Displaying items by tag: Sustainability

Earlier this year South Africa’s PPC commented on the drought facing Cape Town. It said that cement manufacturing was not water intensive, that its operations were ‘totally’ self-sufficient from its own surface water sources with capacity for several months and that it was working with the local government which viewed construction as an important economic sector. Point made!

Water conservation is an established part of the sustainability toolkit for cement producers. Yet recent weather patterns in the Northern Hemisphere may also test how well companies are doing. Above average temperatures have been recorded this summer, in some places accompanied by unusually dry conditions. A news story this week about Cemex Colombia being fined for using water from a river shows one aspect of the problems that can face industrial users. Another story that we’ve covered previously has been the legal action taken against producers using water from a site near to the Katas Raj Temples in Pakistan.

Wet process cement manufacturing uses more water than dry process but even modern plants use water for cooling equipment and exhaust gases, in emission control systems such as wet scrubbers. In addition, quarrying and aggregate production may require water, and concrete production also needs water. Issues also arise with quarry dewatering and discharging water into rivers and the like. Global Cement Directory 2018 data indicates that, where known, about 10% of integrated cement plants still use a wet production method.

Graph 1: Specific water consumption by selected cement producers in 2017. Source: Corporate sustainability reports.

As Graph 1 shows there is some variation between the major cement producers with regards to how much water they use. They all operate with different types of equipment and production methods in different geographical locations so the difference between the companies is to be expected. A cement plant in northern Europe that normally experiences high levels of rainfall will have a different approach to water conservation than one, say, in a water stressed area like the Middle East. Incidentally, the definition used to define a water-stressed or scarce area is one where there is less than 1000m³/yr per person. One other point to note here is that each of the companies has a higher consumption figure than the 100 – 200L/t that the Cement Manufacturers' Association of the Philippines (CeMAP) reckoned that an average dry-process cement plant used when it was promoting water conservation back in 2013.

Looking at specific recent success stories, India’s UltraTech Cement reported a specific water consumption of 54L/t of clinker at its Star Cement plant in Dubai, UAE in 2016 – 2017 following a dedicated initiative at the site. An another milestone that UltraTech Cement was keen to point out in its last sustainability report was that three of 13 integrated plants had achieved water sufficiency though the use of the company’s 360° Water Management Model with its use of rainwater harvesting and recharging groundwater. These plants are not dependent on any groundwater or fresh water sources. The other larger cement producers all have similar water management schemes with reduction targets in place.

Climate change models generally predict hotter and wetter weather but changing weather patterns and growing populations are likely to impact upon water management and consumption. Given the integral nature of water in the cement production process, many cement producers have realised the importance of it and treat it as an input material like fuel or limestone. Hence the highlighting of water conservation in company sustainability reports over the last decade. The test for the success of these initiatives will be how producers cope in drought situations where they may be seen as being in competition with domestic users. Thankfully in PPC’s case, Cape Town avoided having to ration water to the general public, as the rains returned in the spring.

Germany: HeidelbergCement has highlighted occupational safety and research into CO₂ reduction as priorities in its sustainability report for 2017. It reduced its accident frequency rate for employees with at least one lost working day per 1,000,000 hours across cement, ready-mixed concrete and aggregates to 1.8 in 2017 from 2.2 in 2016.

“This represents a significant improvement. A large number of locations have now been accident-free for several years, while others have seen drastically reduced accident rates. Nevertheless, serious accidents still occurred in 2017. We will therefore further intensify our efforts to prevent accidents on a permanent basis,” said Bernd Scheifele, the chairman of HeidelbergCement.

The building materials producer has also singled out its commitment to reduce its specific CO₂ emissions by 30% in 2030 compared with 1990. It plans to support this by continually increasing the proportion of alternative raw materials and fuels and, wherever possible, to make its production processes more efficient. In addition, HeidelbergCement has invested in research programmes on carbon capture and its utilisation as a raw material. In 2017, it spent Euro141m on research and technology, an increase of around Euro24m from 2016.

Following HeidelbergCement’s acquisition of Italcementi in 2016 its CO₂ emissions have increased. Its specific net CO₂ emissions (per tonne of cementitious material) rose by 1.9% year-on-year to 609kg Co₂/t in 2017 from 598 kg Co₂/t in 2016. Its overall proportion of alternative fuels has also decreased slightly dropping to 20.8% from 21.4%. However, its specific energy consumption for cement and clinker continued to fall in 2017.

UK: Hanson UK’s sustainability report for 2017 shows that its CO₂ emissions per tonne of product have fallen by 7.2% to reach the lowest level for five years. However, the subsidiary of Germany’s HeidelbergCement may face issues meeting its target of a 10% reduction by 2020 from its 2010 figures as its CO₂ emissions from production have rise by 5.7% since 2010.

