Displaying items by tag: Sustainability
Update on COP27
09 November 2022Readers may have noticed the 2022 United Nations Climate Change Conference (COP27) is currently taking place at Sharm El Sheikh in Egypt. Many of the cement companies, suppliers and related associations are present at the annual jamboree and getting stuck in. For example, Holcim’s chief sustainability officer Magali Anderson was scheduled on 8 November 2022 to discuss solutions to decarbonise the built environment at the event’s Building Pavilion, Cemex’s chief executive officer Fernando A González took part in the First Movers Coalition (FMC) panel, FLSmidth is down for a number of talks and both the Global Cement and Concrete Association (GCCA) and World Cement Association are busy too.
Stone cold progress, if any, from the conference is yet to emerge although there is still time given that the event runs until 18 November 2022. No doubt some sort of ‘big message’ style international commitment or plan will emerge from the haggling. However, on the cement sector side, the biggest story so far has been the FMC plan for some of its members to procure at least 10% near-zero cement and concrete for its projects by 2030. Both Holcim and Cemex were founding members of the collation of companies that intend to use their purchasing power to support sustainable technologies in hard to abate sectors. Commitments for the aviation, shipping, steel and trucking sectors were set at COP26 in Glasgow, aluminium and CO2 removal followed in May 2022 and chemicals and concrete were scheduled for November 2022. The latter has started to happen with the formation of the FMC’s cement and concrete group. Companies involved include ETEX, General Motors, Ørsted, RMZ Corporation and Vattenfall. Of these, Sweden-based energy producer Vattenfall has publicly said it is going for the 10% near-zero cement and concrete target by 2030.
Company | 2021 | 2030 Target | Notes |
Cemex | 591 | 480 | ESTIMATE, 40% less CO2/t of cementitious material compared to 1990 |
China Resources Cement | 847 | UNKNOWN | Emission intensity is for clinker |
CRH | 586 | UNKNOWN | 25% reduction in Scope 1 and Scope 2 CO2 emissions by 2030 (on a 2020 baseline) |
Heidelberg Materials | 565 | 500 | |
Holcim | 553 | 475 | |
UltraTech Cement | 582 | 483 | ESTIMATE, Reduction in CO2 emission intensity by 27% from FY2017 level by FY2032 |
Votorantim | 597 | 520 |
Table 1: Net CO2 emission intensity (kgCO2/t) for cement production at selected large cement producers.
While we wait for more announcements to escape from Sharm El Sheikh it might be worth reflecting upon one of the targets some of the cement companies have set themselves for 2030. Table 1 above compares the net CO2 emission intensity for cement production at some of the large cement producers. It doesn’t tell us much, other than that the CO2 emission intensity for these companies was in the region of 550 - 600kgCO2/t of cementitious material in 2021. This compares to 580kgCO2/t in 2020 for the GCCA’s Getting the Numbers Right (GNR) data for the companies it covers. The companies featured in Table 1 are all aiming – or appear to be aiming – for 475 - 525kgCO2/t by 2030. This may not sound like much but it has and will require hard work, innovation, investment and risk on the part of the cement producers. This is also before carbon capture, utilisation and/or storage (CCUS) units will have been built at most cement plants. Yes, until the CO2 emission intensity goes to down to zero, if cement production volumes keep rising sufficiently then total gross CO2 emissions from the cement industry will also increase. Yet, gross CO2 emissions from cement production are likely to peak sometime between now and 2030 if they haven’t already.
One sobering fact to end with is that 1990 is now further in the past than 2050 is in the future. If you can remember George Bush Sr as US president or you saw the film Goodfellas at the cinema then that’s the amount of time we have left to reach net zero. The global economic shocks of the post-coronavirus period and the war in Ukraine are stressing the world’s climate targets more than ever before. Let’s see how COP27 reacts to this. So far though, serious commitments to using low-carbon cement and concrete from big companies are a useful step to entrenching these products in the market.
Cemex chief participates in First Movers Coalition panel at COP27
09 November 2022Egypt: Cemex’s chief executive officer (CEO) Fernando A González was part of the First Movers Coalition panel at the 2022 United Nations Climate Change Conference (COP27) in Sharm El Sheikh on 8 November 2022. He participated alongside the World Economic Forum’s president Borge Brende, Microsoft president Brad Smith, ReNew chair and managing director Sumant Sinha, Volvo Group chief purchasing officer Andrea Fuder and US Special Climate Envoy John Kerry.
Cemex is a founding member of the First Movers Coalition, a partnership between the World Economic Forum and the US Office of the Special Presidential Envoy for Climate, John Kerry. It is the only buyers’ club working to scale new technologies across the heavy industry and heavy-duty transport sectors.
