Displaying items by tag: Norway

Ghana: Denmark-based Investeringsfonden for Udviklingslande (IFU) and Norway-based Norfund have invested US$27.9m in CBI Ghana. The funding will support the cement producer’s upgrade of a clay calcination unit at its 0.6Mt/yr Tema grinding plant in Accra. Denmark-based FLSmidth is supplying the equipment for the project.

Norway: HeidelbergCement, agricultural cooperative Felleskjøpet AGRI and shipping company Egil Ulvan Rederi plan to build what they say will be the world's first zero-emission bulk carrier. The project has also received support of around Euro12m from the Norwegian government-owned sustainability company Enova. The vessel is scheduled for completion and commissioning in 2024. Once operational the ship will be used to transport aggregates products for HeidelbergCement and grain for Felleskjøpet between west Norway and east Norway using hydrogen powered transport.

Egil Ulvan Rederi was selected following a tendering process in 2021. The ship is intended to be highly energy efficient, using rotor sails and has a streamlined design to reduce energy consumption. It will be powered by hydrogen from Norwegian energy supplier Statkraft but will also have small auxiliary batteries and a fuel cell on board to maximize flexibility.

Giv Brantenberg, general manager HeidelbergCement Northern Europe, said “The project addresses emissions from the transport part of our value chain. It is unique, ambitious and future-orientated. It is fully in line with HeidelbergCement Group's target to be the leading actor in our industry on the path to carbon neutrality." HeidelbergCement estimates that the carbon footprint of the aggregates products can be reduced by 50 - 60% by using the zero emission vessel, as transport accounts for a significant part of the total carbon footprint of these products.

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

Norway: Germany-based MAN Energy is supplying a compressor system for a carbon capture and storage (CCS) unit being built at Norcem’s Brevik cement plant. The scope of supply includes an RG 63-7 type electrically-powered compressor train. The steam generators cool the CO₂ mixture between the compressor stages and generate steam that is in turn used for capture. The project will be the first to use the ‘Carbon Capture Heat Recovery’ technology (CCWHR) developed by MAN and Aker Carbon Capture. This new process allows the heat emerging from the compressor system to be recovered and used as steam to meet approximately one third of the total heat demand from the Aker Carbon Capture plant. Consequently, MAN says that the system solution demands less energy compared with conventional carbon-capture technologies.

Alexander Sobolyev, Head of Standardisation & Solutions at MAN Energy Solutions, said: "As part of the Norcem project, the digital-twin-based engineering approach of MAN Energy Solutions has led to concrete optimisations. The dynamic process simulation showed that originally planned system components, including heating, valves and additional pipes for safe plant operation, were not required. The time taken for a cold start of the plant can thus be reduced from around 12 hours to 20 minutes – an important characteristic as quick-start capability is always a central criterion for renewable energies."

Spain/Norway: A team from Cartagen Polytechnic and Ostfold University College has demonstrated that Cementos La Cruz could reduce the cost of its concrete production by Euro1.45/m3, or Euro29,000/month by curing concrete with captured CO₂. EuropaPress has reported that the use of CO₂ would reduce the amount of cement required by 7 – 8%. This in turn would remove an estimated 4.6% of CO₂ from the concrete’s production.

In the two and a half years since Calix brought together cement producers across corporate and national boundaries to form the first Low Emissions Intensity Lime And Cement (LEILAC-1) consortium and commissioned a carbon capture installation at the Lixhe cement plant in Belgium on 10 May 2019, carbon capture and storage (CCS) has passed some major milestones. New installations have made Global Cement headlines from Canada (at Lehigh Cement’s Edmonton plant in November 2019) to China (at a China National Building Material (CNBM) plant in July 2021). Twelve other European cement plants now host current or planned carbon capture trials – including the first full-scale system, at HeidelbergCement’sBrevik plant in Norway. A second Calix-led project in Germany, LEILAC-2, attracted Euro16m-worth of funding from the European Union in April 2020.

