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News Geocycle

Displaying items by tag: Geocycle

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Holcim trials char fuel in Plastics2Olefins project

03 June 2025

Spain: Holcim is exploring the use of char as an alternative fuel in cement production as part of the Plastics2Olefins project, in collaboration with Geocycle. The producer is evaluating char samples made from different types of plastic waste.

Geocycle plant manager Cristina Gómez said “Since char properties can vary depending on the feedstock, the company is conducting detailed evaluations – looking at calorific value, moisture content, heavy metals, halogens, and sulphur levels, among other parameters.”

These full-scale industrial tests aim to understand how char behaves during combustion, how it affects emissions of CO₂, NOx, and SOx, and whether it impacts the stability of the production process or the quality of the cement. Char samples produced at the Repsol pilot plant are being tested at two of Holcim’s facilities: the Quality Central Laboratory and Geocycle Albox. Gómez added “These comprehensive tests provide a solid understanding of char’s properties and help anticipate how it will perform in real-world industrial conditions.”

Holcim is also experimenting with blends of char and petcoke to optimise energy performance and environmental compliance.

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Holcim Philippines partners with URC and Obando for refuse management

15 October 2024

Philippines: Holcim Philippines and Universal Robina Corporation (URC) have entered a tripartite agreement with the local government of Obando, Bulacan, to provide incentives for workers at the town's material recovery facility, based on the volume of refuse diverted. The material recovery facility in Obando has collected and sorted 785t of plastic waste for co-processing. Since 2021, URC and Holcim's waste management unit Geocycle has been processing plastic from URC's operations for co-processing. The plastics are converted into alternative fuels used to power the kiln at Holcim’s plant in Misamis Oriental.

Irwin Lee, URC president and CEO, said "This new agreement, with Obando as a key partner, aims to further drive community-based ‘waste’ diversion efforts. We hope to replicate it in other towns and cities to amplify the impact of what we set out to do three years ago."

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Lafarge Canada launches low-carbon fuel facility at Exshaw plant

04 October 2024

Canada: Lafarge Canada, a subsidiary of Holcim, has inaugurated a new low-carbon fuel facility at its Exshaw cement plant, in a joint effort with Geocycle Canada. The US$28m facility is supported by a US$7.4m contribution from Emissions Reduction Alberta through the government’s Technology Innovation and Emissions Reduction fund. It will reduce natural gas consumption by up to 50% for one of the plant’s kilns by substituting it with alternative fuels (AF) sourced from construction and demolition materials, primarily wood. Geocycle will process the materials into AF. This initiative is expected to divert up to 120,000t/yr of discarded materials from landfill, reducing CO₂ emissions by approximately 30,000t/yr.

President and CEO of Lafarge Canada (West), Brad Kohl, said "Our commitment to building a sustainable future is at the core of everything we do. The low-carbon fuel project is a prime example of how innovation and collaboration can drive positive change, lowering our environmental footprint through the use of discarded biomass materials while closing the material loop to conserve natural resources.”

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Geocycle and Lafarge Canada partner for low-carbon fuel facility at Brookfield plant

25 September 2024

Canada: Geocycle and Lafarge Canada, together with the Department of Natural Resources Canada, have opened a new low-carbon fuel plant at the Lafarge Canada Brookfield cement plant in Nova Scotia. The facility, which cost over US$7.5m and received US$2.6m in federal funding, will convert 14,000t/yr of discarded materials headed for landfill into low-carbon fuels, reducing the plant's reliance on fossil fuels and its carbon emissions by over 12,000t/yr. The materials to be repurposed include plastic and construction and demolition materials. The cement created at the facility will be used to make concrete for construction projects in the local area and is expected to create jobs for the local community.

President and CEO of Lafarge Canada (East) David Redfern said "Cement is a vital component of infrastructure projects that contribute to economic growth. By implementing sustainable and innovative solutions to reduce our environmental impact, we're serving the needs of our customers and the communities in which we operate both now and in the future. Our continued collaboration with Geocycle Canada reinforces our commitment to invest and advance circular construction in Canada."

Head of Geocycle North America Sophie Wu said "At Geocycle, our solutions are circular by design. We are happy to take another significant step in our ongoing partnership with Lafarge Canada. This is a great example of our work toward the decarbonisation of the construction industry in Canada."

Published in Global Cement News
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Mexico advances tyre recycling for cement production

05 July 2024

Mexico: The Secretariat of the Environment (Sedema) has reported that over 5600 tyres collected from illegal dumps in the districts of Xochimilco and Gustavo Madero have been transported to a treatment plant to be used as an alternative fuel for cement production. This initiative is part of a strategy to manage tyre waste, supported by a collaboration with Geocycle Mexico. The effort aims to address public environmental issues caused by tyre disposal in public spaces and environmentally sensitive areas, potentially leading to wildfires. Sedema also plans to expand tyre collection through the Reciclatrón Program to promote comprehensive waste management and reduce the reliance on fossil fuels and mineral extraction.

