Displaying items by tag: Tarmac

In the two and a half years since Calix brought together cement producers across corporate and national boundaries to form the first Low Emissions Intensity Lime And Cement (LEILAC-1) consortium and commissioned a carbon capture installation at the Lixhe cement plant in Belgium on 10 May 2019, carbon capture and storage (CCS) has passed some major milestones. New installations have made Global Cement headlines from Canada (at Lehigh Cement’s Edmonton plant in November 2019) to China (at a China National Building Material (CNBM) plant in July 2021). Twelve other European cement plants now host current or planned carbon capture trials – including the first full-scale system, at HeidelbergCement’sBrevik plant in Norway. A second Calix-led project in Germany, LEILAC-2, attracted Euro16m-worth of funding from the European Union in April 2020.

The work of LEILAC-1 – backed by HeidelbergCement, Cemex, Lhoist, Tarmac and others, with Euro12m in funding – set the benchmark in innovation. Its pilot plant successfully captured 100% of 'unavoidable' process emissions by indirectly heating raw materials inside a vertical steel tube. Called direct capture, the model removes a CO₂ separation step, as our subsequent price analysis will reflect.

In October 2021, the LEILAC-1 consortium published its report of the concluded Lixhe trial. It described the three-fold key successes of the study:

1) Both limestone and raw meal may be processed;

2) CO₂ is successfully separated;

3) The energy penalty for indirect calcination is not higher than for conventional direct calcination.

Additionally, Calix’s first departure into the cement sector has demonstrated that its model exhibits no operational deterioration, does not suffer from material build-up and has no impact on the host plant when used in cement production. The plant’s clinker capacity remained the same as before the trial. Most importantly of all, the Lixhe cement plant recorded no process safety incidents throughout the duration of the trial.

The study has also put an evidence-based price tag on industrial-scale CCS at a cement plant for the first time: Euro36.84/t. Figure 1 (below) plots the full-cycle costs of three different carbon capture installations at retrofitted 1Mt/yr cement plants using 100% RDF, including projections for transport and storage. Installation 1 is an amine-based carbon capture system of the kind installed in the Brevik cement plant’s exhaust stack; Installation 2 is the Calix direct capture system and Installation 3 consists of both systems in combination. Direct capture’s costs are the lowest, while the amine retrofit and the combination installation are close behind at Euro43.68/t and Euro43.25/t respectively.

Figure 1: Full-cycle costs of three different carbon capture installations at retrofitted 1Mt/yr cement plants using 100% RDF

Installations 1 and 3 both entail additional energy requirements for the separation of CO₂ from flue gases and air. With the inclusion of the CO₂ produced thereby, the cost of Installation 1 rises to Euro94/t of net CO₂ emissions eliminated, more than double that of Installation 2 at Euro38.21/t. The combination of the two in Installation 3 costs Euro67.3/t, 76% more than direct capture alone. Figure 2 (below), breaks down the carbon avoidance costs for each one and compares them.

Figure 2: Carbon avoidance costs of three different carbon capture installations at retrofitted 1Mt/yr cement plants using 100% RDF

The Global Cement and Concrete Association (GCCA)’s seven-point Roadmap to Net Zero strategy puts CCS at the forefront of concrete sector decarbonisation. CCS is expected to eliminate an increasing share of global concrete’s CO₂ emissions, rising to 36% in 2050 – by then 1.37Bnt of a total 3.81Bnt. This will depend on affordability. Calix’s model has reduced the capital expenditure (CAPEX) of a carbon capture retrofit by 72% to Euro34m from Euro98m for the amine-based equivalent. When built as part of a new plant, the CAPEX further lowers to Euro27m. Both models may also be retrofitted together, for Euro99m. In future, Calix expects to install direct capture systems capable ofachieving Euro22/t of captured CO₂. By contrast, the cost of emitting 1t of CO₂ in the EU on 11 October 2021 was Euro59.15.

In what it calls the Decade to Deliver, the GCCA aims to achieve a 25% CO₂ emissions reduction in global concrete production between 2020 and 2030, in which CCS plays only a minor part of less than 5%. LEILAC-1 presents a visionof affordable carbon avoidance which complements cement companies’ 2030 CO₂ reduction aspirations.

Unlike conventional CCS methods, however, direct capture only does two thirds of a job – eliminating the emissions of calcination, but not combustion. This would appear to make it unsuited to cement’s longer-term aim of carbon neutrality by 2050 in line with the Paris Climate Accords’ 2°C warming scenario. On the other hand, direct capture is not designed to work alone. Calix recommends use of the technology in conjunction with a decarbonised fuel stream to eliminate the plant’s remaining direct emissions. This increases the price - by 47% to Euro56.05/t of CO₂ avoided for biomassand by more than double to Euro104.48/t for an E-kiln.

The Lixhe cement plant’s carbon capture story is one of a successful crossover from one industry into another: Calix previously applied the technology in the Australian magnesite sector. Realisation of the Calix carbon capture vision in the global cement industry is a challenge primarily due to the scale of the task. It will require continued collaboration between companies and with partners outside of the industry. Further than this, parliaments must continue to enact legislation to make emission mitigation the economic choice for producers.

