Displaying items by tag: Italy

Italy: Buzzi Unicem’s earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 1.8% year-on-year in 2021 to Euro795m. Despite this, its net profit for the year declined by 3.2% year-on-year to Euro542m.

In 2022, Buzzi Unicem forecasts a 10% full-year EBITDA decline due to the impacts of the Russian invasion of Ukraine.

From the Nordics to the Mediterranean, European countries lead the field in reduced-clinker cement production using supplementary cementitious materials (SCMs). While consumers, faced with ever-greater choice, continue to opt for sustainability, projects to improve existing SCMs and develop new ones have won government backing and have become a matter of serious investment for other heavy industries beside cement. European cement producers’ decisions are steering the course to a world beyond CEM I. Yet, even in Europe, great untapped potential remains.

Companies generated a good deal of marketing buzz around their latest reduced-CO₂ cement ranges in 2021 and the first quarter of 2022: Buzzi Unicem’s CGreen in Germany and Italy, Holcim’s EcoPlanet in six markets from Romania to Spain, Cementir Holding’s Futurecem in Denmark and Benelux, and Cemex’s Vertua in Spain and several other countries. All boast reduced clinker factors through the use of alternative raw materials. This, however, is really a rebranding of a long-established norm in Europe.

Since 2010, cements other than CEM I have constituted over 75% of average annual cement deliveries across Cembureau member countries (all cement-producing EU member states, plus Norway, Serbia, Switzerland, Turkey, the UK and Ukraine). This statistic breaks down differently from country to country. CEM II is the norm in Austria, Finland, Portugal and Switzerland, with deliveries in the region of 90%. Portland limestone cement (PLC) makes up a majority of deliveries in all four. It has been central to Switzerland’s transition to 89% (3.72Mt) of CEM II deliveries out of a total 4.18Mt of cement despatched in 2021. There, the main types of cement were CEM II/B-M (T-LL) Portland composite cement, with 1.38Mt (33%), and two different classifications of PLC: CEM II/A-LL PLC, with 1.28Mt (31%), and CEM II/B-LL PLC, with 888,000t (21%).

A second approach is that of the Netherlands, where CEM III blast furnace slag cement with a clinker factor below 65% predominates, favoured for its sulphate resistance and the protection it offers against chloride-initiated corrosion of steel reinforcement in marine settings. By contrast, the UK has traditionally maintained a higher reliance on CEM I cement. This can be partly explained by the preference of builders there for adding fly ash or ground granulated blast furnace slag (GGBFS) at the mixing stage. Nonetheless, CEM II Portland fly ash cement held a 14% (1.43Mt) market share in the UK’s 10.2Mt of cement consumption in 2021.

The UK Mineral Products Association (MPA) has identified limestone as an underutilised resource in the country’s cement production. Together with HeidelbergCement subsidiary Hanson Cement, it has applied for a change to National Application standards to allow the production of Portland composite cement from fly ash and limestone or GGBFS and limestone. The association has forecast that Portland composite cement could easily rise to 30 – 40% of UK cement consumption, and that this has the potential to eliminate 8% of the sector’s 7.8Mt/yr-worth of CO₂ emissions.

Metallurgical waste streams have long flowed into European cement production, primarily as GGBFS, but also as bauxite residue. In 2021, alumina production in the EU alone generated 7Mt of bauxite residue, of which the bloc recycled just 100,000t (1.4%) that year. Two projects – the Holcim Innovation Center-led ReActiv project and Titan Cement and others’ REDMUD project – aim to produce new alternative cementitious materials from bauxite residue.

By collaborating with other industries, cement producers’ investments can most effectively reduce the overall cost of using these materials in cement production. In Germany, HeidelbergCement and ThyssenKrupp’s Save CO₂ project aims to develop new improved latent hydraulic binders or alternative pozzolan from GGBFS by producing slag from directly reduced iron (DRI). The Save CO₂ team believes that GGBFS substitution for clinker has the capacity to eliminite 200Mt/yr of CO₂ emissions from global cement production.

Meanwhile in the world of mining, ThyssenKrupp and others’ NEMO project is investigating the recovery of a useable mineral fraction for cement production from the extractive waste of the Luikonlahti and Sotkamo mines in Finland and the Tara mine in Ireland, through bioleaching and cleaned mineral residue upcycling. This may give cement producers full access to Europe’s 28Bnt stockpiles of sulphidic mining waste, of which mines generate an additional 600Mt each year.