As a First Movers Coalition member, Cemex committed to making 32% of its heavy-duty transport purchases zero emissions by 2030. This commitment aligns with the company’s ambitious goals of reducing transport carbon emissions by 30% by 2030 and becoming net zero by 2050, part of its Future in Action program to achieve sustainable excellence and become a net zero CO2 company.
This commitment is particularly challenging, as zero-emission heavy-duty transport is presently unavailable at scale. At the panel, Fernando A Gonzalez talked about how collaboration and innovation are at the core of his company’s efforts. Cemex is already piloting fully electric concrete mixer trucks with partners like Volvo. It is also investing in transition technologies such as natural gas, replacing 200 diesel trucks with this lower-emission alternative in 2022.
Cemex will a host a discussion panel called Working Together to Decarbonise the Construction Value Chain, to be moderated by Thomas Guillot, chief executive of the Global Cement and Concrete Association (GCCA), on 10 November 2022. The panelists will include Diane Hoskins (Gensler Co), Aniruddha Sharma (Carbon Clean), Hubertus Meinecke (BCG) and Adair Turner (Energy Transitions Commission), in addition to Cemex’s Fernando A González.
Holcim New Zealand takes receipt of Christian Pfeiffer ball mill
04 November 2022New Zealand: Holcim New Zealand says that it has received a mill for use in its upcoming Auckland cement replacement products import and distribution facility. The company opted for a Christian Pfeiffer ball mill for the project.
Holcim New Zealand says that alternative materials imported via the Auckland facility will eliminate 100,000t/yr of cement from New Zealand's 1.6Mt/yr consumption. The company expects that this will cut 78,000t/yr of CO2 emissions.
Slashing cement's CO2 emissions Down Under
02 November 2022In Australia and New Zealand, four producers operate a total of six integrated cement plants, with another 13 grinding plants situated in Australia. This relatively small regional cement industry has been on a decades-long trajectory towards ever-greater sustainability – hastened by some notable developments in recent weeks.
Oceania is among the regions most exposed to the impacts of climate change. In Australia, which ranked 16th on the GermanWatch Global Climate Risk Index 2021, destructive changes are already playing out in diverse ways.1 Boral reported 'significant disruption' to its operations in New South Wales and southeast Queensland due to wet weather earlier in 2022. This time, the operational impact was US$17.1m; in future, such events are expected to come more often and at a higher cost.
Both the Australian cement industry and the sole New Zealand cement producer, Golden Bay Cement, have strategies aimed at restricting climate change to below the 2° scenario. Golden Bay Cement, which reduced its total CO2 emissions by 12% over the four-year period between its 2018 and 2022 financial years, aims to achieve a 30% reduction by 2030 from the same baseline. The Australian Cement Industry Federation (CIF)'s 2050 net zero cement and concrete production roadmap consists of the following pathways: alternative cements – 7%; green hydrogen and alternative fuels substitution – 6%; carbon capture – 33%; renewable energy, transport and construction innovations – 35% and alternative concretes – 13%, with the remaining 6% accounted for by the recarbonation of set concrete.
Australia produces 5.2Mt/yr of clinker, with specific CO2 emissions of 791kg/t of clinker, 4% below the global average of 824kg/t.2 Calcination generates 55% of cement’s CO2 emissions in the country, and fuel combustion 26%. Of the remainder, electricity (comprising 21% renewables) accounted for 12%, and distribution 7%. Australian cement production has a clinker factor of 84%, which the industry aims to reduce to 70% by 2030 and 60% by 2050. In New Zealand, Golden Bay Cement's main cement, EverSure general-purpose cement, generates CO2 at 732kg/t of product.3 It has a clinker factor of 91%, and also contains 4% gypsum and 5% added limestone.
Alternative raw materials
Currently, Australian cement grinding mills process 3.3Mt/yr of fly ash and ground granulated blast furnace slag (GGBFS). In Southern Australia, Hallett Group plans to commission its upcoming US$13.4m Port Augusta slag cement grinding plant in 2023. The plant will use local GGBFS from refineries in nearby Port Pirie and Whyalla, and fly ash from the site of the former Port Augusta power plant, as well as being 100% renewably powered. Upon commissioning, the facility will eliminate regional CO2 emissions of 300,000t/yr, subsequently rising to 1Mt/yr following planned expansions. Elsewhere, an Australian importer holds an exclusive licencing agreement for UK-based Innovative Ash Solutions' novel air pollution control residue (APCR)-based supplementary cementitious material, an alternative to pulverised fly ash (PFA), while Australian Graphene producer First Graphene is involved in a UK project to develop reduced-CO2 graphene-enhanced cement.