The work of LEILAC-1 – backed by HeidelbergCement, Cemex, Lhoist, Tarmac and others, with Euro12m in funding – set the benchmark in innovation. Its pilot plant successfully captured 100% of 'unavoidable' process emissions by indirectly heating raw materials inside a vertical steel tube. Called direct capture, the model removes a CO₂ separation step, as our subsequent price analysis will reflect.

In October 2021, the LEILAC-1 consortium published its report of the concluded Lixhe trial. It described the three-fold key successes of the study:

1) Both limestone and raw meal may be processed;

2) CO₂ is successfully separated;

3) The energy penalty for indirect calcination is not higher than for conventional direct calcination.

Additionally, Calix’s first departure into the cement sector has demonstrated that its model exhibits no operational deterioration, does not suffer from material build-up and has no impact on the host plant when used in cement production. The plant’s clinker capacity remained the same as before the trial. Most importantly of all, the Lixhe cement plant recorded no process safety incidents throughout the duration of the trial.

The study has also put an evidence-based price tag on industrial-scale CCS at a cement plant for the first time: Euro36.84/t. Figure 1 (below) plots the full-cycle costs of three different carbon capture installations at retrofitted 1Mt/yr cement plants using 100% RDF, including projections for transport and storage. Installation 1 is an amine-based carbon capture system of the kind installed in the Brevik cement plant’s exhaust stack; Installation 2 is the Calix direct capture system and Installation 3 consists of both systems in combination. Direct capture’s costs are the lowest, while the amine retrofit and the combination installation are close behind at Euro43.68/t and Euro43.25/t respectively.

Figure 1: Full-cycle costs of three different carbon capture installations at retrofitted 1Mt/yr cement plants using 100% RDF

Installations 1 and 3 both entail additional energy requirements for the separation of CO₂ from flue gases and air. With the inclusion of the CO₂ produced thereby, the cost of Installation 1 rises to Euro94/t of net CO₂ emissions eliminated, more than double that of Installation 2 at Euro38.21/t. The combination of the two in Installation 3 costs Euro67.3/t, 76% more than direct capture alone. Figure 2 (below), breaks down the carbon avoidance costs for each one and compares them.

Figure 2: Carbon avoidance costs of three different carbon capture installations at retrofitted 1Mt/yr cement plants using 100% RDF

The Global Cement and Concrete Association (GCCA)’s seven-point Roadmap to Net Zero strategy puts CCS at the forefront of concrete sector decarbonisation. CCS is expected to eliminate an increasing share of global concrete’s CO₂ emissions, rising to 36% in 2050 – by then 1.37Bnt of a total 3.81Bnt. This will depend on affordability. Calix’s model has reduced the capital expenditure (CAPEX) of a carbon capture retrofit by 72% to Euro34m from Euro98m for the amine-based equivalent. When built as part of a new plant, the CAPEX further lowers to Euro27m. Both models may also be retrofitted together, for Euro99m. In future, Calix expects to install direct capture systems capable ofachieving Euro22/t of captured CO₂. By contrast, the cost of emitting 1t of CO₂ in the EU on 11 October 2021 was Euro59.15.

In what it calls the Decade to Deliver, the GCCA aims to achieve a 25% CO₂ emissions reduction in global concrete production between 2020 and 2030, in which CCS plays only a minor part of less than 5%. LEILAC-1 presents a visionof affordable carbon avoidance which complements cement companies’ 2030 CO₂ reduction aspirations.

Unlike conventional CCS methods, however, direct capture only does two thirds of a job – eliminating the emissions of calcination, but not combustion. This would appear to make it unsuited to cement’s longer-term aim of carbon neutrality by 2050 in line with the Paris Climate Accords’ 2°C warming scenario. On the other hand, direct capture is not designed to work alone. Calix recommends use of the technology in conjunction with a decarbonised fuel stream to eliminate the plant’s remaining direct emissions. This increases the price - by 47% to Euro56.05/t of CO₂ avoided for biomassand by more than double to Euro104.48/t for an E-kiln.

