Displaying items by tag: Finland

Mexico: Cemex and Coolbrook have signed a memorandum of understanding to test technology to electrify the cement kiln heating process. Coolbrook says that its Roto Dynamic Heater (RDH) technology can heat a cement kiln to 1700°C using electrical power. If generated from renewable sources this could potentially remove around 45% of the carbon emissions in cement production that normally arise from the use of fossil fuels. The companies expect the technology to be ready for commercial use at an industrial scale in 2024. They will jointly evaluate the best production site to test and develop this technology.

Ilpo Kuokkanen, the executive chair of Coolbrook, said "Coolbrook has set a target to build a comprehensive ecosystem around its revolutionary technology and to test its use in as many industrial processes as fast as possible. Together with Cemex, we can bring the technology to cement production and achieve significant emission reductions in one of the most energy and CO₂-intensive industrial processes.”

Finland-based Coolbrook is a technology and engineering company that is developing processes to replace the burning of fossil fuels in major industrial sectors. Its RDH has potential applications in cement, steel and chemical production process. Its Roto Dynamic Reactor (RDR) is intended to eliminate CO₂ emissions from the steam cracking process used in the production of plastic.

Finland: Betolar has signed a letter of intent with Australia-based RISAB and the Vanadium Recovery Project to research the use of steel slag from which vanadium has been extracted in concrete production. Dow Jones Institutional News has reported that the company says that, through it Geoprime alkali-activated additive technology, the new slag source could replace 10% of the cement used in concrete production in Finland.

CEO Matti Löppönen said "We see a huge opportunity for Betolar here. If successful, we would be able to offer our customers a specific, currently unused slag of the steel industry to replace cement in concrete. Our customers already have experience in utilising other types of slag in the production of concrete using Geoprime. Utilising new side streams will expand the reach of our solution as planned.”

Betolar launched Geoprime in September 2021. It is currently developing a recipe-optimising artificial intelligence (AI) and data platform to bring together concrete producers and suppliers of slag, ash and other materials.

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

Finland: Betolar has announced the commencement of trading in its shares on the Nasdaq Helsinki exchange. Betolar launched its Geoprime alkali-activated slag and fly ash-based concrete additive in September 2021.

Tero Ojanperä, chair of Betolar’s board of directors, said “The company has so far been developed with a strong ownership with the aim of creating a significant position for Betolar in the global cement market. The share issue expands our shareholder base and provides a significant capital injection to accelerate Betolar's internationalisation.” He continued “The oversubscription of the share issue signals the market's strong belief that effective market-based solutions to the climate crisis can be found. We thank all the retail and institutional investors who participated in the share issue for their trust."

CEO Matti Löppönen added “The outstandingly successful share issue provides Betolar’s executive management with a supportive mandate to start promoting the green transition in various industries globally. At the same time, it also obliges us to steer the company in line with our strategy, in which trust is constantly strengthening among shareholders and customers, as well as society decision-makers.” He concluded “The Betolar team is strongly committed to taking the growth company to the next level.”

Finland: Cross Wrap has appointed Jukka Pennanen as its chief executive officer from the start of 2022. He succeeds Satu Kivelä in the post. She has held the position since 1994. Saalasti Group purchased 100% of Cross Wrap’s shares in February 2021.

Pennanen joined the baling and wrapping engineering company in October 2021 as a chief operating officer. Prior to this he has held a number of positions including running managing consultancy Luotsaaja for a decade. Earlier in his career he worked for Nokia for over 10 years in marketing and sales positions.

India: Finland-based Betolar has launched a partnership with sustainable housing company Tara. The arrangement is intended to enhance India’s ‘green’ construction sector by encouraging the use Betolar’s pre-cast concrete products. These use waste inputs to create a low-carbon alternative to Ordinary Portland Cement. Betolar has been working with Tara since around 2019 to bring its commercial products to the local market.

Betolar's Head of Asia said, "There is a tremendous appetite for sustainable construction materials in India which we are tapped into through our work with Tara and its mission to develop alternative and sustainable models for rural development, democratizing construction from the bottom up."

Finland: Wärtsilä’s sales fell by 6% year-on-year to Euro3.18bn in the first nine months of 2021 from Euro3.39bn in the corresponding period of 2020. It increased its order intake by 11% to Euro3.58bn from Euro3.24bn. The company’s cash flow from operating activities fell by 12% to Euro360m from Euro407m. It expects that demand for its offering will increase ‘considerably’ year-on-year in the fourth quarter of 2021.

The supplier announced that it will aim to achieve carbon neutral operations and to provide a product portfolio which will be ready for zero carbon fuels by 2030. It published a report entitled Front Loading Net Zero on how production economies can make savings while managing the renewable energy transition. The report concludes that full decarbonisation before 2050 will be financially viable if properly supported by governments and energy companies.

President and CEO Håkan Agnevall said “These new targets demonstrate our commitment to a sustainable future. Our aim is to support our customers on their decarbonisation. Our products, solutions, and services will meet the stringent environmental requirements, and the fuel flexibility and fuel efficiency of the engines powering these sectors are key to enabling the transformation.” Agnevall added “Naturally, we also need to do our part as an organisation and minimise our own environmental footprint.”

Finland: The VTT Technical Research Centre of Finland and Finnsementti have revealed work on the Decarbonate project to test a 12m electrically-heated rotary kiln. Other partners on the initiative included Nordkalk and UPM. Precalcination was tested as well as the projection of quick lime. The eventual goal is to use electricity from renewable sources to power the kiln and then capture the CO₂ released for utilisation.

The Decarbonate project has been exploring CO₂ capture and utilisation concepts that can be commercialised. It has run for two years since late 2019 and has funding of Euro1.2m. It has also looked at oxyfuel and electrolysis experiments.

Finland: Wärtsilä has announced that its upcoming Capital Markets Day event will take place at 1pm – 4.30pm, Eastern European Time (EET), on 18 November 2021. The supplier says that attendees will be able to follow proceedings via a webcast. President and CEO Håkan Agnevall together will host the event, during which members of the board of management will provide information on the company's business operations, strategy, and financial development.

Registration is open until 11 November 2021 and may be accessed here.

Nigeria: Finland-based Wärtsilä has extended its operation and maintenance agreement with Lafarge Africa by another five years. The agreement covers the 100MW Ewekoro power plant, which provides a dedicated supply of electricity to the company’s concrete and cement manufacturing processes. The extension of the deal was signed in July 2021 and it follows a previous 10-year agreement. The scope of the agreement includes the operating crew, performance guarantees, plant availability and spare parts.

The captive Ewekoro plant was supplied and commissioned by Wärtsilä in 2011. It consists of six Wärtsilä 50DF dual-fuel engines, operating primarily on gas, but with the flexibility to automatically switch to liquid fuel in case of a disruption to the gas supply. The engines are also designed to function efficiently with a low-pressure gas supply, a necessity given the region’s vulnerability to supply interruptions.

“We have benefited significantly from the efficient way by which Wärtsilä has operated and maintained this plant for the past 10 years, and we had no hesitation in extending the agreement for a further five years. An uninterrupted reliable supply of electricity is essential to our production, and having our own power plant, built, operated and maintained by Wärtsilä, gives us this assurance,” said Lanre Opakunle, Strategic Sourcing Director, Power & Gas, Middle East & Africa, Holcim.

Wärtsilä has also supplied Lafarge Africa with another 100MW power plant located in Mfamosing.