Displaying items by tag: Particulate matter

India: Dalmia Cement (Bharat) has successfully launched its new fleet of 35 liquefied natural gas (LNG)-fuelled trucks from its Murli cement plant in Maharashtra. The trucks are of two types, covering ranges of 50 - 600km, and will transport bagged cement and bulk raw materials. They have 28% lower CO₂ emissions than conventional diesel-powered trucks, and are thus able to eliminate 840t/yr of CO₂ emissions, while also reducing emissions of nitrous oxides (NO_x) by 59% and particulates by 91%, and eliminating emissions of sulphur oxides (SO_x).

Dalmia Cement (Bharat) says that its next move will be to launch a second fleet of 25 trucks from its Ariyalapur cement plant in Tamil Nadu. By April 2024, it plans to convert 10% of its 3000 truck-strong fleet to LNG fuel.

A spokesperson for the company said “Dalmia Cement has been following the business philosophy of Clean & Green is Profitable and Sustainable. Our overall CO₂ emissions have come down from 670kg/t to 467kg/t – one of the lowest globally – and we are focusing on realising our carbon negative goal by 2040. We are delighted to partner with GreenLine Logistics for further reduction of our Scope 3 greenhouse gas emissions.”

UK: Cemex has bought 10 Volvo 460 8x4 tipper trucks for use at its Angerstein Wharf aggregates depot in Greenwich. From there, the trucks will deliver sand and aggregates all around London. The trucks’ bodies are made of lightweight aluminium, and they conform to Euro 6 emissions standards. This corresponds to 80% NO_x emissions reduction and 50% particulate emissions reduction compared to Euro 5 standards.

Cemex UK fleet engineering manager Nigel Ponton said “The addition of these new trucks to our fleet will enable us to better meet customer demand, safely and efficiently. Safety is the number one focus whenever we add new trucks to our operation and these Volvos tick every box in that respect.” Ponton continued “These trucks will all be working in busy streets across London so it’s imperative we provide our drivers with the best tools possible to do the job and help protect any vulnerable road users. Moreover, thanks to the improved fuel efficiencies and enhanced payload these new Volvos are the most sustainable vehicles we’ve ever had and will help decarbonise our delivery footprint.”

Pakistan: The Pakistan National Forum of Environment and Health (NFEH) has recognised Lucky Cement’s sustainability successes with a prize at the 19th Annual Environment Excellence Awards 2022. The company’s comprehensive environmental management and monitoring plan covers its solid waste, noise pollution and emissions, including particulates. It says that this is essential to preserving the ecosystem in which it operates.

Chief operating officer Amin Ganny said “We believe in environment-friendly practices and are committed to conserving the environment. Implementation of sustainability into our core business operations has always been one of our main objectives.”

US: Italy-based Buzzi Unicem subsidiary Lone Star Industries has concluded a settlement with the US Department of Justice, the Environmental Protection Agency and the state of Indiana over Clean Air Act violations at its integrated Greencastle plant in Indiana, dating from 2010 to the present day. The Indy Star newspaper has reported that under the terms of the settlement the producer must pay a fine of US$700,000. The authorities ordered the company to upgrade the plant in line with state and federal pollution regulations. The violations involved emissions of particulate matter that exceeded state and federal limits.

US: Dragon Products has been fined US$67,000 by the Maine Department of Environmental Protection for exceeding air emissions regulations since 2013. Ammonia, carbon monoxide and particulate matter levels were all breeched, according to the Bangor Daily News newspaper. Other irregularities with standards were also noted, such as baghouse inlet temperature limits and clinker cooler opacity standards.

China: China Tianrui Group has reported gross CO₂ emissions per tonne of cement of 910kg/t in 2019 in its latest sustainability report. Nitrogen oxide and particulate matter emissions were 7862t and 1380t, year-on-year decreases of 13% and 4% respectively. Its water consumption intensity decreased by 42% year-on-year to 1.12Mm3.

The group operates 20 clinker production lines and 59 cement grinding production lines. Its production capacity of clinker and cement was 28.4Mt tonnes and 56.7Mt respectively in 2019. Its plants are based in Henan, Liaoning, Anhui and Tianjin, with Henan and Liaoning accounting for the largest proportion.