The Lixhe cement plant’s carbon capture story is one of a successful crossover from one industry into another: Calix previously applied the technology in the Australian magnesite sector. Realisation of the Calix carbon capture vision in the global cement industry is a challenge primarily due to the scale of the task. It will require continued collaboration between companies and with partners outside of the industry. Further than this, parliaments must continue to enact legislation to make emission mitigation the economic choice for producers.

It’s been a good week for carbon capture in cement production with new projects announced in France and Poland.

The first one is a carbon capture and utilisation (CCU) collaboration between Vicat and Hynamics, a subsidiary of energy-provider Groupe EDF. The Hynovi project will see an integrated unit for capturing CO₂ and producing methanol installed at Vicat’s Montalieu-Vercieu cement plant in 2025. It aims to capture 40% of the CO₂ from the kiln exhaust stack at the plant by using an oxy-fuel method and installing a 330MW electrolyser to split water into oxygen and hydrogen for different parts of the process. The CO₂ will then be combined with hydrogen to produce methanol with potential markets in transport, chemicals and construction. The setup is planning to manufacture over 0.2Mt/yr of methanol or about a quarter of France’s national requirement. The project was put forward under a call for proposals by the Important Projects of Common European Interest (IPCEI) program. Pre-notification of its participation in the program has been received from the French government and it is currently being evaluated by the European Commission. Vicat’s decision to choose its Montalieu-Vercieu plant for this project is also interesting since it started using a CO₂ntainer system supplied by UK-based Carbon8 Systems there on an industrial scale in November 2020. This system uses captured CO₂ from the plant’s flue gas emissions to carbonate cement-plant dust and produce aggregate.

The second new project is a pilot carbon capture and storage (CCS) pilot by HeidelbergCement at its Górażdże cement plant in Poland. This project is part of the wider Project ACCSESS, a consortium led by Sintef Energi in Norway that aims to cut carbon capture, utilisation and storage (CCUS) costs and to link CO₂-emitters from mainland Europe to storage fields in the North Sea. The cement plant part in Poland will test an enzyme-based capture method using waste heat at the plant. Another part of the project will look at how the captured CO₂ can then be transported to the Northern Lights storage facility in Norway including the regulatory aspects of cross-border CO₂ transport. ACCSESS started in May 2021 and is scheduled to end in April 2025. It has a budget of around Euro18m with Euro15m contributed by the European Union (EU) Horizon 2020 fund.

HeidelbergCement also says that the second stage of its LEILAC (Low Emissions Intensity Lime And Cement) project at the Hannover cement plant is part of ACCSESS, with both testing of the larger-scale Calix technology to capture CO₂ and the connected transport logistics and bureaucracy to actually get it to below the North Sea. That last point about Calix is timely given that US-based Carbon Direct purchased a 7% stake in Calix in mid-September 2021 for around US$18m. Whilst on the topic of carbon capture and HeidelbergCement don’t forget that the group’s first full-scale carbon capture unit at Norcem’s Brevik cement plant, using Aker Solution’s amine solvent capture technology, is scheduled for commissioning in September 2024. Another carbon capture unit is planned for Cementa’s Slite plant in 2030 but the proposed capture method has not been announced.