Golden Bay Cement is investigating the introduction of New Zealand's abundant volcanic ash in its cement production.
Fuels and more
Alternative fuel (AF) substitution in Australian cement production surpassed 18% in 2020, and is set to rise to 30% by 2030 and 50% by 2050, or 60% including 10% green hydrogen. In its recent report on Australian cement industry decarbonisation, the German Cement Works Association (VDZ) noted the difficulty that Australia's cement plants face in competing against landfill sites for waste streams. It described current policy as inadequate to incentivise AF use.
Cement producer Adbri is among eight members of an all-Australian consortium currently building a green hydrogen plant at AGL Energy’s Torrens Island gas-fired power plant in South Australia.
Across the Tasman Sea, Golden Bay Cement expects to attain a 60% AF substitution rate through on-going developments in its use of waste tyres and construction wood waste at its Portland cement plant in Northland. The producer will launch its new EcoSure reduced-CO2 (699kg/t) general-purpose cement in November 2022. In developing EcoSure cement, it co-processed 80,000t of waste, including 3m waste tyres. The company says that this has helped in its efforts to manage its costs amid high coal prices.
Carbon capture
As the largest single contributor in Australia's cement decarbonisation pathway, carbon capture is now beginning to realise its potential. Boral and carbon capture specialist Calix are due to complete a feasibility study for a commercial-scale carbon capture pilot at the Berrima, New South Wales, cement plant in June 2023.
At Cement Australia's Gladstone, Queensland, cement plant, carbon capture is set to combine with green hydrocarbon production in a US$150m circular carbon methanol production facility supplied by Mitsubishi Gas Chemical Company. From its commissioning in mid-2028, the installation will use the Gladstone plant's captured CO2 emissions and locally sourced green hydrogen to produce 100,000t/yr of methanol.
More Australian cement plant carbon capture installations may be in the offing. Heidelberg Materials, joint parent company of Cement Australia, obtained an indefinite global licence to Calix's LEILAC technology on 28 October 2022. The Germany-based group said that the method offers effective capture with minimal operational impact.
Cement Australia said “The Gladstone region is the ideal location for growing a diverse green hydrogen sector, with abundant renewable energy sources, existing infrastructure, including port facilities, and a highly skilled workforce." It added "The green hydrogen economy is a priority for the Queensland government under the Queensland Hydrogen Industry Strategy.”
Logistics
Australian and New Zealand cement facilities' remoteness makes logistics an important area of CO2 emissions reduction. In Australia, cement production uses a 60:40 mix of Australian and imported clinker, while imported cement accounts for 5 – 10% of local cement sales of 11.7Mt/yr.
Fremantle Ports recently broke ground on construction of its US$35.1m Kwinana, Western Australia, clinker terminal. It will supply clinker to grinding plants in the state from its commissioning in 2024. Besides increasing the speed and safety of cement production, the state government said that the facility presents 'very significant environmental benefits.'
Conclusion
Antipodean cement production is undergoing a sustainability transformation, characterised by international collaboration and alliances across industries. The current structure of industrial and energy policy makes it an uphill journey, but for Australia and New Zealand's innovating cement industries, clear goals are in sight and ever nearer within reach.
References
1. Eckstein, Künzel and Schäfer, 'Global Climate Risk Index 2021,' 25 January 2021, https://www.germanwatch.org/en/19777
2. VDZ, 'Decarbonisation Pathways for the Australian Cement and Concrete Sector,' November 2021, https://cement.org.au/wp-content/uploads/2021/11/Full_Report_Decarbonisation_Pathways_web_single_page.pdf
3. Golden Bay Cement, 'Environmental Product Declaration,' 12 May 2019, https://www.goldenbay.co.nz/assets/Uploads/d310c4f72a/GoldenBayCement_EPD_2019_HighRes.pdf
Suez Cement to undertake US$14.4m solar project at Suez cement plant
02 November 2022Egypt: Suez Cement has partnered with Intro Power and Utilities for the construction of a 20MW solar power plant at its Suez cement plant. From its commissioning in early-mid-2023, the installation will provide the plant with 45GWh of energy annually, 20% of its annual consumption. Suez Cement says that this will eliminate 22,000t/yr-worth of CO2 emissions. Construction is expected to cost US$350m and commence in 2023.
Suez cement aims to achieve specific CO2 emissions of 400kg/t of cementitious product by 2030, down by 47% from 1990 levels.
