Displaying items by tag: Heidelberg Materials

Germany: Heidelberg Materials' sales increased by 13% year-on-year to Euro21.1bn in 2022 from Euro18.7bn in 2021. This was despite a 6.1% drop in cement and clinker volumes, to 119Mt from 127Mt. Heidelberg Materials' cement and clinker volumes fell by 10% in Western and Southern Europe, by 7.8% in Northern and Eastern Europe-Central Asia, by 14% in North America, by 1.3% in Africa-Eastern Mediterranean Basin and by under 1% in Asia-Pacific. The group's materials costs rose by 23% to Euro21.4bn from Euro18.8bn. Meanwhile, its profit dropped by 9.4% to Euro1.72bn from Euro1.9bn.

Chief executive officer Dominik von Achten said "It’s evident that we can only be profitable in the long term by shaping our future as a company in a climate-compatible way, further reducing the footprint of our products and closing material loops. We are making good strides in all areas. Compared with the previous year, we were able to reduce our specific net CO₂ emissions by another 2% in 2022. Our carbon capture, utilisation and storage projects launched worldwide are progressing favourably. At our CCS project in Brevik, Norway, we are well on track with the construction of the world's first CO₂ capture plant in our industry, and we look forward to commissioning in 2024." Von Achten continued "We have made a good start to 2023. The fourth quarter showed that we have laid a good foundation for the development in this year. Volatility on energy and raw material markets remains high, but the current easing in energy prices is giving us some breathing room. On the demand side, government infrastructure plans should compensate for the decline in private housing construction. We are optimistic about the further course of the year.”

US: The Department of Energy’s (DOE) Carbon Storage Assurance Facility Enterprise (CarbonSAFE) initiative has awarded funding of US$8.9m to Heidelberg Materials North America to study the subsurface geology for suitability for the storage of carbon dioxide at the Mitchell integrated cement plant in Indiana. The proposed project will geologically characterise several prospective reservoirs under the Mitchell plant for storage of more than 50Mt of CO₂ over a 30-year timeframe.

The award, which is managed by the National Energy Technology Laboratory, will be issued to the Illinois State Geological Survey at the University of Illinois (ISGS) as the prime contractor, with the company acting as a technical and industrial partner. Heidelberg Materials is contributing about US$1.5m in funding while ISGS will be contributing approximately US$0.6m for a project total of US$11.1m. The funding was part of a DOE initiative that generated nearly US$125m in funding for 10 projects to characterise suitability for carbon storage across the US.

Heidelberg Materials’ Mitchell cement plant is being upgraded with a new production line. Full production on the new line is anticipated to start in early 2023.

Cemex launched a new waste management division called Regenera this week. Cemex describes Regenera as a “business that provides circularity solutions, including reception, management, recycling, and coprocessing of waste.” The Mexico-based company has a long and leading history with sourcing and using alternative fuels in the cement sector and the new organisation looks set to utilise this experience. What is notable though is how the business is targeting three waste streams: municipal and industrial; industrial by-products; and construction, demolition and excavation waste (CDEW). Bringing the three waste streams together in this way appears to be novel for the heavy building materials sector, particularly the inclusion of CDEW, which we will explore further here.

CDEW is split into fractions, just like the municipal and solid waste streams that end up as alternative fuels at cement plants, but the biggest fractions are generally concrete, followed by bricks. The recycled concrete is then typically used as an aggregate, either in new concrete production or in areas like road construction and earthworks. The use of recycled aggregates (RA) made from CDEW goes back to at least the 1930s in its current form although ‘reusing’ materials from structures such as castles and churches goes back far further. Recycling and reusing CDEW gained a boost in 2020 when the European Union (EU) set a 70% recovery target. However, within the EU the CDEW recycling rates vary considerably and that 2020 target includes the use of CDEW in backfill applications.

In its launch statement for Regenera, Cemex noted that it operates a dock in Paris, where it receives a variety of materials, including construction debris, excavated material and inert soil. These materials are sorted, processed and then transformed into recycled aggregates or organic material used to restore quarries. Cemex then promptly followed up the official launch of Regenera on 30 January 2023 with the acquisition of a majority stake in Shtang Recycle, an Israel-based CDEW recycling company. It added that Shtang Recycle is preparing to build a recycling plant with a production capacity of 0.6Mt/yr of CDEW waste materials. The output from the plant will be used as raw materials for aggregate production.

The focus on CDEW recycling was flagged up at Cemex’s investor event in November 2022. It said that it was targeting a recycling rate of 14Mt/yr of construction and demolition waste by 2030. Other managed waste stream goals included doubling the amount of municipal and industrial waste it manages, to achieve a 50% to fossil fuel substitution rate, and increasing its usage of alternative raw materials and by-products by 30%, thereby eliminating 13Mt/yr of extracted materials.

Cemex is not alone in targeting the CDEW waste sector. Holcim’s recent work in the area goes back to at least 2016 when a recycling unit near its Retznei cement plant in Austria started processing 130,000t/yr of CDEW. It announced in December 2022 that it was setting up a similar recycling centre, also in Austria, at its Mannersdorf cement plant. In October 2022 Holcim acquired Wiltshire Heavy Building Materials in the UK. This company recycles 150,000t/yr of construction and demolition waste into aggregates and concrete. Holcim linked the acquisition to its Strategy 25 target of recycling 10Mt/yr of construction and demolition waste by 2025.

Activity by other cement companies includes the commissioning of a construction waste recycling plant at Gennevilliers in France by CRH-subsidiary Eqiom in April 2022. It was aiming for a target of 50,000t in 2022. In November 2022 Heidelberg Materials agreed to acquire RWG Holding based in Berlin, Germany. Then, in December 2022, it announced a deal to buy Mick George Group in the UK. Both proposed acquisitions are subject to competition authority approval. Heidelberg Materials’ current target is to offer circular alternatives for half of its concrete products by 2030.

