Displaying items by tag: Holcim
Storing energy at scale at cement plants
27 September 2023Taiwan Cement has just commissioned a 107MWh energy storage project at its Yingde plant in Guangdong province, China. Subsidiary NHOA Energy worked on the installation and has been promoting it this week. The battery storage works in conjunction with a 42MW waste heat recovery (WHR) unit, a 8MWp solar photovoltaic unit and a proprietary energy management system. It is expected to store about 46,000MWh/yr of electricity and save just under US$3m/yr in electricity costs.
NHOA Energy, formerly known as Engie EPS before Taiwan Cement bought a majority stake in it, claims it is one of the largest industrial microgrids in the world. We can’t verify this for sure, but it is definitely large. For comparison, the 750MW Vistra Moss Landing Energy Storage Facility in California often gets cited as the largest such facility in the world. This is run by a power company, as are many other large battery energy storage systems. In its annual report for 2022 Taiwan Cement said it was planning to using NHOA’s technology to build seven other large-scale energy storage projects at sites in Taiwan including its integrated Suao, Ho-Ping and Hualien cement plants.
The aim here appears to be supplying renewable electricity to the national grid in Taiwan. Taiwan Cement is diversifying away from cement production, with an aim to derive over 50% of its revenues from other activities besides cement by 2025. In 2022 cement and concrete represented 68% of its sales, while its electricity and energy division, including power supply and rechargeable lithium-ion batteries, represented 29%. The company is also not using its own batteries at the Yingde plant. Instead it is using lithium iron phosphate batteries supplied by Ningde Times. This is worth noting, as the cement producer’s batteries are used in vehicles.
Global Cement regularly reports news stories on cement plants that are building photovoltaic solar power arrays. However, so far at least, energy storage projects at scale have been rarer. One earlier example of an energy storage system loosely associated with a cement plant includes the now decommissioned Tehachapi Energy Storage Project that was situated next to the Tehachapi cement plant in California. That project tested using lithium ion batteries to improve grid performance and integrate intermittent generation from nearby wind farms. It is also worth noting that Sumitomo Osaka Cement’s sister company Sumitomo Electric is one of the world’s larger manufacturers of flow batteries, although no installation at a cement plant appears to have happened yet. In simple terms, flow batteries are an alternative to lithium ion batteries that don’t store as much energy but last longer.
More recently, Lucky Cement in Pakistan started commercial operation of a 34MW solar power plant with a 5.59MWh energy storage unit at its Pezu plant in Khyber Pakhtunkhwa in late 2022. Reon Energy provided the equipment including a lithium-ion based battery approach to the storage. Then, in March 2023, Holcim US said that it was working with TotalEnergies to build solar power capacity and a battery energy storage unit at the Florence cement plant in Colorado. TotalEnergies will install, maintain and operate a 33MW DC ground-mounted solar array and a 38.5MWh battery energy storage system at the site. Operation of the renewable energy system is expected to start in 2025.
Away from electrical batteries, the other approach to energy storage at cement plants that has received attention recently from several quite different companies has been thermal batteries. The two prominent groups using them at different scales are Rondo Energy and Synhelion. The former company has developed its Heat Battery technology, which uses refractory bricks to absorb intermittent renewable energy and then supply the energy back as a steady stream of hot gas for use in a cement plant mill, dryer, calciner or kiln. Both Siam Cement Group (SCG) and Titan Cement have invested in Rondo Energy. In July 2023 SCG and Rondo Energy said that they were planning to expand the production capacity of a heat battery storage unit at a SCG plant to 90GWh/yr. Synhelion, meanwhile, has been working with Cemex on using concentrated solar power to manufacture clinker. It achieved this on an ‘industrially viable scale’ in August 2023. It has since been reported that the companies are working on building a small scale industrial plant at Móstoles near Madrid by 2026. Crucially for this discussion though, the process also uses a thermal energy storage unit filled with ceramic refractory material to allow thermal energy to be released at night, and thus ensure continuous operation.
The examples above demonstrate that some cement companies are actively testing out storing energy at scale. Whilst this will not solve the cement sector’s process emissions, it does potentially start to make using renewable energy sources more reliable and reduce the variable costs of renewable power. Whether it catches on remains to be seen. Most of these kinds of projects have been run by power companies and that is where it may stay. It is instructive to note that Reon Energy was the only company to state that its battery-based energy storage system has a life-span of 8 - 12 years. Our current vision of a net-zero future points to high electrical usage but it may be shaped by how good the batteries are… from our phones to our cars to our cement plants.
For more information on Rondo Energy read the January 2023 issue of Global Cement Magazine
Mexico: Holcim Mexico says that its supply of cement to the government’s Tren Maya railway project is 170,000t/month. This corresponds to 50 – 60% of its total production volumes. Local press has reported that construction of the 1500km-long Tren Maya railway will consume 1Mm3 of concrete. Holcim supplied its cement for Sections 1 – 3 of the line between 2020 and 2022. It is currently supplying Section 5, which is 50% complete. The cement comes from the company’s Orizaba, Veracruz, plant; its Macuspana, Tabasco, plant and its Mérida, Yucatán, plant.
Holcim Mexico’s infrastructure development manager Fernando Roldan said "Our participation has been a challenge, but the relationship we have with the suppliers and with the construction companies in charge of the railway has allowed us to meet the requirements."
Tarek Talaat becomes new Raysut Cement CEO
20 September 2023Oman: Tarek Talaat has moved from Egypt-based Misr Cement Group to Raysut Cement, where he takes over the role of CEO. He was previously managing director and CEO of Misr Cement Group. Before that, he held leadership positions across Europe, Egypt and the Middle East at Holcim, Arabian Cement Company and Ras Al Khaimah White Cement. Raysut Cement called Talaat the ‘standout’ choice for the CEO position, due to his vision, strategic mindset and proven turn-around experience. Tarek holds a bachelor’s degree in civil engineering from Cairo University and studied financial management at INSEAD University in France. He has a Master of Business Administration (MBA) degree from the Swiss Business School, Zurich, in Switzerland.
