Displaying items by tag: France

Both Limak Çimento and Cemento Yura revealed plans to work with hydrogen this week. Additionally, Lhyfe and Fives signed a deal to sell decarbonised products and services to industries, including cement, covering hydrogen production to combustion.

Türkiye-based Limak Çimento said that it had successfully conducted a hydrogen-enhanced alternative fuel test at its integrated Anka plant near Ankara. As part of the project it blended hydrogen with an alternative carbon-neutral fuel and then operated the plant’s kiln at a 50% substitution rate. The cement company says that the trial achieved a world first by feeding the hydrogen-enhanced fuel directly into the calciner instead of the main burner in the rotary kiln. According to local press, Air Liquide supplied grey hydrogen for the test, although this could be switched to green hydrogen in the future. As a reminder, ‘green’ hydrogen is produced by the electrolysis of water using renewable energy sources. ‘Grey’ hydrogen is made from steam reforming using fossil fuels.

Limak’s wider ambition is to use hydrogen-blended alternative fuels at all of its cement plants by 2030. By doing so it aspires to reduce its CO₂ emissions by 700,000t/yr. Its CEO Erkam Kocakerim remarked in mid-2023 that focusing on the carbon risks that energy-intensive industries might face exporting to the European Union (EU) paled in comparison to the potential payback from the green energy transition. At a climate change summit in mid-2023 organised by the United Nations and the Turkish government, he called for the Turkish Emission Trading System to be put into action as soon as possible, the creation of an updated renewable energy roadmap with renewable hydrogen, CCUS and renewable fuels, and the publication of a hydrogen and CO₂ country atlas. At the same time, he stated that the local cement sector could meet the EU’s 2030 emissions targets through the increased uptake of alternative fuels and blended cements.

Meanwhile in Peru this week Juan Carlos Burga, the general manager of Grupo Gloria subsidiary Cemento Yura, told the Gestión newspaper that its cement plant near Arequipa is preparing to start a green hydrogen trial in 2025. The catalyst for this is a solar power unit at the site that is currently scheduled for commissioning in early 2025. Once it is ready then the plant’s hydrogen project can use the renewable energy source to manufacture hydrogen and inject small quantities of it to stabilise the burning process and reduce the amount of coal used.

By contrast the memorandum of understanding that Lhyfe and Fives announced this week looks like the pair are marking their territory in the hydrogen supply and equipment chain for heavy industry. As part of the agreement the companies are targeting the metals, glass and cement industries and some other selected industrial heating processes and applications in Europe and North America. France-based Lhyfe develops, builds and runs green hydrogen production plants both for external clients and itself. It operates one plant at Bouin in France and is building other plants in France and Germany. However, the output of these sites is low. In spite of this, it says it is set to become the largest producer of renewable hydrogen in France in 2024. Fives, well known as a cement equipment supplier, says it has been a “technological leader in hydrogen for over 50 years” and that it sells “the widest range of hydrogen-proven burners available on the market to serve all industries.” The Lhyfe-Fives agreement follows a similar deal between Air Products and ThyssenKrupp Uhde Chlorine Engineers in 2020.

Projects in West Asia and South America such as those discussed by Limak Çimento and Cemento Yura are not necessarily where one might expect them to be. Typically all the sustainability news in the cement sector tends to be dominated by companies in Europe and North America. This is reflected in the continents that Lhyfe and Fives have targeted this week. Yet, the focus by Limak and Yura on hydrogen suggests that these companies are hunting for decarbonisation options that are cost effective ahead of potential legislative enforcement. Both appear to be using hydrogen as a fuel enhancer or additive rather than on its own.

We have reported upon a steady stream of hydrogen projects for the cement sector in the last year. These include Heidelberg Materials' study looking at using ammonia as a hydrogen source for fuelling cement kilns at its Ribblesdale cement plant in the UK, Fives work with Holcim at the La Malle plant in France and much work by Cemex such as the increase of its stake in green hydrogen production technology developer HiiROC in late 2023. As with Global Cement Weekly’s previous reporting on hydrogen, the jury is still out on whether it is a ‘goer’ for heavy industry at scale. An executive at Mitsubishi Heavy Industries told a conference in March 2024 that the infrastructure investment to support the use of hydrogen would cost over US$1Tn in the US and Europe alone. The head of Saudi Aramco then pointed out at the same event that oil and gas, for now at least, cost far less than hydrogen. Despite this, the projects keep coming.

France/Europe: Eurazeo, via its Smart City fund, alongside the EIC Fund and existing investors, is supporting Materrup with a €26m fundraising effort to expand its low-carbon cement technology across France and Europe. This investment will accelerate the deployment of Materrup's circular low-carbon cement plants using its non-calcined clay technology. Already operational with its first scale plant in Landes, Materrup plans to establish an additional 10 plants, in collaboration with European industrial partners.

Ireland: Ecocem has appointed Ghizlane Ruf as its Chief of Staff. The role will see her work with the company’s senior executives to prioritise strategic business decisions and enhance team efficiency. She has been in post since the start of 2024.