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Holcim’s Hagerstown plant increases use of alternative fuels

20 May 2024

US: Holcim’s Hagerstown plant in Maryland has increased its alternative fuels substitution rate to 45%, equivalent to 58,000t/yr of engineered fuel. This US$11m initiative utilises end-of-life materials like non-recyclable paper, plastics and fibres, sourced from commercial and industrial materials like packaging. Geocycle, a subsidiary of Holcim US, will process these materials at its new Cumberland facility, which has a capacity of up to 75,000t/yr.

Senior vice president of Manufacturing North for Holcim US, Michael Nixon, said "Expanding our alternative thermal energy use to 45% provides multiple environmental and economic benefits, from lowering the net carbon intensity of our cement to reducing our consumption of traditional fuels. Importantly, it enables us to play a role in the circular economy, offering a highly safe and ecological solution for unused materials."

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Lafarge Canada and Geocycle complete successful pilot on recycled clinker

15 May 2024

Canada: Lafarge Canada and Geocycle Canada have successfully completed a pilot at the Lafarge Brookfield cement plant in Nova Scotia to produce clinker using recycled minerals from discarded material. This pilot can potentially cut CO₂ emissions by 60% of clinker. The new clinker product will be used to produce recycled cement in 2024.

CEO of Lafarge Canada David Redfern said "Our teams have been tirelessly working towards finding solutions to decarbonise our business in Canada. This new recycled-minerals clinker combines operational excellence with circular construction, building new and green from what is considered old and waste. This is a great example of how far we can go - the local team at Brookfield is certainly setting the tone for the industry in Canada."

Since May 2023, Lafarge Canada, Geocycle Canada and the Holcim Group Innovation Centre have been collaborating on a 100% circular production of clinker at the Brookfield plant. The new production method involves substitution of raw materials with lower carbon options from discarded materials, as well as alternative fuels produced from these materials. The trial was performed in February 2024 and cement from this clinker will be produced in 2024 for further testing and development of the technology.

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Holcim Philippines to invest in sustainability at its plants

16 April 2024

Philippines: Holcim Philippines will invest US$35m in sustainability initiatives at its four plants over the next three years. The investments will also include US$17.5m for its waste management arm, Geocycle, increasing capacity for local government unit waste processing.

Chief sustainability officer Samuel Manlosa Jr. said "There is also a side where, if we want to take in more volume, we need to increase our capacity to shred and prepare the materials. Our cement plants, even as sophisticated and technologically advanced as they are, were constructed 20 years ago when norms were different, so we had to make changes in the process to make sure that the plants were able to accept more."

The company will further invest between US$8.7m and US$17.5m in renewable energy and electrification of its vehicle fleet. President and CEO Horia Adrian said "We are purchasing electricity right now, but we have plans to put in place solar facilities and we are looking at the possibility of using electricity generated from biowaste here. By the end of 2024, some of them should be ready."

He concluded that investments at the Bulacan and La Union plants are set to start this year, with those in Davao and Lugait scheduled for 2025.

Published in Global Cement News
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Aggregate Industries to use waste tiles as alternative raw material

24 November 2023

UK: Thousands of tonnes of waste ceramics from one of the UK’s largest ceramic tile manufacturers will be recycled to make cement as part of a new initiative from Aggregate Industries. The cement producer, owned by Holcim, has agreed a four-year deal with Johnson Tiles to take 20,000t/yr of legacy waste scrap from its Stoke factory in Staffordshire. They will be transported a short distance to Aggregate Industries’ Cauldon cement plant, where they will be crushed and mixed with limestone and the other raw materials prior to entering the kiln.

Andrew Whyatt, Geocycle UK General Manager at Aggregate Industries, said “We are delighted to be working with such a potteries stalwart as Johnson Tiles in order to recycle what would otherwise be a waste product. Materials such as this offer a great alternative to excavating fresh raw materials, preserving our local natural resources, whilst offering a solution whereby 100% of the material will be upcycled into new local cement. Both companies share a drive towards sustainable manufacturing and partnerships like this are vital as Aggregate Industries aims to reclaim or recycle 3Mt/yr of materials by 2025.”

Published in Global Cement News
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Holcim US inaugurates waste tyre processing plant at Alpena cement plant

02 June 2023

US: Holcim US has inaugurated a waste tyre processing plant at its Alpena cement plant in Michigan. The facility will process 22,000t/yr of tyres into refuse-derived fuel (RDF) for use at the cement plant. Holcim US partner Geocycle will collect, pre-process and deliver the tyres to the new facility.

Holcim US’ North regional senior vice president of manufacturing Michael Nixon said "Holcim has invested more than US$100m in eco-friendly technologies at the Alpena plant in the past 15 years. The tyre-derived fuel facility is another strong demonstration of our commitment to reducing emissions."

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