Raysut Cement said “With Mr Tarek at the helm, we are confident that Raysut Cement will continue to thrive and reach new heights. His leadership will be instrumental in guiding the company through the ever-evolving landscape of the cement industry.”
Reuters has reported that Talaat’s resignation as managing director of Misr Cement Group will take effect on 12 October 2023.
Holcim invests in Neustark
20 September 2023Switzerland: Holcim has invested in CO2 mineralisation technology developer Neustark. Neustark aims to remove 1Mt of atmospheric CO2 by 2030 and sequester it in recycled construction and demolition waste. The company’s technology achieved Gold Standard certification as a method of CO2 removal in March 2022. Holcim says that its investment advances its group commitment to putting clean technologies to work towards achieving net zero.
Holcim’s Europe regional head Miljan Gutovic said "At Holcim, we are working to decarbonise building for a net zero future, and Neustark's technology helps us reach this goal. After the successful demonstration of Neustark's solution in Switzerland, we are ready to scale up this carbon removal technology globally."
Argentina: Holcim Argentina has awarded a contract to 360Energy to supply 30,000MWh/yr of electricity from its solar power plants. La Voz del Interior newspaper has reported that 360Energy will supply the energy from its 200MW network via the Renewable Energy Term Market (MATER). This will cover 75% of Holcim Argentina’s power consumption, corresponding to the production of 2.7Mt of cement. This will eliminate 68,600t/yr of CO2.
Holcim Argentina chief executive officer Christian Dedeu said “I am very happy because we are taking a new step in our commitment to zero emissions in Holcim's operations, and we will continue working every day to build progress for people and the planet.”
Holcim US rebrands Boston businesses
13 September 2023US: Holcim US has rebranded its businesses in Boston, Massachusetts, to unite them under the Holcim name. Resources News has reported that Lafarge Cement, which operates the Charlestown cement terminal, as well as building materials producer Aggregate Industries, will rebrand as Holcim US.
Holcim US’ Northeast and Great Lakes regional senior vice president and general manager Domenico D'Aqui said "With the integration of local legacy operations into Holcim, the Boston area will see expanded benefits of construction projects made from innovative materials, such as ECOPact reduced-CO2 concrete, that not only build needed infrastructure but also meet ambitious sustainability targets."
Holcim seeks to acquire outstanding Holcim Philippines shares
12 September 2023Philippines: Holcim plans for its subsidiary Holderfin to make a tender offer for all remaining shares in Holcim Philippines by 28 September 2023. Altogether, minority shareholders control a 5.1% stake in the producer. The Manila Bulletin newspaper has reported that Holderfin ended its previous tranche of tenders for Holcim Philippines shares on 30 August 2023.
Holcim launches Innovation Hub
06 September 2023Switzerland/France: The Swiss multinational building materials producer Holcim has launched a global Innovation Hub to accelerate sustainable building at its Global Research & Development Center in Lyon, France. The Hub showcases Holcim's innovative and sustainable building solutions to scale up low-carbon, circular and energy-efficient buildings. Spread across three floors, it offers working spaces to host start-ups and think tanks to accelerate innovation together. It will also serve as a platform to explore the future of sustainable cities and their construction via interactive exhibits and events.
The showroom showcases how Holcim is decarbonising building across its lifecycle, featuring low-carbon materials like ECOPact concrete and ECOPlanet cement products, roofing and insulation systems that drive energy efficiency - from Elevate boards to Airium, and circular construction solutions, such as its proprietary ECOCycle circular technology platform to recycle construction demolition materials into new building solutions.
Nollaig Forrest, Holcim’s Chief Sustainability Officer, said, "It's a very exciting time for the building sector, with so much momentum in innovation to advance sustainable solutions. At Holcim we want to partner with the best and brightest innovators to accelerate the transition to low carbon, circular and energy-efficient buildings. Our Innovation Hub, within our Global Research & Development Center, is designed to host partners from start-ups to architects to explore new solutions together."
Six dormant cement plants reportedly received Euro88m in European Union emissions allowances
05 September 2023Europe: Six cement plants were reportedly issued around Euro88m in free European Union emissions allowances (EUA) from 2019 to 2022 despite the clinker kilns at the units being idle or running at low levels. Research by the Oil Price Information Service (OPIS) has revealed that plants operated by Buzzi, Cementos Portland Valderrivas (CPV), Cemex, Holcim and Votorantim Cimentos all benefited from the scheme despite only emitting 36,370t of CO2. The companies would then have been able to use the subsidy to cover emissions costs at other plants or sell the permits. OPIS identified five plants in Spain and one in Germany.
Lafarge Egypt confirms aim to reduce CO2 emissions by 2030
04 September 2023Egypt: Lafarge Egypt has confirmed that it is aiming to reduce its CO2 emissions in excess of 20% by 2030. Its key steps to achieve this include increasing its use of alternative fuels and lowering its clinker factor, according to the Daily News Egypt newspaper. Chief executive officer Jimmy Khan added that the company is also working on developing digital methods to reduce emissions by improving transport logistics. The cement producer launched its Shatbna Masonry Cement product in 2022, part of parent company Holcim’s ECOPlanet range.
Holcim has set a worldwide target to reduce its gross Scope 1 CO2 emissions from cement production of 22% by 2030 from a baseline of 590kg/t in 2018. It reported a 5% reduction to 562kg/t in its 2022 sustainability report. Ultimately the group is targeting net zero emissions from its activities by 2050.