Displaying items by tag: US

US: The Portland Cement Association (PCA) has releases a two-year forecast of moderate growth in cement consumption between 1 January 2020 and 31 December 2021. It projected growth of 1.7% in 2020, slowing slightly to 1.4% in 2021, corresponding to 2.1% and 1.7% GDP growth annually. Speaking at the 38th International Cement Seminar in Atlanta, PCA senior vice president and chief economist Ed Sullivan projected consumption growth of 1.6% - 2.3% in 2019 against GDP growth of 2.4% over the period, with consumption bolstered by the 2018 Federal Budget, which allowed for US$20bn in infrastructure investments in 2018 and 2019. He noted growing uncertainty (21% in 2019) with the expiry of the ‘pent-up demand zip that invigorates the initial stages of economic recovery long past.’

Rising house prices and mild inflation signify the continuation of the US economy’s longest expansion post-World War Two, with 161,000 net new jobs generated so far in 2019. With a forecasted population increase of 60m by 2040, US cement producers appears still have their work cut out in keeping up with demand.

US: The National Stone, Sand and Gravel Association (NSSGA) has honoured Cemex USA’s ‘exemplary use of environmental controls and systems’ at two quarries with its Environmental Excellence Gold Award. Its Center Hill quarry in Florida won a Community Relations Gold Award. Ten further aggregates operations won Silver or Bronze Awards in the Environmental Excellence or Community Relations categories. “We take pride in stewardship and serving as good neighbours in communities in which we operate and as examples others can emulate,” said Jaime Muguiro, Cemex USA president.

Microsoft co-founder Bill Gates entered the world of cement this week with a public relations blitz for Heliogen. He’s one of the backers of a new Californian technology startup looking to use concentrated solar power (CSP) to power heavy industrial processes like clinker or steel production. The company says it has concentrated solar energy commercially to levels above 1000°C.

Its process, called HelioMax, uses a closed-loop control system to improve the accuracy of a heliostat system. It says it achieves this by using computer vision software to better align an array of mirrors to reflect sunlight towards a single target. Temperatures of up to 1500°C is one of its targets so that it can apply itself to a variety of processes in the cement, steel, mining, petrochemical and waste treatment industries. It says it can do this for US$4.5/MCF. Another target once it hits 1500°C is to start manufacturing hydrogen or synthetic gas fuels.

Heliogen’s press release was picked up by the international press, including Global Cement, but it didn’t mention the similar work that SOLPART (Solar-Heated Reactors for Industrials Production of Reactive Particulates) project is doing in France. This project, backed by European Union Horizon 2020 funding, is developing a pilot scale high temperature (950°C) 24hr/day solar process for energy intensive non-metallic minerals’ industries like cement and lime. It’s using a 50kW solar reactor to test a fluidised bed system at the PROMES (PROcédés, Materials and Solar Energy) testing site in Odeillo, France.

Heliogen’s claim that it can beat 1000°C is significant here but it doesn’t go far enough. Clinker production requires temperatures of up to around 1450°C in the sintering phase to form the clumps of clinker. SOLPART has been only testing the calcination stage of clinker production that suits the temperature range it can achieve. Unless Heliogen can use its method to beat 1450°C then it looks likely that it will, similarly, only be able to cut fossil fuel usage in the calcination stage. If either Heliogen or SOLPART manage to do even this at the industrial scale and it is cost effective then the gains would be considerable. As well as cutting CO₂ emissions from fossil fuel usage in cement production this would reduce NO_x and SO_x emissions. It would also cut the fuel bill.

As usual this comes with some caveats. Firstly, it doesn’t touch process emissions from cement production. Decomposing limestone to make calcium oxide releases CO₂ all by itself with no fuel. About one third of cement production CO₂ emissions arise from fossil fuel usage but the remaining two thirds comes from the process emissions. However, one gain from cutting the amount of fossil fuels used is a more concentrated stream of CO₂ in the flue gas. This can potentially reduce the cost of CO₂ capture and utilisation. Secondly, concentrated solar power systems are at the mercy of the weather, particularly cloud cover. To cope with this SOLPART has been testing a storage system for hot materials to allow the process to work in a 24-hour industrial production setting.

Looking more broadly, plenty of cement producers have been building and using solar power to supply electricity. Mostly, these are photovoltaic (PV) plants but HeidelbergCement built a CSP plant in Morocco. Notably, PPC Zimbabwe said this week that it was building a solar plant to supply energy to two of its cement plants. It is doing this in order to provide a more reliable source of electricity than the local grid. India’s Birla Corporation has also said that it is buying a solar energy company today. The next step here is to try and run a cement plant kiln using electricity. This is exactly what Cementa, HeidelbergCement’s subsidiary in Sweden, and Vattenfall have been exploring as part of their CemZero project. The pilot study demonstrated that it was technically possible but only competitive compared with ‘other alternatives in order to achieve radical reductions in emissions.’

