Displaying items by tag: Sustainability

Japan: Mitsubishi Heavy Industries (MHI) has won an Award for Excellence at the 41st Nikkei Excellent Products and Services Awards for its carbon capture system. It was among eight industrial products to win the award for the year. The panel of judges selected MHI's system for its compact and versatile module configuration, which shortens installation and transport times.

MHI's model has been in industrial operation since June 2022, when MHI inaugurated its first system at Taihei Dengyo Kaisha's Seifu Shinto biomass power plant. The technology is now in operation or under implementation at cement plants in Japan and overseas. Most recently, MHI secured a carbon capture contract with a UK cement plant, Hanson's Padeswood plant, in mid-December 2022.

Cemex launched a new waste management division called Regenera this week. Cemex describes Regenera as a “business that provides circularity solutions, including reception, management, recycling, and coprocessing of waste.” The Mexico-based company has a long and leading history with sourcing and using alternative fuels in the cement sector and the new organisation looks set to utilise this experience. What is notable though is how the business is targeting three waste streams: municipal and industrial; industrial by-products; and construction, demolition and excavation waste (CDEW). Bringing the three waste streams together in this way appears to be novel for the heavy building materials sector, particularly the inclusion of CDEW, which we will explore further here.

CDEW is split into fractions, just like the municipal and solid waste streams that end up as alternative fuels at cement plants, but the biggest fractions are generally concrete, followed by bricks. The recycled concrete is then typically used as an aggregate, either in new concrete production or in areas like road construction and earthworks. The use of recycled aggregates (RA) made from CDEW goes back to at least the 1930s in its current form although ‘reusing’ materials from structures such as castles and churches goes back far further. Recycling and reusing CDEW gained a boost in 2020 when the European Union (EU) set a 70% recovery target. However, within the EU the CDEW recycling rates vary considerably and that 2020 target includes the use of CDEW in backfill applications.

In its launch statement for Regenera, Cemex noted that it operates a dock in Paris, where it receives a variety of materials, including construction debris, excavated material and inert soil. These materials are sorted, processed and then transformed into recycled aggregates or organic material used to restore quarries. Cemex then promptly followed up the official launch of Regenera on 30 January 2023 with the acquisition of a majority stake in Shtang Recycle, an Israel-based CDEW recycling company. It added that Shtang Recycle is preparing to build a recycling plant with a production capacity of 0.6Mt/yr of CDEW waste materials. The output from the plant will be used as raw materials for aggregate production.

The focus on CDEW recycling was flagged up at Cemex’s investor event in November 2022. It said that it was targeting a recycling rate of 14Mt/yr of construction and demolition waste by 2030. Other managed waste stream goals included doubling the amount of municipal and industrial waste it manages, to achieve a 50% to fossil fuel substitution rate, and increasing its usage of alternative raw materials and by-products by 30%, thereby eliminating 13Mt/yr of extracted materials.

Cemex is not alone in targeting the CDEW waste sector. Holcim’s recent work in the area goes back to at least 2016 when a recycling unit near its Retznei cement plant in Austria started processing 130,000t/yr of CDEW. It announced in December 2022 that it was setting up a similar recycling centre, also in Austria, at its Mannersdorf cement plant. In October 2022 Holcim acquired Wiltshire Heavy Building Materials in the UK. This company recycles 150,000t/yr of construction and demolition waste into aggregates and concrete. Holcim linked the acquisition to its Strategy 25 target of recycling 10Mt/yr of construction and demolition waste by 2025.

Activity by other cement companies includes the commissioning of a construction waste recycling plant at Gennevilliers in France by CRH-subsidiary Eqiom in April 2022. It was aiming for a target of 50,000t in 2022. In November 2022 Heidelberg Materials agreed to acquire RWG Holding based in Berlin, Germany. Then, in December 2022, it announced a deal to buy Mick George Group in the UK. Both proposed acquisitions are subject to competition authority approval. Heidelberg Materials’ current target is to offer circular alternatives for half of its concrete products by 2030.

The moves by the bigger cement companies into the CDEW sector follow sustainable thinking and the waste hierarchy. Yet the big prize here is to gain a route to dispose of some of their CO₂ emissions through recarbonation and this has been flagged up in several net-zero roadmaps for the cement sector such as those by Cembureau and the Global Cement and Concrete Association (GCCA). Holcim has been involved in the FastCarb project in France, running a pilot at its Val d’Azergues cement plant in 2021. Heidelberg Materials has been testing its own process with so-called recycled concrete paste. The development now appears to be that utilising CDEW has entered the sustainability strategies for some of the big cement-concrete-aggregate producers, targets have been set and acquisitions are happening.