Ruf previously worked for LafargeHolcim from 2016 to 2022 in a variety of customer service roles eventually becoming the Head of Customer Services for Cements and Aggregates and Standards France. She has also worked for Salesforce and Teksial.

Spain: Heidelberg Materials plans to stop clinker production at its Añorga plant near San Sebastián and run the site as a cement grinding plant instead. It says it intends to use the change to focus on low-carbon cement products in Spain and the South-West of France. The clinker required to supply the markets in Northern Spain and the South-West of France will be produced at Heidelberg Materials Spain’s Bilbao plant instead. The closure of the clinker production line at Añorga will start once staff negotiations at the plant are completed. The company said that, “socially acceptable solutions for all affected employees are being sought.”

Germany: France-based Fives has won a contract to build a 50t/day clay calcination unit at Rohrdorfer’s Rohrdorf cement plant in Bavaria. The unit will integrate into the plant’s clinker line in order to allow it to test the production of limestone calcined clay cement with up to 40% reduced CO₂ emissions. Fives’ clay calcination unit uses a flash calcination process, based on a three-stage preheater, flash calciner and decolourisation system.

Rohrdorfer’s Net Zero Emissions Labs team is responsible for the project to decarbonise the Rohrdorf cement plant by 2038. Its managing director Helmut Leibinger said “After a detailed technical review, we decided that the flash calciner with an integrated clay calcination unit from Fives FCB was the best solution in terms of reliability, efficiency and colour control. We are confident that the unit will be essential in moving forward on our pathway to net zero.”

France: Cem’in’log has surpassed 1Mt of clinker processed at the Sète site since its inception over four years ago, encouraging parent company Cem’in’EU to continue investments there. Since 2019, the Port of Sète has served as a key entry point for Cem’in’EU’s clinker imports, mainly from North Africa. The site's storage capacity was expanded to 300,000t/yr in 2023. A new warehouse set to increase capacity to 500,000t/yr will begin construction in summer 2024 with a €5m budget. Cem’in’log will also boost its equipment, expecting to operate six rail services weekly by the end of 2024, supporting future expansion.

General manager Jean-Yves Apard said "We are currently dispatching four to five trains per week from Sète, loaded with 1850t of clinker. By the end of 2024, with a second locomotive provided by Regiorail and handled at the port by Viia, we will increase to six trains per week."

France: Holcim has committed €200m over the past three years to decarbonise its French manufacturing sites. This initiative is part of a roadmap signed with the French government in November 2023, aiming to reduce CO₂ emissions by over 50% by 2030 and 95% by 2050 compared to 2015 levels.

At the 7th Choose France summit on 13 May 2024, Holcim announced an additional investment of €64m for developing new technological and industrial platforms across its seven French plants located in Saint-Pierre-la-Cour, Martres-Tolosane, Port-la-Nouvelle, Val d'Azergues, Le Teil, Altkirch and La Malle. These platforms, set to be operational between 2025 and 2026, will focus on CO₂ capture technology (€9m at Martres Tolosane), integration of construction waste in cement processes (€24m across all plants), and the use of biomass waste fuels (€13m at Saint-Pierre-la-Cour, €11m at Martres-Tolosane, and €1m at Port-la-Nouvelle). An additional €6m will be allocated to recycling and transformation platforms for construction waste in five urban areas: Laval, Le Havre, Martres-Tolosane, Orange and Lyon.

These investments are expected to reduce Holcim's CO₂ emissions in France by over 120,000t/yr and create more than 40 jobs.

Heidelberg Materials announced this week that it is preparing to close its integrated cement plants at Beffes and Villiers-au-Bouin in France by October 2025. It framed the restructuring as a response to ‘a significant decline in cement sales in France’ and a plan to focus on low-carbon products. Unfortunately, local media reported that around 170 jobs will be lost at the two sites. The company says it is looking at ‘socially acceptable solutions’ including redeployment to other locations in the country.

Investment has been forthcoming from Heidelberg Materials France in recent years. It reminded everyone that it initiated a Euro400m scheme at its France-based subsidiary Ciments Calcia in late 2020. Most of this was earmarked towards a new production line at the Airvault plant, which is currently being built. Other schemes at the Beaucaire, Bussac-Forêt and Couvrot integrated plants followed. More recently, Heidelberg Materials launched a carbon capture, utilisation and storage (CCUS) project at Airvault, part of the GOCO2 initiative, with the aim of starting initial capture in 2030 with full 1Mt/yr capture planned later. What the company didn’t mention though was at the time of that 2020 investment it was also preparing to convert the integrated Gargenville plant into a grinding unit, stop white cement production at its Cruas plant with the intention of turning the site into a terminal and it wanted to reduce its workforce by around 140. To be fair to Heidelberg Materials though, it did have the same goal of reducing its specific net CO₂ emissions. The added detail this week was that the group aims to generate half of its revenue from sustainable products that are either low-carbon or circular by 2030.