None of the above presents short or medium-term reasons for the cement industry to switch to solar power in bulk but it clearly deserves more research and, critically, funding. One particular strand to pull out here about using non-fossil fuel powered clinker production systems is that it produces purer process CO₂ emissions. Mounting carbon taxes could gradually force cement plants to capture their CO₂ but once the various technologies above become sufficiently mature they could bring this about sooner and potentially at a lower cost. In the meantime the more billionaires who take an interest in cement production the better.

US: Global Cement is exhibiting at the 36th International Cement Seminar & Exhibition taking place in Atlanta, Georgia. The long running cement equipment and technology event has returned after a lengthy break. Portland Cement Association (PCA) chief economist Ed Sullivan gave the keynote address at the conference with an industry forecast for 2020.

US: Cemex is looking to sell its majority stake in the Kosmos Cement plant at Louisville in Kentucky. Sources quoted by the El Financiero newspaper said that the integrated plant could be valued as high as US$750m. Cemex is working with Bank of America and Citigroup on the potential sale. Buzzi Unicem, through its subsidiary Dyckerhoff, owns the remaining stake in the plant. Cemex’s decision to try and sell the plant follows falling sales and profits for the Mexican building materials producer so far in 2019.

US: Heliogen, a new technology venture, says it has concentrated solar energy to exceed temperatures greater than 1000°C at its commercial plant in Lancaster, California. The company hopes to use the process to replace fossil fuels used in industrial cement, steel and petrochemical production processes. It is using computer vision software to align a large array of mirrors to reflect sunlight to a single target.

The company is based in Pasadena, California and is lead by Bill Gross, the founder of Idealab, a US technology startup incubator. Heliogen is supported by Parsons Corporation, a company that operates in defence, intelligence and critical infrastructure markets. Other backers include Bill Gates, the co-founder of Microsoft.

US: CalPortland has been awarded a US$175,000 grant from the Mojave Desert Air Quality Management District (MDAQMD) to replace a 1999 Terex Bore/Drill rig with a 2019 Caterpillar MD2650 drill. The new drill expects to see a 76% reduction on average in nitrogen oxides (NO_x), reactive organic gases (ROG) and particulate matter (PM) combined. The grant comes from the Carl Moyer Program, which provides monetary grants to private companies and public agencies to clean up their heavy-duty engines beyond legal requirements through retrofitting, repowering or replacing their engines with newer and cleaner ones.

US: Union workers at the Keystone Cement plant in Bath, Pennsylvania have started legal action against the company over its sale to HeidelbergCement. The American Federation of Labor and Congress of Industrial Organizations (AFL–CIO) union says that the company must honour its contracts, according to the Morning Call newspaper. It is representing around 132 workers at Keystone’s cement and aggregate operations.

According to the lawsuit, HeidelbergCement’s subsidiary Lehigh Hanson announced in October 2019 that it would not accept or assume the terms of any existing contracts. The union claims that this contravenes a requirement that any new owners or operators of the plant assume the contracts in place at the time of sale. The agreement to sell the plant to Germany’s HeidelbergCement for US$151m was announced in late September 2019. It is subject to regulatory approval.

US: LafargeHolcim subsidiary Lafarge North America’s Presque Isle quarry, which supplies raw limestone to its 2.6Mt/yr Alpena integrated cement plant – both in Michigan – has won the National Stone, Sand and Gravel Association (NSSGA)’s Gold Award in the Community Relations Excellence category. Business Wire has reported that it previously won Gold for Environmental Excellence in 2018. In recognition of its consecutive Golds, the NSSGA honoured the quarry with its prestigious Two Stars of Excellence award. LafargeHolcim’s operations in the country extend over 350 sites across 43 states. Its aim is to ‘help build better communities with innovative solutions that deliver structural integrity and eco-efficiency.’

US: Eagle Materials has reported financial results for the second quarter of its 2020 fiscal year, a period that ended on 30 September 2019. Its overall revenue was US$414.5m for the period, a 9% year-on-year improvement.

Revenues from its cement activities, including joint venture and intersegment revenue, were up by 18% to US$227m, reflecting improved sales volume and net sales prices. Cement sales volume for the quarter were a record 1.8Mt, up by 14% compared to the prior year quarter. Operating earnings from cement were also a record at US$66.5m, 16% higher than the same quarter a year ago. The earnings improvement was primarily due to higher sales volume and net sales prices.

Commenting on the second quarter results, Michael Haack, President and CEO, said, "We are proud to have achieved record revenue and net earnings per share for the second quarter of our 2020 fiscal year. Our second quarter performance was driven mostly by increased cement shipments, cost control initiatives and strong operational execution, as we capitalised on the robust underlying demand across our geographic footprint.”

Commenting on the remaining six months of its 2020 fiscal year, Haack said “The outlook continues to be positive. Demand for our building materials and construction products is supported by a number of favourable market dynamics including ongoing growth in jobs, high consumer confidence and low interest rates."