assets/Uploads/d310c4f72a/GoldenBayCement_EPD_2019_HighRes.pdf

Pakistan: Fauji Cement says that its sustainability initiatives across its three cement plants reduced CO₂ emissions by 215,000t in the 2022 financial year. The Pakistan Today newspaper has reported that clinker factor reduction in reduced-CO₂ products such as Askari Green cement and Pamir cement eliminated 89,900t-worth of emissions, 42% of total reductions. Waste heat recovery (WHR) plants eliminated 79,400t of emissions (37%), solar power plants eliminated 31,500t (15%), alternative fuel (AF) substitution eliminated 8030t (3.5%) and reforestation eliminated 600t (2.5%).

Austria: The Austrian Cement Industry Association (VÖZ) has launched a roadmap for carbon neutrality by 2050. The initiative follows the 5C approach of Clinker, Cement, Concrete, Construction and Carbonation as prompted by the European Cement Association, Cembureau. Selected targets from the document include reducing the sector’s average clinker factor to 52% by 2040 from 70% in 2020, using carbon-neutral electricity from 2030 and meeting a recycling rate for concrete and demolition waste of 25% in 2050 from 10% in 2022. Sebastian Spaun, the managing director of VÖZ, highlighted the ‘Carbon2ProductAustria’ (C₂PAT) initiative as a key project where capture CO₂ from Lafarge Zementwerke’s Mannersdorf cement plant will be used with hydrogen to produce synthetic fuels, plastics or other chemicals.

India: JK Lakshmi Cement has partnered with the Society for Technology and Action for Rural Advancement (TARA) to integrate calcined clay technology into its operations in order to commence production of limestone calcined clay cement (LC3). United News of India has reported that the producer says that this type of composite cement reduces the product's clinker factor by 50% and its carbon footprint by 40%.

JK Lakshmi Cement said "This partnership will be a game-changer for the cement industry, giving impetus to its efforts in mitigating emissions, combating climate change and bringing a holistic change in the surrounding communities to create sustainable livelihoods in large numbers."

France: Eqiom has launched its new reduced-CO₂ CEM II/C cement range on the French market. The range includes the Portland limestone, slag and clinker filler CEM II/CM (SL) 42.5 N cement produced at its La Rochelle cement plant. The cement is the first product to obtain NF certification from the Scientific and Technical Center for Building (CSTB) under its new standard designation EN 195-5. The producer says that in mid-2022 EN 197-5 will assimilate into the EN 206/CN standard for use in structural concrete.

Eqiom said that the range will offer its customers a more sustainable alternative to its other NF EN 197-1 certified compositions. La Rochelle cement plant operations manager Ahmed Mansouri said “We are proud of this result, which is the result of close collaboration between the different Eqiom teams. This commitment has made it possible to provide our customers with a solution with low CO₂ emissions while guaranteeing sufficient performance so as not to impact practices on the construction sites.”

Mexico: Cemex has published its 2021 Integrated Report. Under the report’s Climate Action section, Cemex recorded a 4.7% year-on-year decrease in its CO₂ emissions per tonne of cementitious material. Alternative fuel (AF) substitution rose to 29%, while its products’ average clinker factor fell to 75%. It was the first company to complete a global roll-out of its reduced-CO₂ cement and concrete range (Vertua). It established Science-Based Targets Initiative (SBTi)-verified well below 2°C 2030 climate action goals and joined the UN’s Race to Zero and the Business Ambition for 1.5°C coalition. It also became a founding member of the World Economic Forum’s First Movers Coalition for zero-carbon economic development.

The year also brought major Sustainability and Circular Economy milestones, including managing 57 times the volume of waste it sent to landfill, positively impacting 25m lives through its Social Impact Strategy and processing 61% of global sales through its Cemex Go digital sales platform. For the second consecutive year, its Net Promotor Score was 68, ‘substantially above’ the construction and engineering industry average.

Germany: Master Builders Solutions has announced the addition of a new range of admixtures consisting of MasterEase and Master X-Seed to its admixtures portfolio. The company developed MasterEase and Master X-Seed to best enable European cement companies to produce cement of the EU’s new CEM II/C-M and CEM VI Portland-composite cements. Master Builders Solutions hopes that the new products will drive the construction industry’s transition to low-clinker cements and CO2-optimised concrete.

Parent company MBCC Group’s European president Christian Geierhaas said “Providing sustainable solutions is a key factor of Master Builders Solutions’ portfolio and overall strategy. Strong partnerships are essential and support and accelerate the development of significant innovations. We work with major players to continuously develop efficient admixtures to add value to our customers and achieve a long-term sustainable positive effect on the construction industry.” He added “In addition to the usual performance criteria, such as fluidity and compressive strength, our new solutions for our ready-mix customers are characterised by their outstanding robustness. Our admixtures provide an important differentiator by guaranteeing consistently high quality concrete, even upon variation of the cement type and fluctuation of the raw materials used to produce these new, more sustainable cements.”

Australia: First Graphene has started a five year collaboration research and development agreement with construction chemicals manufacturer Fosroc International to develop its PureGraph graphene-based cement additive product range. First Graphene will provide access to its formulation and dispersion process technologies and Fosroc will take responsibility for additive raw material supplies and formulations, mixing and dispersion and extensive laboratory trials. The objective of the deal is to jointly develop a range of PureGraph-enhanced cement additives that Fosroc will add to its portfolio of specialty products.

Michael Bell, the managing director and chief executive officer of First Graphene, said, “The agreement with Fosroc is a significant further step for First Graphene as we implement our go-to-market plan to become the world’s leading supplier of graphene-enhanced cement and concrete solutions. Fosroc has significant penetration into multiple global markets that will be highly beneficial in helping expand our reach and educating the market on the significant benefits, including emission reductions, that graphene-enhanced products provide.”

First Graphene says that the clinker factor of cement can be reduced by up to 20% through the use of its PureGraph additive products during the final grinding phase of cement production.

Colombia: Cementos Argos has announced its new commitment to reduce the CO₂ emissionsfrom its cement operations by 29% over a period ending in 2030. The company has additionally committed to producing all of its concrete CO₂-neutrally by 2050. It said that its strategy will comprise several carbon mitigation techniques, including maximised alternative fuel (AF) substitution, clinker factor reduction, energy optimisation, clean technology upgrades and a diversification of its range of its cement range to include more sustainable products.

Chief executive officer Juan Calle said "We are determined to face this important challenge and we are convinced that we can build the future we have planned and achieve a more prosperous, inclusive and low-carbon world if we work together with determination to accelerate this transition." He added "We will continue to strive to implement tangible actions, achieve measurable progress each year and deliver information about out opportunities and progress transparently."