Denmark-based CemGreen, which produces the calcined clay supplementary cementitious material CemShale, is developing a shale granule heat-treating technology called CemTower. This consists of three pieces of equipment vertically integrated into cement plants’ preheaters, kilns and coolers, and brings the processing of waste materials – here oil shale – to the cement plant.

Lastly, cement producers are exploring the possible uses of waste made of cement itself. In Wallonia, HeidelbergCement subsidiary CBR’s CosmoCem project is investigating the production of alternative cement additives from large available flows of local demolition, soil remediation and industrial waste. Similarly, the Greece-based C2inCO₂ project seeks to mineralise fines from concrete recycling for HeidelbergCement to use in the production of novel cements in its Greek operations.

In Switzerland, ZND Portland composite cement (produced using fine mixed granulate from building demolitions) is the third largest cement type, with 178,000t (4.3%) of total deliveries – narrowly behind CEM I with 239,000t (5.7%).Holcim Schweiz developed its Susteno 4 ZND Portland composite cement with Switzerland’s lack of any ash or slag supply in mind, demonstrating the potential flexibility of a circular economic approach to cement production.

On 21 March 2022, the University of Trier reported that it is in the process of mapping mineral resources, waste deposits and usable residues ‘on a cross-border scale,’ in an effort to produce new materials for use in cement production. Industry participants include France-based Vicat, CBR, Buzzi Unicem subsidiary Cimalux and CRH subsidiary Eqiom. Vicat is preparing a kiln at its 1Mt/yr Xeuilley cement plant in Meurthe-et-Moselle to use in testing new alternative raw materials developed under the project.

For Cembureau and its members, work continues, with the goal of Net Zero by 2050 constantly in sight. This goal includes a reduction in members’ clinker-to-cement ratios to well below 65%. In this, the association and its members are working towards a world not just beyond CEM I, but beyond CEM II, too. What exactly this will mean remains to be seen.

Sources

CemSuisse, ‘Lieferstatistik,’ 11 January 2022, https://www.cemsuisse.ch/app/uploads/2022/01/Lieferstatistik-4.-Quartal-2021.pdf

WSA, ‘December 2021 crude steel production and 2021 global crude steel production totals,’ 25 January 2022, https://worldsteel.org/media-centre/press-releases/2022/december-2021-crude-steel-production-and-2021-global-totals/

MPA, ‘Low carbon multi-component cements for UK concrete applications,’ July 2018, https://prod-drupal-files.storage.googleapis.com/documents/resource/public/Low%20carbon%20multi-component%20cements%20for%20UK%20concrete%20applications%20PDF.pdf

European Commission, ‘European Training Network for Zero-waste Valorisation of Bauxite Residue (Red Mud),’ 16 July 2020, https://cordis.europa.eu/project/id/636876

European Commission, ‘Industrial Residue Activation for sustainable cement production,’ 16 February 2022, https://cordis.europa.eu/project/id/958208

Recycling Portal, Zement der Zukunft – Forschungsprojekt „SAVE CO₂“ gestartet, 28 May 2021, https://recyclingportal.eu/Archive/65677

h2020-NEMO, ‘Project,’ https://h2020-nemo.eu/project-2/

European Commission, ‘Green cement of the future: CemShale + CemTower,’ 14 April 2021, https://cordis.europa.eu/project/id/101009382

CosmoCem, ‘Communiqué de Presse,’ https://cosmocem.org/

CO₂ Win, ‘C²inCO₂: Calcium Carbonation for industrial use of CO₂,’ https://co2-utilization.net/en/projects/co2-mineralization/c2inco2/

Les Echos, ‘Rendre le ciment moins gourmand en CO₂,’ 21 March 2022, https://www.lesechos.fr/pme-regions/innovateurs/des-substituts-au-clinker-rendent-le-ciment-moins-gourmand-en-co2-1395002

Austria: Alpacem has held the groundbreaking ceremony for the construction of its new headquarters at Wietersdorf, Carinthia. The company will invest Euro6m to establish the new headquarters on the site of its Wietersdorf cement plant. It will contain 50 office work stations, with meeting rooms and socialising zones.

In 2021, Alpacem says that it supplied 2Mt of cement and 350,000m² of ready-mix concrete to projects in the Alpine/Adriatic region.

Germany/Italy: Italy-based Buzzi Unicem has launched its CGreen reduced-CO₂ cement on the German and Italian cement markets. The product uses alternative raw materials to partially replace clinker and also optimises grinding and mixing conditions through the use of novel specialist additives. In Germany, the available range of CGreen cements will consist of Dyckerhoff Eco Comfort cement and Dyckerhoff Cedur cement.