UK: Tarmac has completed a seven-week repair job on its PC2000 backhaul excavator at its Dunbar, East Lothian, quarry. The East Lothian Courier newspaper has reported that the work consisted of a rebuild of all major components, including the 11t bucket, pins and bushes. The equipment has been in service since 2014. It will next require servicing in 2026. Marubeni Komatsu carried out the work.

Quarry manager Mark Grieve said “With the excavator playing an absolutely key role in our process, this was a major project for Tarmac Dunbar.”

UK: Archaeologists have completed the excavation of a 52-grave cemetery dated to 3rd century Roman Britain at Ireland-based CRH subsidiary Tarmac’s Knobb’s Farm quarry in Cambridgeshire. The company said that the find is remarkable for its high proportion of decapitated bodies (33%), indicating the proximity of an execution site. The graveyard is situated near a settlement on a peninsula in the Fens wetland area. The settlement itself is lost to the quarrying activities of the previous owner.

UK: Tarmac has renewed its partnership with the Peak District National Park until 2026. Under the partnership, the company organises volunteering and funds an engagement conservation job role at the national park in Derbyshire. Since 2016, volunteers from Tarmac’s Tunstead quarry have built dry stone walls, restored a footbridge and helped to manage ancient hay meadows. In several areas of the park, volunteers have also replaced benches.

Tunstead quarry stone and powders director Pete Butterworth said that he was ‘delighted’ about the renewal. He added, “By sponsoring the engagement role, we also enable many people to get involved in practical projects which make a significant contribution to the maintenance and improvement of this beautiful area.”

UK: Tarmac, part of Ireland-based CRH, has relocated reptiles to purpose-built bespoke habitats at its Bellhouse, Essex, quarry. The reptiles lived in an area of planned quarry expansion. Work began in 2016 on the new habitat for grass snakes, common lizards and slow worms, consisting of acid grassland, tussocks and ponds. The company plans to expand the reserve under its site restoration process. It says that this will enable reptile populations to grow.

Restoration manager Enrique Moran Montero said, “The restoration phase of a quarry provides so many opportunities to promote local fauna and flora, and we pride ourselves in making the most of this land. From nature reserves to parks and wildlife learning zones for schools to use, we always strive to provide benefits for local wildlife as well as the communities we work in.”

UK: CRH subsidiary Tarmac has appointed Chris Bradbury as the plant manager at its integrated Dunbar cement plant in East Lothian, Scotland. He previously worked at Tarmac’s Tunstead plant in Derbyshire. Bradbury began working in the cement industry as an apprentice in 1994 and has held many roles at plants both in the UK and in Nigeria and the Philippines.

UK: HeidelbergCement subsidiary Hanson has appointed Michael Wildmore as the technical development manager for its cement business. He holds over 30 years’ experience in senior technical and quality management roles in the building materials industry, according to Construction Index.

Wildmore joined Hanson UK, part of the HeidelbergCement, as a technical sales advisor in January 2020 having previously spent five years with Tarmac, latterly as technical manager at Tarmac Building Products. Before that, he worked for 20 years with Redland and subsequently Lafarge and LafargeHolcim after acquisitions and mergers. He is an associate member of the Institute of Concrete Technology and is on technical committees of the Mineral Products Association (MPA).

UK: The Mineral Products Association (MPA) has appointed Jeremy Greenwood as the Chair of UK Concrete. He will work with Chris Leese, the Director of UK Concrete, to coordinate the work of the Concrete Centre, MPA Cement, British Ready-mixed Concrete Association (BRMCA) and British Precast on the roadmap the sector is implementing to go ‘Beyond Net Zero by 2050.’ Greenwood previously worked for Tarmac as its managing director, having been at the company since 1988.

UK: CRH subsidiary Tarmac has announced its renewal of multiple contracts for transportation of its products by rail, effective until 2025. The contracts - with Colas Rail UK, GB Rail Freight, Freightliner and DB Cargo - cover the shipment of 9.0Mt/yr of cement and building products.

Head of rail Chris Swan said, “The renewal of these contracts highlights both our on-going commitment to supporting the delivery of a lower-carbon built environment and the continued enhancement of our rail freight capabilities. Effective use of the rail freight network is key in supporting the UK’s transition to a net-zero society and supporting a green recovery as we emerge from the Covid-19 crisis. Collaborative working has a vital role to play in this and we are looking forward to working with our freight operating partners as the industry focuses on increasing the volumes of material moved by rail, as well as enhancing efficiencies and service.”

UK: The Mineral Products Association (MPA) has appointed Simon Willis as its chairman for the next two years. He succeeds Martin Riley, Senior Vice President at Tarmac, as the eighth incumbent in the role. Willis is currently the chief executive officer (CEO) of HeidelbergCement subsidiary Hanson UK. He holds experience in the aggregates and construction materials industry and has held previous directorship roles at Eurovia Infrastructure, Midland Quarry Products and Tarmac.