Displaying items by tag: Lafarge Zementwerke

Austria: Lafarge Zement has successfully demolished the chimney of a former gas power plant at its Mannersdorf cement plant in Lower Austria. Hans Zöchling GmbH carried out the demolition work. Lafarge Zement plans to use the cleared space for a new solar power plant. Plant manager Helmut Reiterer said that further renewable power projects are also planned at the site.

Austria: Lafarge Austria and Perlmooser Beton will operate under the new name Holcim Austria from May 2023. Both companies have been part of Holcim Group since 2015. The rebranding exercise follows the renaming of LafargeHolcim as Holcim that took place in mid-2021.

Lafarge Austria operates two cement plants, at Mannersdorf and Retznei respectively, with a total production capacity of 1.6Mt/yr. Its headquarters is in Vienna. The company employs around 250 people.

Austria: Lafarge Zement plans to invest Euro8m in the establishment of the Recycling Centre Mannersdorf at its 1.2Mt/yr Mannersdorf cement plant in Lower Austria. Niederösterreichische Nachrichten News has reported that the facility will process demolition waste into alternative raw materials for use in the cement producer’s operations.

Plant manager Helmut Reiterer said “The Recycling Centre Mannersdorf is of great importance for the construction industry. It enables people to build in a much more environmentally friendly way, increases the recycling rate and strengthens the domestic circular economy.”

Austria: The Austrian Cement Industry Association (VÖZ) has launched a roadmap for carbon neutrality by 2050. The initiative follows the 5C approach of Clinker, Cement, Concrete, Construction and Carbonation as prompted by the European Cement Association, Cembureau. Selected targets from the document include reducing the sector’s average clinker factor to 52% by 2040 from 70% in 2020, using carbon-neutral electricity from 2030 and meeting a recycling rate for concrete and demolition waste of 25% in 2050 from 10% in 2022. Sebastian Spaun, the managing director of VÖZ, highlighted the ‘Carbon2ProductAustria’ (C₂PAT) initiative as a key project where capture CO₂ from Lafarge Zementwerke’s Mannersdorf cement plant will be used with hydrogen to produce synthetic fuels, plastics or other chemicals.

Austria: Lafarge Zement has ordered a new conveying system for raw materials and alternative fuel (AF) for its Mannersdorf cement plant from Germany-based Beumer Group. The system consists of two pipe conveyors. The first will be 192m long with a capacity of 22t/hr. While the second will be 87m long and have a conveying capacity of 10t/hr. The lifting heights will be approximately 39m and the maximum angle of inclination will be 15 degrees. The order also includes three buffer bins and a weigh feeder.

The system replaces the cement plant’s pre-existing conveyors, which were seriously damaged in a fire in June 2020. Beumer will be responsible for delivery, installation, engineering and commissioning of the new conveyors. Commissioning is scheduled for mid-April 2021.

Austria: Germany-based Loesche has received an order to supply a new raw materials grinding plant to LafargeHolcim subsidiary Lafarge Zement’s Mannersdorf cement plant. The plant will consist of a type LM 45.4 mill, a LSKS type classifier, a rotary feeder, a magnetic separator, a conveyor, a pair of Hurriclons, a mill fan and the ‘Digital Ready 4.0!’ digital package. Loseche’s subsidiaries Kingsblue and AixProcess are responsible for the digital products and A-Tec for the Hurriclons. Commissioning is scheduled by the end of February 2022.

Cement and ore head of sales Stefan Baaken said, "Many cement plants in Europe are facing similar challenges to our customer in Mannersdorf. For us as an original equipment manufacturer and also for the customer, the new grinding plant is an important signpost towards more energy-efficient and sustainable cement production.”

Austria: Loesche subsidiary A TEC has won a contract for the supply and installation of a Flash Dryer for alternative fuels (AFs) in the kiln line of Lafarge Zementwerke's 1.1Mt/yr Mannersdorf cement plant in Lower Austria. The supplier said that it will complete the project in early 2021.

The company said, “Reaching high thermal substitution rates (TSR) requires firing of alternative fuels at the kiln burner. To reach a stable sintering zone for the required clinker quality a high fuel quality (high LCV, small particle size) is needed, otherwise the clinker quality may suffer or the TSR can be limited. With the A TEC Flash Dryer various waste heat sources can be used (clinker cooler flue gas, bypass gas, preheater gas, etc.). The material is dosed to the hot gas flow in the flash dryer and transported with this gas flow, while the moisture is evaporated, to a cyclone and a subsequent filter where the fuel is separated from the gas flow and on-line fed to a kiln burner or a satellite burner. In addition to the drying the lifting effect of the gas can separate 3D impurities which contributes in a further increase of the fuel quality.”

Hydrogen and its use in cement production has been adding a dash of colour to the industry news in recent weeks. Last week, Lafarge Zementwerke, OMV, Verbund and Borealis signed a memorandum of understanding (MOU) to plan and build a full-scale unit at a cement plant in Austria to capture CO₂ and process it with hydrogen into synthetic fuels, plastics or other chemicals. This week, Air Products and ThyssenKrupp Uhde Chlorine Engineers (TUCE) signed a strategic agreement to work together in ‘key regions’ to develop projects supplying green hydrogen. Both of these developments follow the awarding of UK government funding in February 2020 to support a pilot project into studying a mix of hydrogen and biomass fuels at Hanson Cement’s Ribblesdale integrated plant.

