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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

Mexico: GCC has made new appointments to the roles of project director, chief financial and planning officer and general counsel, effective immediately. Luis Carlos Arias will now serve as project director to the company's Odessa, US, cement plant expansion. Arias previously served as the group's chief financial officer. Maik Strecker steps into the role of chief financial and planning officer. Strecker joined GCC as chief planning officer in 2020. He has two decades' previous experience in roles spanning mergers and acquisitions, business development, product line management, operations and sales and marketing. Lastly, Cesar Conde will serve as GCC's general counsel. Conde has worked for the group since 2006.

GCC's CEO Enrique Escalante said "I am confident these executives bring proved strategic and execution leadership to the Company, and I look forward to the challenges and opportunities ahead."

Finland: Geoprime producer Betolar has named Riku Kytömäki as its new president and CEO. Riku's professional background is in materials technology, having served as president and CEO of Exel Composites and held senior positions in Switzerland-based ABB. Kytömäki holds board positions in several international companies and organisations, including polymers producer Teknikum Group. He has management experience in Asian markets where Betolar has expanded during the past few years.

Betolar said "Riku will lead Betolar through its next growth phase as its Geoprime solution is entering active production. Geoprime is a next-generation, low-carbon solution and sustainable alternative to cement: it delivers 80% fewer emissions and 100% cement-free building materials with the same performance as traditional concrete."

US: Martin Marietta Materials recorded revenues of US$4.68bn throughout the first nine months of 2022, up by 20% year-on-year from US$3.92bn. Cement sales contributed US$455m, 9.7% of total revenues, up by 27% from US$358m. Cost of revenues rose by 4% for the group, to US$3.62bn from US$2.92bn. Nonetheless, Martin Marietta Materials successfully recorded nine-month net earnings growth of 25% year-on-year, to US$638m from US$546m.

Chair and CEO Ward Nye said that double-digit price growth drove the company's record profitability. He said "Importantly, we expect a return to expanding margins in the fourth quarter of 2022, as the compounding effect of multiple pricing actions throughout the year offsets continued inflationary pressure and a slowdown in single-family residential construction. Martin Marietta's strategic coast-to-coast footprint is well positioned for long-term growth, driven by favourable population migration trends, housing shortages in our markets and a long-term federal highway bill complemented by healthy Department of Transportation budgets in the company's key states. Near-term, we expect affordability-driven headwinds in the single-family residential end market will be offset by a significant acceleration in public infrastructure investment and continued strength in large-scale energy, domestic manufacturing and multi-family residential projects."

Taiwan: South Korea-based Hana Technology has won a contract to supply US$33.4m-worth of equipment to Taiwan Cement. Local press has reported that the order will supply a cement plant upgrade by the producer.

India: Adani Group plans to invest US$12.1bn across the various sectors in which it operates in the state of Karnataka before 2030. Press Trust of India News has reported that the company has confirmed that expansions to its cement operations will be included under the investment package.

Adani Group's four cement facilities in Karnataka share a cement production capacity of 7Mt/yr.

Egypt: Suez Cement has partnered with Intro Power and Utilities for the construction of a 20MW solar power plant at its Suez cement plant. From its commissioning in early-mid-2023, the installation will provide the plant with 45GWh of energy annually, 20% of its annual consumption. Suez Cement says that this will eliminate 22,000t/yr-worth of CO₂ emissions. Construction is expected to cost US$350m and commence in 2023.

Suez cement aims to achieve specific CO₂ emissions of 400kg/t of cementitious product by 2030, down by 47% from 1990 levels.

Managing director Mohamed Hegazy said “Through transitioning to renewable solar energy, we are looking at long-term economic benefits, laying the foundation for a low-carbon business and energy security, without jeopardising the health of our environment. We are proud about this new milestone and to be one of the few cement players in Egypt taking this step towards using a more affordable and cleaner energy."

Zimbabwe: A court has ordered Lafarge Cement Zimbabwe to pay US$321,000 to supplier Rubtech Machinery and Spares, in addition to costs. The Standard newspaper has reported that the producer incurred a debt to Rubtech Machinery and Spares for its services in November 2020. Fossil Mines since acquired Lafarge Cement Zimbabwe from Switzerland-based Holcim in June 2022.

China: Anhui Conch Cement recorded revenues of US$11.7bn during the first nine months of 2022, down by 30% year-on-year from US$16.7bn during the same period in 2021. The group's income declined by 45% to US$1.7bn from US$3.08bn.

Nigeria: Dangote Cement's consolidated sales grew by 15% year-on-year to US$2.66bn during the first nine months of 2022 from US$2.31bn in the same period in 2021. In Nigeria the company recorded cement and clinker sales volumes of 13.5Mt, down by 4.7% from 14.1Mt. In the rest of Africa its cement and clinker sales were 7.37Mt, down by 9.7% from 8.16Mt. The group recorded consolidated earnings before interest, taxation, depreciation and amortisation (EBITDA) of US$1.17bn, up by 0.2% from US$1.16bn.

Throughout the first nine months of 2022, Dangote Cement co-processed 102,000t of alternative fuel in its cement production, up by 77% year-on-year from the corresponding period of 2022.