Italy cemeny chief operating officer Antonio Buzzi said "The ecological transition calls for us to adapt our behaviors and actions in order to neutralise our carbon footprint. This transition implies the partial or total redesign of production processes, distribution systems and consumption patterns, heralding the start of a potential industrial revolution and a change in our habits."

Italy: Buzzi Unicem’s full-year consolidated sales rose by 8.9% in 2021 to Euro3.45bn. The group also increased its cement sales, by 6.7% to 31.2Mt.

Buzzi Unicem’s net financial position for the year was Euro231m, compared to a loss of Euro242m in 2020.

Italy: Cementir’s revenue grew by 11% year-on-year to Euro1.36bn in 2021 from Euro1.22bn in 2020. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 17.9% to Euro311m from Euro264m. Sales volumes of cement and concrete increased by 4.1% to 11.2Mt and 14.8% to 5.01Mm3 respectively.

“2021 marked for Cementir the year of the historic record of revenues and EBITDA despite the uncertainties related to the pandemic crisis, the substantial increase in energy costs, materials and services and the devaluation of the Turkish lira,” said Francesco Caltagirone Jr, chair and chief executive officer of Cementir.

The group also reviewed and approved the three-year Group Industrial Plan update for the period 2022 - 2024 and the 2022 budget. It has a target of reduce CO₂ emissions (scope 1) by 30% in 2030 compared to 1990 levels. It is also planning to invest Euro116m in the 2022 – 2025 to meet this goal and others. Some of this will go towards building a new production line at its integrated Gaurain cement plant in Belgium, where the work is intended to raise the unit’s alternative fuels substitution rate to 80% from 40%. The group noted that this project has been delayed to 2022 due to the coronavirus pandemic. Changes at other cement plants include switching to natural gas and biogas as well as energy efficiency projects. It is also said it was planning to ‘significantly’ increase the production of its FUTURECEM calcined clay cement and related sustainable products.

Italy: Holcim has signed a collaboration agreement with energy company Eni for the development of ENI’s magnesium silicate-based carbon utilisation technology. The reaction of the magnesium silicate with captured CO₂ emissions yields a product which Holcim hopes to use in its cement production.

Holcim Innovation Center head Edelio Bermejo said “Reaching net zero in cement manufacturing will require the deployment of carbon capture, utilisation and storage technologies at scale. ENI’s solution is very promising, and we are happy to explore its potential as it could take us all one step further on our decarbonisation journey.”

Italy/Albania: Officials from the Customs and Monopoly Agency (ADM) and the soldiers of the Guardia di Finanza, have identified cement lacking CE and proper importation markings, among other questionable building materials, in three articulated trucks that disembarked from Albania at the port of Ancona. A total of more than 36t of materials has been held.

The authorities stated that the use of trademarks of Italian companies on imported products or goods without clearly indicating the country or place of manufacture and, more generally, incorrect information on the origin of the goods, damages both the market and consumers’ interests.

Italy: Buzzi Unicem has signed an agreement with Italgas to collaborate on the development of power to gas plants for implementation in combination with carbon capture systems. Their research will assess the possibility of producing and using synthetic methane obtained from the combination of green hydrogen from power to gas plants with captured CO₂.

Buzzi Unicem’s group technical director at Luigi Buzzi said "We are very interested in the opportunity to collaborate with Italgas as an experienced partner to develop a project that is fully integrated into our industrial investment plan aimed at identifying technologies for capturing and reusing the CO₂ released by our plants, in line with the roadmaps defined by industry associations.” He added “Our aim is to responsibly contribute to containing climate change by developing CO₂ capture technologies and identifying the best solutions for its reuse. We are currently experimenting with calcium looping technology for capturing the carbon dioxide released by the production process at our plant in Vernasca, Piacenza. Thanks to the EU Horizon 2020 Cleanker project, it will be possible to assess the technical and economic sustainability of this technology and estimate the changes to the plant and the investments required to adopt this process in existing cement plants.”

Italy: Cementir Holding has been achieved its first CDP A- rating for climate change mitigation in its operations. The producer said that the global average rating is B-, compared to B in Europe and in the cement and concrete industry globally. CDP awarded Cementir a B for water security, its first such rating in the category.

Chair and chief executive officer Francesco Caltagirone said “This achievement is a further recognition of our efforts to make our carbon footprint more sustainable. We are committed to tackling climate change and minimising our environmental impact.”