The moves by the bigger cement companies into the CDEW sector follow sustainable thinking and the waste hierarchy. Yet the big prize here is to gain a route to dispose of some of their CO₂ emissions through recarbonation and this has been flagged up in several net-zero roadmaps for the cement sector such as those by Cembureau and the Global Cement and Concrete Association (GCCA). Holcim has been involved in the FastCarb project in France, running a pilot at its Val d’Azergues cement plant in 2021. Heidelberg Materials has been testing its own process with so-called recycled concrete paste. The development now appears to be that utilising CDEW has entered the sustainability strategies for some of the big cement-concrete-aggregate producers, targets have been set and acquisitions are happening.

For more information on Heidelberg Materials research into concrete recycling read the January 2023 issue of Global Cement Magazine

Democratic Republic of Congo: Heidelberg Materials has appointed Abderrahim Touile as the plant manager of its Lukala cement plant, operated by local subsidiary Cimenterie de Lukala.

Touile previously worked as the Industry Director for Vicat in Mauritania. He also worked as production manager for Ciments de l'Afrique (CIMAF) in Burkina Faso. Before these roles he held production roles with Lafarge in Morocco and South Africa between 2002 and 2015. Amongst other business and management qualification, Touile holds as master’s degree in business administration (MBA) from the Sorbonne Business School in France.

Sweden: Cementa is running trials on a pilot water treatment plant in the File Hajdar limestone quarry near its Slite cement plant in Gotland. The pilot plant has been running since September 2022 and the subsidiary of Germany-based Heidelberg materials describes the first results as ‘promising.’ The cement company plans to build and pay for a full-scale water treatment plant at the site. Engineering and design company AFRY has been collaborating with Cementa on the project.

Matilda Hoffstedt, the manager of the Slite cement plant, said “We can contribute to greatly strengthening the public water supply here in northern Gotland. The results from the pilot project are extremely promising and we see that a new water plant would really make a difference to the water supply throughout the year.”

Cementa started work on the water project in 2021 with a feasibility study and plans for the pilot. The entire feasibility study is expected to be completed in the summer of 2023 and the goal is to be able to put a full-scale water plant into operation in 2027. However, Cementa says that it needs a long-term permit for its mining operations in Gotland in order to invest in the project. The cement producer has faced opposition to renewing its permit at the site since 2021. A perceived threat to the area’s drinking water supplies has been a repeated concern made by groups against continued quarrying in the area.

Bulgaria: The European Union (EU) Innovation Fund has awarded a Euro190m grant to Devnya Cement and oil and gas producer Petroceltic for their 800,000t/yr ANRAV carbon capture, transportation and storage project. Devnya Cement's parent company Heidelberg Materials says that the partners expect to commission the full-chain project in 2028.

Heidelberg Materials Northern and Eastern Europe-Central Asia board member Ernest Jelito said "Devnya Cement's Devnya plant will be the first carbon-neutral cement plant in the country and the region. ANRAV will also enable other industrial players to join the carbon chain in the future and share storage capacity. In this way, we want to not only decarbonise our company in Bulgaria, but also provide opportunities for the whole region."

Germany: Heidelberg Materials has placed a Euro750m sustainability-linked bond as part of a Euro10bn medium-term note programme. Interest on the bond is linked to group CO₂ emissions reduction, according to key performance indicators up to 2026 and 2030. Heidelberg Materials is committed to reducing its emissions per tonne of cementitious product by 30% between 2021 and 2030, to 400kg/t.

Heidelberg Materials' chief financial officer René Aldach said "The placement reinforces our aspiration to achieve the most ambitious climate targets within the industry and to increase the share of sustainable financial instruments to over 70% by 2025. With the denomination of Euro1000, we are the only company on the capital market to date to also offer retail investors the opportunity to invest in sustainability-linked bonds."

Belgium: Heidelberg Materials has announced an upcoming project called Anthemis at its subsidiary CBR's Antoing cement plant in Hainaut. The project will implement Heidelberg Material's OxyCal model, which combines Oxyfuel and amine-based carbon capture technology. When operational, the system will capture 800,000t/yr of CO₂, reducing the Antoing cement plant's CO₂ footprint by 97%.

Heidelberg Materials chair Dominik von Achten said “We are excited to add yet another pioneering technology to our CCUS project portfolio, and to build on what we have already achieved in terms of research and innovation. From the Antoing plant alone, we will be able to offer more than 15Mt of carbon-free cement to the construction market during the first 10 years of operation." Von Achten concluded "This is a key contribution to Belgium’s transition to net zero greenhouse gas emissions.”

Canada/US: Lehigh Hanson has rebranded as Heidelberg Materials North America, with immediate effect. The cement producer said that the new brand reflects its broad, innovation-driven approach to becoming the North American industry leader in sustainability and digital solutions.

President and chief executive officer Chris Ward said “This is a major step change for our company, both globally and here in North America. We are thrilled to begin this transformation in North America today, and continue our global journey to grow our business beyond cement and aggregates and become the most sustainable company in the sector.”

US: Lehigh Hanson is preparing to start cutting jobs at the Glens Falls cement plant in New York from April 2023. The majority of the employees at the site will be laid off in April 2023 with some staff to be retained until later until 2023, according to the Times Union newspaper. It was previously reported in November 2022 that the subsidiary of Germany-based Heidelberg Materials was planning to close the plant in a phased manner in 2023. Production from the Glens Falls site will be covered in the future by the company’s new Mitchell plant in Indiana.