For more information on Heidelberg Materials research into concrete recycling read the January 2023 issue of Global Cement Magazine

Finland: Finnsementti and energy provider St1 have selected Norway-based Aker Carbon Capture to carry out a pre-engineering study for a planned carbon capture system at the cement producer's Lappeenranta cement plant in South Karelia. Dow Jones Institutional News has reported that Aker Carbon Capture offers a 40,000t/yr carbon capture system, capable of producing 25,000t/yr of methanol for use as transport fuel. The project is scheduled to deliver commercial synthetic methanol by 2026.

The Lappeenranta cement plant carbon capture project recently received Euro35.4m in additional funding from the Finnish government, subject to European Commission approval.

Philippines: CRH subsidiary Republic Cement and its waste management subsidiary Ecoloop are seeking to establish partnerships with 'sustainability-minded' organisations. BusinessWorld News has reported that Republic Cement and Ecoloop process waste for 12 private companies and 30 local government units. Philippines law will require that large organisations recover 80% of their plastic packaging waste by 2030. For 2023, the minimum is 2023.

Ecoloop managing director Angela Edralin-Valencia said “Our goal is to make our cement a greener and more environmentally friendly product. Our ambition is to replace 50% of our fuel consumption with alternative fuel (AF)." She added "A lot of investments have to be put in place from our end to get to that number, but we are still reviewing our options.”

Mexico: Cemex has launched its global waste management subsidiary Regenera. Regenera will be involved in the reception, management, recycling and coprocessing three major waste streams: municipal and industrial waste, construction, demolition and excavation waste (CDEW) and industrial by-products. It will tie in with Cemex’s own cement sustainability initiatives, for instance in its supply of waste recovered from the River Nile to Cemex Egypt’s Assiut cement plant for co-processing as alternative fuel (AF).

Poland: The European Union (EU) Innovation Fund has awarded Euro228m towards the Go4ECOPlanet carbon capture and storage project at Lafarge Poland’s Kujawy cement plant. The project has a total cost of Euro380m.

It will use Air Liquide's Cryocap FG technology to capture the CO₂ at the plant. The CO₂ will be liquefied and transported by rail to a port and then injected into a depleted oil field for permanent storage. The transport and storage of CO₂ once it has left the cement plant will be accomplished by cooperation with other partners with knowledge and experience in the liquefaction, transport and storage of gases. The goal is to create a complete carbon capture and storage industrial and logistics chain. Commissioning of the cement plant upgrade is planned for 2027.

Austria: Lafarge Zement has successfully demolished the chimney of a former gas power plant at its Mannersdorf cement plant in Lower Austria. Hans Zöchling GmbH carried out the demolition work. Lafarge Zement plans to use the cleared space for a new solar power plant. Plant manager Helmut Reiterer said that further renewable power projects are also planned at the site.

Austria: Zementwerk Hatschek's Gmunden cement plant eliminated 3800t of CO₂ emissions from its local area during 2022 through its contribution to municipal heating. Zementwerk Hatschek, a subsidiary of Rohrdorfer, heats local households using recovered heat from the Gmunden cement plant's waste heat recover (WHR) system.

A delegation of cement plant representatives and local officials from Baden-Württemberg, Germany, visited the plant to learn about its WHR and heat supply systems on 20 January 2022.

Plant manager Peter Fürhapter said "Municipal heating based on our waste heat contributes to CO₂ reduction in Upper Austria, helping us to achieve our CO₂ reduction goals under the Paris Climate Agreement." He added "We are pleased that with this forward-looking project we are a model for similar projects in Europe."

Thailand: ThyssenKrupp Polysius says that it has successfully supplied and installed a Prepol SC alternative fuels (AF) system at a 12Mt/yr cement plant in Thailand. The system will supply the plant's four lines with 4000t/day of AF.

ThyssenKrupp Polysius' Asia Pacific CEO Lukas Schoeneck said "Asia Pacific, with its tremendous municipal solid waste (MSW) problem, is ideal when it comes to replacing coal with AF. The Prepol SC technology significantly reduces the need to treat MSW before using the inherent calorific value. Additionally, it helps to further reduce the ambitious CO₂ limit targets in the region."

Germany: The German Cement Works Association (VDZ) has appointed Kristina Fleiger as the head of its new Climate-neutral Process Technology department. Stefan Schäfer has become the head of Environment and Industrial Engineering department. Both posts report to Volker Hoenig, who retains his position as the managing director of the VDZ.

Fleiger has worked for the VDZ in project management and engineering roles since 2011.

Schäfer was previously the VDZ’s Deputy Head of Environment and Plant Technology. He has worked for the VDZ since 1999.