Uzbekistan: The State Committee of Uzbekistan for Ecology and Environmental Protection plans to create a system of monitoring stations for automatic measurement of air pollution, including particulate matter (PM), throughout the country. Part of this will include the installation of automatic emissions sampling and analysis stations at a number of industrial plants, as well as static monitoring stations within and near plant sites, including in the cement sector. Installation will be at the cost of the industrial facility.

In late 2019 the State Committee for Ecology, together with the Ministry of Health and Uzhydromet, took samples of air from 13 cement plants, finding that five greatly exceeded international norms for dust emissions. Based on the results of the audit, the committee has developed a draft government decree on strengthening environmental control over cement plants. If the document is approved, then all existing cement manufacturers will be obliged to install automatic sampling stations for analysis of air pollution by 1 January 2022, as well as stationary posts in the adjacent territory at their own expense.

It’s the end of the year so it’s time to look at trends in the sector news over the last 12 months. It’s also the end of a decade, so for a wider perspective check out the feature in the December 2019 issue of Global Cement Magazine. The map of shifting production capacity and the table of falling CO₂ emissions per tonne are awesome and inspiring in their own way. They also point towards the successes and dangers facing the industry in the next decade.

Back on 2019 here are some of the main themes of the year in the industry news. This is a selective list but if we missed anything crucial let us know.

European multinationals retreat

LafargeHolcim left the Philippines, Malaysia and Indonesia, HeidelbergCement sold up in Ukraine and reduced its stake in Morocco and CRH is reportedly making plans to leave the Philippines and India, if local media speculation can be believed. To be fair to HeidelbergCement it has also instigated some key acquisitions here and there, but there definitely has been a feel of the multinationals cutting their losses in certain places and retreating that bit closer to their heartlands.

CRH’s chief executive officer Albert Manifold summed it up an earnings meeting when he said, “…you're faced with a capital allocation decision of investing in Europe or North America where you've got stability, certainty, overlap, capability, versus going for something a bit more exotic. The returns you need to generate to justify that higher level of risk are extraordinary and we just don't see it.”

The battle for the European Green Deal

One battle that’s happening right now is the lobbying behind the scenes for so-called energy-intensive industries in Europe as part of the forthcoming European Green Deal. The cement industry is very aware that it is walking a tightrope on this one. The European Union (EU) Emissions Trading Scheme (ETS) CO₂ price started to bite in 2019, hitting a high of Euro28/t in August 2019 and plant closures have been blamed on it. The rhetoric from Ursula von der Leyen, the new president of the European Commission, has been bullish on climate legislation and the agitation of Greta Thunberg internationally and groups like Extinction Rebellion has kept the issue in the press. Cembureau, the European Cement Association, is keen to promote the industry’s sustainability credentials but it is concerned that aspects of the proposed deal will create ‘uncertainty and risks.’ Get it wrong and problems like the incoming ban on refuse-derived fuel (RDF) imports into the Netherlands may proliferate. What the Green Deal ends up as could influence the European cement industry for decades.

The managed march of China

Last’s week article on a price spike in Henan province illustrated the tension in China between markets and government intervention. It looks like this was driven by an increase in infrastructure spending with cement sales starting to rise. Cement production growth has also picked up in most provinces in the first three quarters of 2019. This follows a slow fall in cement sales over the last five years as state measures such as consolidation and peak shifting have been implemented. The government dominates the Chinese market and this extends west, as waste importers have previously found out to their cost.

Meanwhile, the Chinese industry has continued to grow internationally. Rather than buying existing assets it has tended to build its own plants, often in joint ventures with junior local partners. LafargeHolcim may have left Indonesia in 2018 but perhaps the real story was Anhui Conch's becoming the country's third biggest producer by local capacity. Coupled with the Chinese dominance in the supplier market this has meant that most new plant projects around the world are either being built by a Chinese company or supplied by one.

India consolidates but watches dust levels

Consolidation has been the continued theme in the world's second largest cement industry, with the auction for Emami Cement and UltraTech Cement’s acquisition of Century Textiles and Industries. Notably, UltraTech Cement has decided to focus its attention on only India despite the overseas assets it acquired previously. Growth in cement sales in the second half of 2019 has slowed and capacity utilisation rates remain low. Indian press reports that CRH is considering selling up. Together with the country's low per capita cement consumption this suggests a continued trend for consolidation for the time being.