Overall, the company described 2017 as a year of ‘solid’ progress. It passed its 2020 targets for reducing both mains water use and waste to landfill. The number of lost time injuries remained static at 21, but the frequency rate was down on the prior year and there was a three-month unbroken spell without a lost time injury. The building materials producer also launched HeidelbergCement’s Sustainability Commitments 2030, including a set of targets for the group to achieve by 2020.

Sweden: Cementa, a subsidiary of HeidelbergCement, has handed its environmental roadmap to Minister of Trade and Innovation Mikael Damberg and Deputy Prime Minister and Climate Minister Isabella Lövin. The initiative is part of the Fossil-free Sweden plan to coordinate reduced reliance of industry on fossil fuels and increased competitiveness.

India: Heidelberg Cement India has been certified as over six times net water positive by TOV SOD, an independent certifying agency. During the 2016 – 2017 financial year the company’s cement plants withdrew 1.09kL of water from various sources but they harvested 6.97kL of water. This implies that the company collected more water from sustainable sources, such as rainfall, than it used. The company's multidimensional approach includes diverting rainwater to
reservoirs, installing water harvesting systems, reviving of bore wells, controlling seepage and educating its staff on water conservation.

UK: CO₂ emissions from cement production fell by 2% year-on-year to 696kg/t in 2016 from 709kg/t in 2015. Data from the Mineral Products Association (MPA) Sustainable Development (SD) Summary Data for 2017 report shows that local cement sales rose by 3% to 10.5Mt from 10.2Mt at the same time. Alongside this waste and by-products recovered as raw materials and fuels by the cement industry fell by 6% to 1.5Mt from 1.6Mt.

“The MPA supports the industry's continuing commitment to measuring and reporting data and to transparency on performance. The reporting process is now evolving to reflect the 7 strategic priorities set out in the MPA Charter and as part of this process we will be working to further improve the quality and coverage of our sustainability data,” said Nigel Jackson, the chief executive of the MPA.

UK: Nine cement and concrete companies have launched the Global Cement & Concrete Association (GCCA), a new association that intends to develop the sector’s role in sustainable construction. The association also wants to build innovation throughout the construction value chain, in collaboration with both industry associations and architects and engineers.

The GCCA will be led by international cement companies and headquartered in London, complementing and supporting the work done by existing associations at national and regional level. Membership of the GCCA is available for cement manufacturers from all over the world that share the organisation’s values, and partnerships will be developed with organisations that share its vision. GCCA’s founding members are Cemex, CNBM, CRH, Dangote, Eurocement, HeidelbergCement, LafargeHolcim, Taiheiyo and Votorantim. They represent 1046Mt of cement production capacity, according to the Global Cement Top 100 Report.

Belgium: Cembureau, the European cement association, has published a position paper outlining its stance European Commission’s plastics strategy. The association wants policymakers to ensure any plastic waste that has a calorific value that can be recovered as a fuel source is not landfilled. At present there are differences in waste management policies across the member states of the European Union.

Other points that Cemburea wants to highlight include: a ban on landfill of recoverable and recyclable waste; recognition that cement plants can treat different waste streams such as plastics and simultaneously recycle them as material in the manufacturing process of cement and recover them as energy; the specific relevance that co-processing offers the unique opportunity of a simultaneous energy and material recovery; and the potential to minimise investment costs in dedicated facilities.

In January 2018, the European Commission published a dedicated Plastics Strategy as part of the Circular Economy package. The strategy indicates that there is currently a low rate of recycling or reuse of plastics with most of it going to landfill or used in incinerators.

India: Ambuja Cement has been ranked seventh in the Construction Material category of the Dow Jones Sustainability Index (DJSJ) 2017. The subsidiary of LafargeHolcim was invited to participate in the DJSI Emerging Markets Index and beat its score from 2016. Each year about 2500 global companies, listed on the stock exchange, belonging to about 59 economic sectors, are invited to participate in the DJSI.

US: The Wildlife Habitat Council (WHC) has recertified four of Roanoke Cement Company’s terminals in Virginia and North Carolina. Units at Front Royal, Richmond and Bristol in Virginia and Winston-Salem, North Carolina received the certification.

"Having the Wildlife Habitat Council's recertification for each of them is a distinguished recognition confirming that all of Roanoke Cement's sites are on the right track ecologically. We look forward to continuing our conservation efforts providing pleasing, ‘green’ features within our terminal campuses. A few examples include pollinator meadows at Front Royal and Winston-Salem, avian habitats for the Eastern Bluebird in Richmond, and stream restoration in Bristol," said David Brinkley, Director of Distribution & Customer Resources at Roanoke Cement Company.

WHC's certification program, ‘Conservation Certification,’ is built on global recognition programs, reflects contemporary conservation efforts and applies its collective learning to the future of biodiversity in the US and the globe. Front Royal, Richmond and Winston-Salem were originally certified in 2013. Bristol was originally certified in 2015. Certification by WHC is valid for two years.