Displaying items by tag: UK

UK: Heidelberg Materials subsidiary Hanson has awarded a contract to Mitsubishi Heavy Industries subsidiary MHI Engineering for installation of a planned 800,000t/yr carbon capture system at its Padeswood cement plant in Flintshire. The producer plans to store its captured CO₂ in exhausted Irish Sea natural gas fields. MHI Engineering will carry out a pre-front-end engineering design study using its Advanced KM CDR solvent-based process. The supplier developed the process jointly with fellow Japan-based company Kansai Electric Power.

The project will be MHI Engineering's third of its kind at a cement plant, following similar commissions with Lehigh Cement in Canada and Tokuyama Cement in Canada.

UK: Germany-based Heidelberg Materials has signed a deal for the acquisition of Mick George Group, the leading concrete recycling company in the East Midlands and East of England. Mick George Group’s 40 sites span bulk excavation, earthmoving and demolition services and demolition waste removal and management, as well as ready-mix concrete and aggregates distribution.

Heidelberg Materials Western and Southern Europe director Jon Morrish said “With the acquisition of Mick George, we are clearly moving towards establishing a truly circular materials and services offer in our UK business. I warmly welcome all 1000 Mick George employees to Heidelberg Materials and look forward to further developing the business together.”

Heidelberg Materials aims to offer circular alternatives for half of its products by 2050.

UK: Oscrete UK has appointment three new sales managers and two new trainee concrete technicians as part of on-going growth at the company. David Todd has joined as Area Technical Sales Manager (North), David Taylor as Area Sales Manager (Midlands) and Karl Mobley Area Technical Sales Manager (South East). Keiron and Michael Todd have joining the new product development (NPD) and technical team. Todd worked previously as an account manager for Cemex.

Oscrete is a specialist construction chemical suppliers, manufacturing a range of concrete admixtures for the pre-cast and ready-mix market and developing and supplying additives for the manufacture of dry bagged mortars and adhesives.

UK: C-Capture won an IChemE Global Award in the Energy category for its solvent-based carbon capture system. C-Capture's model differs fundamentally from currently commercially available systems, offering a lower energy penalty than technologies including amine-based capture. It is robust in handling impurities in flue gases, including O₂, SO_x and NO_x, while offering competitive cost and safety performance.

CEO Tom White said “Being shortlisted was honour enough, but to win the global Energy award is fantastic recognition for the C-Capture team and our unique carbon capture technology. The IChemE Global Awards represent the pinnacle of excellence in chemical process engineering. This achievement is testament to our exceptional team and their commitment to accelerating the global adoption of carbon capture and storage to achieve net zero by preventing greenhouse gases from entering the atmosphere.”

UK: The Mineral Products Association (MPA) has appointed Jon Flitney, Michael Conroy, Liam Forde, Steve Callow and Mike Haynes to new roles at the organisation. This follows the appointment of Jon Prichard as the MPA’s chief executive officer in October 2022, succeeding Nigel Jackson.

Jon Flitney has joined MPA Cement as Energy and Climate Change Manager. He will be working with the MPA Cement Climate Change and CO2 Reduction group providing support to sector decarbonisation and associated policies. Flitney joins from the British Ceramic Confederation (BCC) where he has worked across energy, environment, climate change and decarbonisation policy areas for over six years. He also previously worked on air quality and environmental protection for local authorities and the Environment Agency, covering a variety of manufacturing industries.

Michael Conroy joins as Manager - Environment, Safety & Regulatory Affairs for MPA Cement. He has over 20 years’ experience in the mineral products industry and ,since 2016, this has been focussed on environmental management, compliance, permitting and regulation across various sectors within the industry. His role at MPA involves working with members in the cement sector and liaising with the environmental regulators and relevant government departments on behalf of the members to ensure the sector is recognised in a positive and beneficial way. He is secretariat for the Cement Regulatory Interface Group (RIG), which meets regularly to discuss environmental regulatory matters that affect and impact the UK cement sector.

Liam Forde has joined BRMCA/MPA Ready-mixed Concrete as Construction Manager. His main responsibilities will be working with MPA members, the Concrete Centre and UK Concrete to promote safety, best practice, and ready-mixed concrete as the best solution for sustainable and resilient construction. Forde is a chartered civil engineer and joins from BAM Nuttall having had a background in both design and site environments.

Steve Callow has joined as Manager, Masonry and Concrete Products. He joins from Marshalls where he was Specification Manager. He also has sector experience gained from roles in FP McCann, CPM, Milbury Systems and Carillion.
Mike Haynes has joined MPA as British Lime Association Director. He joins MPA after 18 years in the lime industry working in the sales and customer services teams responsible for Construction and Civil Engineering markets and progressing to managing the customer services team. Prior to this, Haynes worked for contractors and consultants in those markets, as an engineer and project manager.

UK: Hanson has announced a 'carbon capture breakthrough' in its use of recycled concrete paste (RCP) in the wet scrubber of its Ribblesdale cement plant in Lancashire. In under 30 minutes, 15t of RCP was able to capture 1.5t of CO₂ from the plant's flue emissions. Carbonated RCP is suitable to replace limestone in cement production.

Hanson's sustainability director Marian Garfield said “The trial was carried out with our parent company Heidelberg Materials’ research and development team, and marks another important milestone in our carbon capture journey."

South Korea: UK-based TCRK has announced a deal with Asia Cement to use its carbon capture and utilisation (CCU) technology at the cement producer’s plant in Jaechon. The project will see the first commercial deployment of TCRK’s CCUS technology from the first quarter of 2023. It will initially target 30,000t/yr of CO₂ equivalent and then ramp up to 120,000t/yr of CO₂ equivalent by mid-2024. The second target is intended to help Asia Cement reduce its emissions by 20% required to meet its 2025 decarbonisation plan.

TCRK’s approach will use two processes to utilise capture CO₂ from cement production. Its Arago Cement Process uses captured CO₂, cement kiln dust and by-pass particles to produce precipitated calcium carbonate, which TCRK uses to produce a product called Arago Cement. The captured CO₂ will also be used to grow microalgae in a process called bio-fixation. This method will offer 10% extra carbon storage capacity. The microalgae has a wide range of potential end-products including bioplastics and animal feed, and can also be used as a source of bio-cement production.

UK: Cookstown Cement has rebranded as Cemcor. The company formed in January 2022 following its acquisition of the 0.45Mt/yr Cookstown cement plant from Holcim in January 2022. It then announced investments of around Euro14m towards making environmental and process upgrades at the unit. The company also purchased a limestone quarry in Cookstown, a shale quarry in Dungannon and a terminal at Belfast Harbour.

UK: RealWear has launched the world’s first voice-controlled head-mounted thermal camera. The new product combines the supplier's RealWear thermal camera and RealWear Navigator 500 headset with Teledyne FLIR's Lepton radiometry technology, enabling effortless capture of visible-spectrum and thermal imagery. Cement plant operators can then quickly identify temperature anomalies in mission-critical equipment like pumps, pipes, wiring and motors.

Chief Product Officer Rama Oruganti said “RealWear Navigator head-mounted devices, with a revolutionary modular design, continue to gain support with global 1000 companies as the new gold standard in assisted reality. The compelling option to add thermal image capture without occupying your hands in hazardous environments gives frontline professionals more real-time information to do their jobs safely and productively.”

In 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