Environmental regulations may also play a part in rationalising the local industry, as has already happened in China. The Indian government considered banning petcoke imports in 2018 in an attempt to decrease air pollution. Later, in mid-2019, a pilot emissions trading scheme (ETS) for particulate matter (PM) was launched in Surat, Gujarat. At the same time the state pollution boards have been getting tough with producers for breaching their limits.

Steady growth in the US

The US market has been a dependable one over the last year, generally propping up the balance sheets of the multinational producers. Cement shipments grew in the first eight months of the year with increases reported in the North-Eastern and Southern regions. Imports also mounted as the US-China trade war benefitted Turkey and Mexico at the expense of China. Alongside this a modest trade in cement plants has been going on with upgrades also underway. Ed Sullivan at the Portland Cement Association forecasts slowing growth in the early 2020s but he doesn’t think a recession is coming anytime soon.

Mixed picture in Latin America

There have been winners and losers south of the Rio Grande in 2019. Mexico was struggling with lower government infrastructure spending hitting cement sales volumes in the first half of the year although US threats to block exports haven’t come to pass so far. Far to the south Argentina’s economy has been holding the cement industry back leading to a 7% fall in cement sales in the first 11 months of the year. Both of these countries’ travails pale in comparison to Venezuela’s estimated capacity utilisation of just 12.5%. There have been bright spots in the region though with Brazil’s gradual return to growth in 2019. The November 2019 figures suggest sales growth of just under 4% for the year. Peru, meanwhile, continues to shine with continued production and sales growth.

North and south divide in Africa and the Middle East

The divide between the Middle East and North African (MENA) and Sub-Saharan regions has grown starker as more MENA countries have become cement exporters, particularly in North Africa. The economy in Turkey has held back the industry there and the sector has pivoted to exports, Egypt remains beset by overcapacity and Saudi Arabian producers have continued to renew their clinker export licences.

South of the Sahara key countries, including Nigeria, Kenya and South Africa, have suffered from poor sales due to a variety of reasons, including competition and the local economies. Other countries with smaller cement industries have continued to propose and build new plants as the race to reduce the price of cement in the interior drives change.

Changes in shipping regulations

One of the warning signs that flashed up at the CemProspects conference this year was the uncertainty surrounding the new International Maritime Organistaion (IMO) 2020 environmental regulations for shipping. A meeting of commodity traders for fuels for the cement industry would be expected to be wary of this kind of thing. Their job is to minimise the risk of fluctuating fuel prices for their employers after all. Yet, given that the global cement industry produces too much cement, this has implications for the clinker and cement traders too. This could potentially affect the price of fuels, input materials and clinker if shipping patterns change. Ultimately, IMO 2020 comes down to enforcement but already ship operators have to decide whether and when to act.

Do androids dream of working in cement plants?

There’s a been a steady drip of digitisation stories in the sector news this year, from LafargeHolcim’s Industry 4.0 plan to Cemex’s various initiatives and more. At present the question appears to be: how far can Industry 4.0 / internet of things style developments go in a heavy industrial setting like cement? Will it just manage discrete parts of the process such as logistics and mills or could it end up controlling larger parts of the process? Work by companies like Petuum show that autonomous plant operation is happening but it’s still very uncertain whether the machines will replace us all in the 2020s.

On that cheery note - enjoy the winter break if you have one.

Global Cement Weekly will return on 8 January 2020

Uzbekistan: The State Committee for Ecology and Environmental Protection plans to ask cement plants to establish sampling and analysis stations for sources of air pollution by the start of 2022. If they don’t the government will take measures up to and including suspension of production, according to the Trend News Agency. Uzbekistan was ranked in 16th place by AirVisual in a listing of the countries with the most air pollution in 2018.

India: Zuari Cement’s integrated cement plant at Sitapuram, Telangana has been issued a show cause notice by the Central Pollution Control Board (CPCB) for exceeding particulate matter emissions. During an inspection it has found to be emitting 40.6mg/Nm³ from the kiln and 78mg/Nm³ from the cement mill, according to the Times of India newspaper. The limit is 30mg/Nm³. CPCB officials also found other violations including an alleged deliberate attempt show reduced levels of sulphur dioxide and nitrogen oxide. The plant has been asked to calibrate its dust monitors properly and submit a compliance report by late July 2019.