Displaying items by tag: Sustainability

Philippines: Holcim Philippines will invest US$35m in sustainability initiatives at its four plants over the next three years. The investments will also include US$17.5m for its waste management arm, Geocycle, increasing capacity for local government unit waste processing.

Chief sustainability officer Samuel Manlosa Jr. said "There is also a side where, if we want to take in more volume, we need to increase our capacity to shred and prepare the materials. Our cement plants, even as sophisticated and technologically advanced as they are, were constructed 20 years ago when norms were different, so we had to make changes in the process to make sure that the plants were able to accept more."

The company will further invest between US$8.7m and US$17.5m in renewable energy and electrification of its vehicle fleet. President and CEO Horia Adrian said "We are purchasing electricity right now, but we have plans to put in place solar facilities and we are looking at the possibility of using electricity generated from biowaste here. By the end of 2024, some of them should be ready."

He concluded that investments at the Bulacan and La Union plants are set to start this year, with those in Davao and Lugait scheduled for 2025.

US: Fortera has inaugurated its first ‘green’ cement production facility in North America, located in Redding, California. The 2787m² ReCarb plant operates alongside the existing CalPortland cement plant, capturing CO₂ emissions and mineralising the CO₂ into calcium carbonate for production of the company’s low-carbon ReAct cement. The process reportedly reduces emissions by 70% compared to traditional methods, yielding a tonne of ‘green’ cement for every tonne of limestone input. The facility aims to capture 6600t/yr of CO₂ and to produce 15,000t/yr of ‘green’ cement.

According to Fortera CEO Ryan Gilliam, Fortera currently has 20 upcoming projects with various cement producers, which will cost US$150m each. This includes a plant in the Midwest that will be a 25-fold capacity increase compared to the Redding plant, producing 400,000t/yr of ‘green’ cement.

Thailand: Biochar Life and Siam Cement Group (SCG) have signed a Memorandum of Understanding to jointly develop biochar-infused cement and sustainable building materials. This collaboration aims to utilise biochar in the construction industry and reduce carbon emissions.

The partnership will begin with a pilot project at Chiang Mai University, focusing on constructing biochar-infused cement roads. Biochar Life will evaluate the scalability of biochar production to meet SCG's material requirements. Both companies will engage in research and development to optimise the production and application of biochar in construction, considering environmental benefits and carbon removal credit opportunities.

SCG also plans to extend Biochar Life’s smallholder farmer program, incorporating mobile industrial units and other technologies. This joint effort is directed towards incorporating carbon-negative biochar into building materials. This will lower construction-related carbon emissions, aid in atmospheric carbon sequestration, and improve the durability and performance of these materials.

China: A new study from Hong Kong Polytechnic University showcases sustainable cement production methods, focusing on low-clinker cements and alternative solutions for incinerator fly ash (IFA). The research demonstrates that using carbonated-washed IFA mixed with slag, coal fly ash, or metakaolin can replace 60% of Portland cement, forming ternary blended cement. This approach reportedly reduces the carbon footprint of cement production.

The study found that slag was the most effective, improving pore structure and increasing ettringite and hemicarboaluminate formation with a blend of 40% slag and 20% IFA. It achieved 90% of the compressive strength of pure Portland cement after 90 days.

The researchers said "This study demonstrated the promising potential of the blended cements to simultaneously divert IFA from landfills and reduce the clinker content of cement."

Philippines: A recent study from Cebu, Philippines presents a method for reducing greenhouse emissions in the cement industry. The research, supported by the Department of Science & Technology (DOST) of the Philippines, focuses on partially substituting cement with coal fly ash (CFA). According to the University of San Carlos researchers, CFA's efficacy as a cement substitute depends on its source, with variations in quality, performance, and water requirements when used in paste and mortar formulations.

The study evaluated CFA from a Philippine power plant, examining its use as a partial cement substitute. Researchers designed paste and mortar mixtures with different CFA-to-binder ratios and water-to-binder ratios. The study revealed that increasing the amount of CFA in cement up to 20% by weight could enhance compressive strength, ‘outperforming’ pure cement mixtures.