Heidelberg Materials France is not alone with its ambitions for low-carbon products. Holcim notably opened in early 2023 what it said was the first calcined clay unit in Europe at its Saint-Pierre-la-Cour cement plant. Heidelberg Materials then followed in May 2023 with the announcement of a calcined clay project at its Bussac-Forêt cement plant. Other clay projects from Vicat, NeoCem and Neo-Eco have been reported since then. The other prominent France-based blended cement producer that has steadily been building its business in recent years is Hoffmann Green Cement. More general plant upgrade projects that are also worth mentioning include Eqiom’s (CRH) upgrade to its Lumbres plant in February 2024 and the ignition of a new kiln at Lafarge France’s Martres-Tolosane plant in October 2023. Both of these projects have been framed as driving sustainability.

Graph 1: Cement production in France, 2014 - 2022. Source: France Ciment.

Heidelberg Materials’ assessment about the poor state of the cement market has been confirmed by local media. Sales reportedly started falling in 2022, were down by 6% year-on-year in 2023 and further downward pressure is expected in 2024. Production data shown in Graph 1 above released by France Ciment, the national cement association, doesn’t really show what has been happening with sales. Over the last 20 years production hit a high of around 22Mt in the mid-2000s before settling around 16 - 17Mt/yr from 2015 onwards. The more telling trend, perhaps, has been the increase in CEM II blended cements from 50% in 2012 to 64% in 2022. Cement production may have stayed roughly the same over the last decade but it is using less clinker than it used to. Hence the pressure on companies like Ciments Calcia to reduce clinker capacity.

A further cost pressure facing cement producers in France is the impending end to the price cap on electricity scheduled by the end of 2025. The government enacted the scheme in late 2021 at the end of the Covid-19 pandemic, but then carried on as energy prices spiked following the Russian invasion of Ukraine. France Ciment lobbied in August 2023 for further protection for the sector using the argument that decarbonisation was not possible without electricity available for a reasonable price. It added that decarbonising the cement sector in France with carbon capture would cost around Euro3.5bn. Electricity prices started rising in February 2024 as part of the government’s phase out of the scheme.

Finally, 17 people were arrested on 5 April 2024 in connection with a demonstration at Lafarge France’s Val-de-Reuil ready-mixed concrete plant in Eure. Environmental activists reportedly trespassed on the site, according to local press, causing an estimated Euro450,000 in damages with acts such as spraying foam into machinery, ripping up bags of cement, breaking windows and more. The activists presented their actions as a response to both the environmental impact of cement and concrete production and the ongoing legal allegations about Lafarge’s actions in Syria in the early 2010s. Lafarge France’s La Malle integrated plant was also similarly targeted in December 2022 when around 200 activists stormed the site and caused damage to machinery and property. Lafarge’s response at the time was to remark that there was a feeling of misunderstanding given that the La Malle plant was piloting various decarbonisation methods.
All of this presents a febrile picture of the cement sector in France. Sales are down, electricity costs are set to go up and producers are switching to low-carbon cement products. Alongside this they are also closing clinker production plants but are also investing in new decarbonisation projects. At the same time environmental protestors have also been targeting cement and concrete plants and Lafarge’s association with its former actions in Syria appear to have made it more of a target than the other manufacturers. It is unsurprising then that Holcim, the parent company of Lafarge France, has raised the risk of damage to the group’s reputation, with both the general public and investors, should it fail to meet its targets. Reaching net zero was never going to be easy but setting unrealistic targets is increasingly not an option.

France: Heidelberg Materials has announced plans to close two of its plants in France - Beffes and Villiers-au-Bouin - by October 2025. This move is part of the company's restructuring efforts aimed at accelerating its decarbonisation efforts and focusing more on low-carbon products.

The decision comes amid a decline in cement sales in France, attributed to weak demand in the construction sector. 170 employees are affected by the impending closures of these plants, according to the company.

These closures align with Heidelberg Materials' commitment to focus on lower carbon alternatives, enhance energy efficiency, increase the use of alternative fuels, and reduce the clinker content in its cement products in France.

France: Ecocem has launched a new low-carbon advanced cement technology (ACT) cement, aiming for widespread adoption in European construction projects. The ACT range promises a clinker concentration of 20%, lower than the current norm of 35% minimum.

Jean-Christophe Trassard, Director, Marketing of Sustainable Innovation, said "We achieve competitive rates by controlling granularity, the fineness of grinding and admixtures. We have also greatly developed our thinking on the addition of additives in our formulations, which required more than fifteen years of R&D and the filing of six patents."

This product contains locally sourced additives, with the capability to adapt mixes to regional availability. The ACT cement is expected to reduce water usage by one-third compared to conventional concrete. An ACT-based concrete reportedly emits 198kg CO₂/t, a substantial reduction from the 614kg CO₂/t for standard concrete in France.

Gaining market entry for ACT required European technical evaluation and European assessment document certification, currently pending in the EU Official Journal. Trassard added, "As we are dealing with clinker rates below the standards, we had to go through this certification, which gives us a very good passport for the European markets. However, local administrative variations will have to be carried out subsequently."

In France, Ecocem has already applied for ATEX certification to facilitate deployment of the ACT range, expected later in 2024. Ecocem aims to include the ACT range in standard norms by 2026.