Other recent developments in carbon capture at cement plants include Aalborg Portland Cement’s plan to capture and store CO₂ as part of the Project Greensand consortium. The overall plan here is to explore the technical and commercial feasibility of sequestering CO₂ in depleted oil and gas reservoirs in the Danish North Sea, starting with the Nini West Field. The project is still securing funding though, with an Energy Technology Development and Demonstration Program application to the Danish government pending. However, the Danish Parliament decided in December 2021 to set aside a special funding pool to support a CO₂ storage pilot project so this initiative seems to be making progress. If the application is successful, the consortium wants to start work by the end 2021 and then proceed with an offshore injection pilot from late 2022. How and when Aalborg Portland Cement fits in is mostly unknown but a 0.45Mt/yr capture unit at its Rørdal cement plant is tentatively planned for 2027. There’s also no information on the capture method although Aker Carbon Capture is also part of the Project Greensand consortium. Finally, also in September 2021, Chart Industries subsidiary Sustainable Energy Solutions announced that it had selected FLSmidth to help adapt and commercialise its Cryogenic Carbon Capture carbon capture and storage (CCS) system for the global cement industry.

All of this tells the cynics in the audience that a large international climate change meeting is coming up very soon. Most cement companies will likely want some good news to show off when the 2021 United Nations Climate Change Conference (COP26) dominates the media agenda in November 2021. Other observations to point out include that none of the projects above are full-scale industrial carbon capture installations, most of them are consortiums of one sort of another and that they are all subsidised or want to be. While hydrogen and CO₂ networks get built this seems inevitable. Yet, we’re not at the stage where cement companies just order carbon capture units from a supplier, like they might a new clinker cooler or silo, without the need for long lists of partners. When this changes then carbon capture looks set to flourish.

On a final note, the UK is currently experiencing a shortage of commercially-used CO₂. The reasons for this have nothing to do with the cement industry. Yet consider the constant doom-and-gloom about record global CO₂ emissions and the sheer amount of effort going into reducing this by the projects mentioned above and others. Life has a sense of humour at times.

For a view on the CO₂ sequestration permitting process in the US look out for the an article by Ralph E Davis Associates, in the forthcoming October 2021 issue of Global Cement Magazine

Poland: Germany-based HeidelbergCement has partnered with Norway-based Sintef Energi install a pilot carbon capture and storage (CCS) system at its Górazdze cement plant. The company will deploy new enzyme-based CCS technology, which it says allows greater use of the waste heat and simplifies the control of secondary emissions. The project, known as Project ACCSess, has received Euro15m-worth of funding from the EU’s Horizon 2020 industrial emissions reduction programme. 18 industry partners and research organisations will collaborate towards the deployment of the technology at the plant. The consortium will store captured CO₂ in storage fields in the Nordic countries. The project is due to conclude in April 2025. The total cost of the work is Euro18m.

HeidelbergCement chair Dominik von Achten said “The tests of an enzyme-based capture unit at our Górazdze plant in Poland will deliver important insights into how we can further reduce costs in the capture process.” He added “At the same time, it will emphasise our strategy to expand CCS further into our Eastern Europe-based assets.”

Colombia: Cementos Argos has signed a contract with Klaveness Digital for the supply of the latter’s CargoValue cement terminal logistics platform throughout its supply chain. The move follows a successful trial project carried out by the parties during the second quarter of 2021. Cementos Argos says that it solidifies its digitisation agenda to preserve its strong market foothold in the Americas.

Trading and business intelligence senior director Gabriel Ballestas said “Our business model is focused on the customer and on creating added value for our stakeholders. CargoValue has enabled us to digitise existing processes to improve visibility and make better decisions throughout the supply chain towards that goal.” He added “This wider rollout will improve collaboration between stakeholders and allow us to identify and improve supply chain efficiencies between sites.”

Norway: Norcem, part of Germany-based HeidelbergCement, has awarded a contract to Denmark-based FLSmidth to provide modifications to allow for downstream CO₂ removal at its integrated Brevik cement plant. The supplier will begin work in the unit’s winter 2022 shutdown. Its upcoming carbon capture and storage (CCS) installation is scheduled for commissioning in September 2024.

Norcem project manager Tor Gautestad said, “We are very excited to have FLSmidth on board and to finally begin the construction of the full-size installation.” He added, “FLSmidth’s extensive process knowledge, and air pollution control in particular, will be critical to the success of the project.”