The study concluded that substituting a portion of cement with CFA not only reduces greenhouse gas emissions but also improves the compressive strength of the resultant material.

Thailand: Siam Cement Group (SCG) has introduced a new low-carbon cement, contributing to Thailand's net-zero ambitions. According to the company, SCG is Thailand's first cement manufacturer to produce this eco-friendly cement, reducing CO₂ emissions to as low as 0.05t during production. The new cement reportedly matches or is stronger than traditional Portland cement. SCG achieved this by improving its manufacturing processes, using clean energy sources and waste heat utilisation, leading to a 38% decrease in energy consumption. The company also modified raw material ratios in order to further reduce emissions.

SCG's president of the cement and green solutions department, Surachai Nimlaor, said “Since cement production consumes a considerable amount of energy and emits CO₂ during the process, we decided to find out how we could reduce this impact." He continued “With the initial low-carbon cement formula, we have reduced emissions by 15 to 20%. Moving forward, our goal is to develop new formulas that can reduce carbon emissions by up to 50%.”

Brazil: Votorantim Cimentos has made progress in reducing its carbon footprint, reporting embodied CO₂ emissions of 556kg/t of cement produced in 2023, a 4% year-on-year decrease. The company aims to reach a target of 475kg of CO₂/t by 2030, aligning with the Science Based Target initiative standards.

The company's decarbonisation strategy involves four stages: co-processing, which involves substituting fossil fuel with biomass and waste; use of cementitious materials to replace clinker; enhancing energy efficiency and use of renewable energy; and developing new technologies and materials, including carbon capture. In 2023, Votorantim Cimentos achieved a 31% global thermal substitution rate through co-processing, an increase from 26.5% in 2022, with a goal of reaching 53% by 2030. The clinker factor was reduced to 72.8% in 2023 from 73.9% in 2022. This reduction means a decrease in emissions, with a target clinker factor of 68% set for 2030. Additionally, 35.1% of the electricity consumed by Votorantim Cimentos in 2023 came from renewable sources, an increase from 22.9% in 2022, with an aim of 45% by 2030.

Álvaro Lorenz, global director of sustainability, institutional relations, product development, engineering, and energy at Votorantim Cimentos, said "The most competitive and sustainable companies will be those with the lowest emissions. In all countries where we operate, we are committed to advancing in our decarbonisation journey, in line with our goal of producing carbon-neutral concrete by 2050."

Votorantim Cimentos’ environmental efforts were recognised with an A score by CDP and a Top-Rated Industry company distinction by Sustainalytics in the Latin American building materials sector. The company also announced a US$989m investment to further reduce its CO₂ emissions. This includes a project at Salto de Pirapora to increase thermal substitution, with expected completion by 2028. Votorantim Cimentos has also started constructing a solar energy complex in Paracatu, with an estimated capacity of 470MWp.

US: A research team from Lehigh University has won a three-year, US$2m grant from the Department of Energy's industrial efficiency and decarbonisation office for a project on concrete decarbonisation. The team, including Carlos Romero, director of Lehigh's Energy Research Centre, aims to develop a sustainable concrete binder using calcined clay, reducing emissions associated with Ordinary Portland Cement production. The project collaborates with Buzzi Unicem USA and focuses on processing and testing calcined clay to mimic the properties of conventional cement.

Lehigh's team will explore various low-grade calcined clays, supplied by Buzzi, testing their compressive strength and durability. The goal is to halve the CO₂ emissions of traditional concrete mixes.

Chair of the Department of Civil and Environmental Engineering Shamim Pakzad said "I am excited about the expansion of the research portfolio of CEE departments into this area of greener cement, which opens many opportunities for future research and implementation in industry."

The US Department of Energy (DOE) announced a US$1.6bn investment in the cement sector this week. The funding was part of a total of US$6bn for 33 projects in over 20 states to decarbonise energy-intensive industries also including chemicals and refining, iron and steel, aluminium and metals, food and beverages, glass, process heat applications and pulp and paper. The DOE was keen to link the money to “the President’s Bipartisan Infrastructure Law and Inflation Reduction Act.” Politics is never far away it seems! The projects are part of the Industrial Demonstrations Program, managed by DOE’s Office of Clean Energy Demonstrations (OCED).