Managing director Mohamed Hegazy said “Through transitioning to renewable solar energy, we are looking at long-term economic benefits, laying the foundation for a low-carbon business and energy security, without jeopardising the health of our environment. We are proud about this new milestone and to be one of the few cement players in Egypt taking this step towards using a more affordable and cleaner energy."
Ecocem becomes founding partner of Cleantech Scale-Up Coalition
31 October 2022Europe: Ireland-based Ecocem and seven other European sustainable technology companies have launched the Cleantech Scale-Up Coalition, with the backing of green investment funding network Breakthrough Energy. The coalition will work to contribute to European climate neutrality, energy autonomy and industrially competitiveness. Other participants' fields include carbon capture, green hydrogen technologies, transport electrification, batteries and recycling.
Ecocem's managing director Donal O’Riain said “Scalable, low carbon cements, which can decarbonise the European cement industry by 50% by 2030, are ready to deploy today. To do so, they need to be rapidly industrialised. This coalition, which allows Ecocem to combine forces with other world-class companies, will enable our ambition by working to remove the barriers to an accelerated decarbonisation of European, and global, industry.”
Thailand: Siam Cement Group (SCG) recorded revenues of US$11.8bn during the first nine months of 2022, up by 15% year-on-year from US$10.2bn in the corresponding period of 2021. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) declined by 26% to US$1.37bn from US$1.86bn.
SCG recorded nine-month costs growth of 15%, to US$3.29bn from US$2.85bn. The Bangkok Post newspaper has reported that the group says that its monthly energy costs have risen by 50% since the outbreak of the Russia-Ukraine war. As such, it is currently focusing its investments on three ‘key’ business areas with smaller energy consumptions than cement. These are smart living, renewable energy and logistics.
SCG renewables subsidiary SCG Cleanergy aims to more than double its renewable power generation capacity to 500MW before 2026 and further increase it to 5GW before 2028. This will consist of wind farms and roof-mounted and floating solar power plants. Meanwhile, SCG Logistics Management secured approval to merge with JWD InfoLogistics on 26 October 2022.
Germany/Australia: Calix subsidiary Leilac has concluded a licence agreement with Heidelberg Materials for use of its carbon capture technology. The cement producer holds the licence indefinitely and for all operations across the globe. It said that Leilac’s technology offers effective capture of unavoidable cement plant CO2 emissions with minimal operational impact.
Heidelberg Materials currently has one Leilac system installed at its Lixhe plant in Belgium. It expects to commence construction of a second unit at its Hanover plant in Germany in 2023. Together, the installations will be able to capture 125,000t/yr of CO2. The producer says that both projects pave the way for future full-scale deployment of Leilac’s carbon capture model.
Cement Australia partners with Mitsubishi Gas Chemical Company for green methanol trial at Gladstone cement plant
28 October 2022Australia: Cement Australia’s Gladstone cement plant in Queensland will host a study of methanol production from green hydrogen and captured CO2. Japan-based Mitsubishi Gas Chemical Company will supply its green methanol production technology, while hydrogen and oxygen feedstocks will be sourced locally. Cement Australia and Mitsubishi Gas Chemical Company will collaborate on commercialisation of their green methanol. Cement Australia said that carbon capture and its utilisation in value added products is a strategic pillar of the company’s decarbonisation roadmap.
The cement producer said “The Gladstone region is the ideal location for growing a diverse green hydrogen sector, with abundant renewable energy sources, existing infrastructure, including port facilities, and a highly skilled workforce. The green hydrogen economy is a priority for the Queensland government under the Queensland Hydrogen Industry Strategy.”
Cemex increases nine-month 2022 sales and income
27 October 2022Mexico: Cemex sold 47.8Mt of cement in the first nine months of 2022, down by 5.3% year-on-year from 40.5Mt in the same period of 2021. Despite this, its consolidated revenues rose by 8%, to US$11.7bn from US$10.8bn. The group's cost of sales grew by 12% to US$8.09bn from US$7.25bn, and its operating earnings before interest, depreciation, taxation, depreciation and amortisation (EBITDA) dropped by 6.6%. Nonetheless, contributions from discontinued operations led to net income growth of 72%, to US$987m from US$574m.
Cemex said that higher prices in local currency terms drove sales growth across all of its regions. As a percentage of sales, costs grew to 70% from 68%, mainly on account of energy price rises. Operating EBITDA fell across all regions apart from Europe, the Middle East, Africa and Asia (EMEAA), where it rose by 2.5% to US$524m from US$511m. Cemex noted Europe's 'remarkable resilience' in implementing 'double-digit' price increases to increase earnings, while also crossing a threshold of 40% in CO2 emissions reduction from its 1990 baseline.