As the title of this column suggests there is an environmental colour code to describe how hydrogen is made for industrial use. This is a bit more codified than when grey cement gets called ‘green’ but it pays to remember what the energy source is. So-called ‘green’ hydrogen is produced by the electrolysis of water using renewable energy sources such as hydroelectric or solar, ‘Grey’ hydrogen is made from steam reforming using fossil fuels and ‘Blue’ hydrogen is similar to grey but has the CO₂ emissions from the fuels captured and stored/utilised. Price is seen as the main obstacle to wider uptake of hydrogen usage as a fuel in industry although this is changing as CO₂ pricing mounts in some jurisdictions and the connected supply chain is developed. A study by BloombergNEF from March 2020 forecasted that green hydrogen prices could become cheaper than natural gas by 2050 in Brazil, China, India, Germany and Scandinavia but it conceded that many barriers would have to be overcome to get there. For example, hydrogen has to be manufactured making it more expensive than fossil fuels without government policy support and its, “lower energy density also makes it more expensive to handle.”

The three recent examples with respect to the cement industry are interesting because they are all exploring different directions. The Lafarge partnership in Austria wants to use hydrogen to aid the utilisation side of its carbon capture at a cement plant. The industrial suppliers, meanwhile, are positioning themselves in the equipment space for the technology required to use hydrogen on industrial plants. Secondly, ThyssenKrupp has alkaline water electrolysis technology that it says it has used at over 600 projects and electrochemical plants worldwide. Air Products works with industrial gas production, storage and handling.

Finally, the Hanson project in the UK will actually look at using hydrogen as a partial replacement for natural gas in the kiln combustion system. A Cembureau position paper in mid-2019 identified that the challenges to explore in using hydrogen in cement production included seeing how its use might affect the physical aspects of the kiln system, the fuel mass flows, temperature profile, heat transfer and the safety considerations for the plant. Later that year a feasibility study by the Mineral Products Association (MPA), Verein Deutscher Zementwerke (VDZ) and Cinar for the UK government department that is funding the Hanson project concluded that a hydrogen flame’s high heat in a burner alone might not make it suitable for clinker formation. However, the study did think that it could be used with biomass to address some of that alternative fuel’s “calorific limitations” at high levels. Hence the demonstration of a mixture of both hydrogen and biomass.

That’s all on hydrogen but, finally, if you didn’t log into yesterday’s Virtual Global CemProducer 2 Conference you missed a treat. One highlight was consultant John Kline’s presentation on using drones to inspect refractory in some hard to reach places. Flying a camera straight into a (cool) pyro-processing line was reminiscent of a science fiction film! Global Cement has encountered the deployment of unmanned aerial vehicles in quarry and stockpile surveys previously but this was a step beyond.

The proceedings pack - including video, presenter slides and delegate list - for the Virtual Global CemProducer 2 Conference 2020 is available to buy now

Austria: Lafarge Zementwerke, OMV, Verbund and Borealis have signed a memorandum of understanding (MOU) for the joint planning and construction of a full-scale plant by 2030 to capture CO₂ and process it into synthetic fuels, plastics or other chemicals. As part of the ‘Carbon2ProductAustria’ (C2PAT) project the companies intend to build the unit at the integrated Mannersdorf cement plant and capture all of the 0.7Mt/yr of CO₂ emitted.

"We are committed to leading the industry in reducing carbon emissions and shifting towards low-carbon construction. We have worked consistently and successfully on the reduction of the CO₂ footprint of our cement plants, products and solutions. Ultimately, CO₂-neutral cement production can only be possible with the implementation of breakthrough technologies, like carbon capture, which is why we have great expectations for the C2PAT project", said Lafarge’s local chief executive officer (CEO) José Antonio Primo.

The project aims to use hydrogen produced by Verbund to allow OMV to transform the captured CO₂ into a range of olefins, fuels and plastics. Borealis would then use some of these products as a feedstock to manufacture plastics. However, the companies say that, “taking the next steps towards a Zero CO₂ economy will require the right financial as well as favourable regulatory framework conditions. The success of C2PAT will largely depend on whether the right financial and regulatory framework conditions are created both at the European Union and Austrian national level.”

The joint project is designed in three phases. In phase one, the partners are currently evaluating and developing a joint strategy for project development, business modelling and process engineering. Based on the results of phase one, a cluster of industrial pilot plants in the Eastern part of Austria could be technically developed and built in the mid-2020s in phase two. Phase three entails building a full scale CO₂ capture and utilisation unit at a cement plant.

Lafarge Zementwerke is the Austrian subsidiary of building materials manufacturer LafargeHolcim. OMV produces and markets oil and gas, energy and other petrochemical products. Verbund is an Austrian-based electricity generator, with a focus on hydroelectric power. Borealis is a chemical company and a producer of polyolefins, base chemicals and fertilisers.