Table 1: Summary of US Department of Energy funding announced on March 2024 to decarbonise cement and concrete production

Table 1 above shows the main approaches each of the projects aim to use. The two most expensive ones involve carbon capture and sequestration (CCS) at Heidelberg Materials US’ Mitchell cement plant in Indiana and National Cement’s Lebec plant in California respectively. In a complimentary press release Chris Ward, the CEO of Heidelberg Materials North America, said “This substantial federal funding investment will help create the first full-scale deployment of carbon capture and storage on a cement plant in the US.” The proposed CCS unit at the plant will capture around 2Mt/yr of CO₂ from 2030. If Ward’s forecast is accurate (and no one beats them to it), then Heidelberg Materials will likely have set up the first full-scale CCS units at cement plants in both North America and Europe. This will be a significant achievement. The National Cement project, by contrast, is a mixed bag of approaches to decarbonising cement production that follows the multi-lever approach advocated for in many of the industry net-zero roadmaps. It intends to use agricultural by-products such as pistachio shells, as alternatives fuels to lower the fuel-based emissions, calcined clay to lower the clinker factor and CCS to capture the remaining 950,000t/yr of CO₂ emissions.

The other projects either involve using calcined clay or substituting limestone with calcium silicate. The Summit Materials proposal is noteworthy because it aims to build four clay calcination units in locations in Maryland, Georgia and Texas. None of these appear to be near Summit’s (or Cementos Argos’) cement plants. This suggests that the company may be intending to use calcined clay in ready-mixed concrete production. The Roanoke Cement Company calcined clay project will be baseEuropead at its cement plant in Troutville, Virginia.

The remaining two grant recipients, Brimstone and Sublime Systems, will both test the companies’ different methods of manufacturing cement by using calcium silicate instead of limestone. Brimstone’s method produces ordinary Portland cement (OPC) and supplementary cementitious materials (SCM). The company said in July 2023 that its OPC met the ASTM C150 standards. However, the company has released less information about its actual process. Sublime Systems’ uses an electrolysis approach to create its ASTM C1157-compliant cement. It calls this ‘ambient temperature electrochemical calcination.’

Investment on the same scale of the DOE has also been happening in Europe. In July 2023, for example, the European Commission announced an investment of Euro3.6bn in clean tech projects to be funded from the proceeds of the European Union emissions trading scheme (ETS). This was the third call for large-scale projects following previous announcements of recipients in 2021 and 2022. Euro1.6bn of the third call funding went towards cement and refining projects including five cement and lime projects in Belgium, Croatia, Germany and Greece. The money granted for each of these schemes was in the region of Euro115 - 235m.

Both the US and Europe are throwing serious finance at the cement industry to try and kickstart the various pathways towards net zero. They are also doing it in different ways, with the US aiming to boost its economy by onshoring sustainable industry, and Europe hoping to fund its approach via carbon taxation. Government-driven decarbonisation investment for cement in other large countries and regions around the world appears to be lagging behind the US and Europe but these may spring up as net zero targets are set, roadmaps drawn up and government policy formulated. These places could also benefit from watching what works and does not work elsewhere first. Back in the US and Europe the next tricky part of this process will be bridging the gap between government subsidy and commercial viability.

Jamaica: Caribbean Cement Company's first phase of its expansion project is set for completion in 2025. The expansion will increase cement production by 30%.

Managing director Jorge Martinez said "When completed, this project will further reduce our CO₂ emissions and deliver increased output from 2600 to 2850t/day of clinker to meet the increased local demand for cement. We will also have the capacity to explore options for exporting to other countries within the Caribbean community. These exports will benefit Jamaica’s economy through foreign currency income."

The US$40m plant expansion in Rockfort, Kingston is financed by the company, with 150 workers already on the project. The expansion was announced in 2022 and aims to strengthen Jamaica's cement industry, reduce import reliance and support the regional construction sector. It will also support parent company Cemex's sustainability targets, including CO₂ emission reduction and optimisation of heat consumption in cement production, as part of its Future in Action programme.