Displaying items by tag: VDZ

Germany: According to a new study backed by the German Cement Works Association (VDZ), the country's cement and lime industries require carbon capture and storage (CCS) for decarbonisation. The study outlines the need for a 4800km CO₂ transport pipeline in Germany by 2035.

The VDZ warns that any delay could jeopardise Germany's 2045 climate neutrality target and estimates the investment for the new CO₂ grid at €14bn. The network is expected to transport 6.5Mt/yr of CO₂ by 2030, increasing to 46Mt by 2045. Additionally, CCS transit from Switzerland, Austria and France is expected to contribute 15 - 20Mt.

VDZ president Christian Knell said "Cement manufacturers and other industries in the EU emissions trading system must produce largely climate-neutrally by 2040."

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.

This week’s Virtual Global CemPower Seminar included an assessment on how interventions in European power markets might affect efforts to decarbonise industry. The presentation by Thekla von Bülow of Aurora Energy Research outlined how different countries in the European Union (EU) were implementing the forthcoming electricity price cap on ‘inframarginal’ producers to 180Euro/MWh. Each of these different proposals will entail differing levels of structural change to the wholesale energy market. For example, the Agency for the Cooperation of Energy Regulators (ACER) has recommended establishing a series of frameworks including a stronger focus on Contracts for Difference (CfD) schemes to promote renewable energy sources.

These changes are a consequence of the EU’s response to the Russian invasion of Ukraine. Gas prices surged and then pushed up other energy prices in turn to record levels. As this column covered in September 2022, the price of electricity shot up in the summer of 2022 whilst at the same time Russian gas imports ceased. Cembureau, the European Cement Association, called for urgent action to be taken to support cement production due to large increases in the cost of electricity. For example, in its latest overview of the German cement industry, the German Cement Works Association (VDZ) said that the sector has an electrical consumption of 30TWh/yr. Clearly energy policy is of great interest to the industry.

Since then, in late September 2022, Heidelberg Materials’ chief executive officer Dominik von Achten told Reuters that his company was preparing to shift production at its Germany-based plants to times and days when power prices are lower including at the weekend. However, this was dependent on negotiations with the unions. Von Achten also warned of plant closures being a possibility. Then, in November 2022, it emerged that Zementwerk Lübeck’s grinding plant in northern Germany had reportedly been only operating its grinding plant at night and at the weekend due to high electricity prices. Also in November 2022 European energy news provider Energate Messenger reported that Heidelberg Materials was preparing its cement plants in Germany with emergency backup power to keep critical services running in the case of electricity power cuts. One view from the outside came from equipment supplier FLSmidth’s third quarter results where it noted it had, “...started to see the first cases of budget constraints imposed by customers to counter the increasing energy cost. A high utilisation is still driving service activity in Europe, but some customers have put large capital investments on stand-by and we have experienced a slowdown in decision-making processes.” On the other hand it also pointed out that this trend is driving sales of products that helped reduce energy usage and/or switch to alternative fuels.

On the financial side, Holcim reiterated in its half-year report that, on the country, level the group uses a mixture of fixed price contracts, long-term power purchase agreements, on-site power generation projects and increased consumption of renewable energy at competitive prices to reduce the volatility from its energy bills. Both Cemex and Heidelberg Materials said similar things in their third quarter results conference calls. Cemex said that nearly 70% of its electricity requirements in Europe were fixed in 2022 with nearly 30% fixed for 2023. It went on to reveal that around 20% of its total costs for cement production in Europe derived from its electricity bill. Interestingly, it added that a higher proportion of its electricity costs in Germany were fixed than elsewhere in Europe, due to the use of a waste-to-electricity system owned by a third party that is fed with refuse-derived fuel (RDF), but that it was more exposed to floating fuel rates in Spain. Heidelberg Materials added that it supported energy price caps in both Germany and the EU whether they affected it directly or not.

So far it has been a mild start to winter in Europe. This may be about to change with colder weather forecast for December 2022. This will stress test the EU’s energy saving preparations and in turn it could force the plans of industrial users, such as the cement sector, to change. Some of the cement producers have commented on the financial implications of rising fuel costs but they have been quieter publicly about how they might react if domestic consumers are prioritised. Plant shutdowns throughout cold snaps are the obvious concern but it is unclear how likely this is yet. The variety of energy policies between fellow member states, their own supply situations and the differences between cement plants even in the same country suggest considerable variation in what might happen. If large numbers of cement plants do end shutting throughout any colder periods, then one observation is that it will look similar to winter peak shifting (i.e. closure) of plants in China. The more immediate worry in this scenario though is whether these plants actually reopen again.

The proceedings pack from the Virtual Global CemPower Seminar is available to buy now

Germany: KHD hosted a meeting of the research and development consortium of the ACCSESS project in Cologne on 18 and 19 October 2022. The consortium is intended to develop replicable carbon capture utilisation and storage pathways to support a net zero strategy in Europe by 2050. KHD’s involvement with the project concerns running engineering feasibility studies for the retrofit of CCUS projects at two cement plants in Europe. It is also working on the concept development for a new clinker production technology, which is optimised as a new plant for operation with downstream carbon capture technology.

Other project partners working on ACCSESS of note to the cement sector include Heidelberg Materials and the German Cement Works Association (VDZ). Project completion is scheduled for mid-2025 with KHD’s contributions to be delivered by mid-2024.

Argos Honduras revealed this week that it has been testing the injection of hydrogen into the kiln of its integrated Piedras Azules cement plant. It has completed a pilot with Portugal-based company UTIS. As part of the process it has been trialling, it has split water by electrolysis and then injected the hydrogen and oxygen directly into the kiln via the main burner. The pilot has reportedly increased clinker production and reduced petcoke consumption at the plant.

Argos is far from alone in using hydrogen in this way. At the end of August 2022 Cemex said that it was also starting to use hydrogen at its San Pedro de Macorís cement plant in the Dominican Republic. CRH UK-subsidiary Tarmac completed a trial in July 2022 using hydrogen as an alternative to natural gas at its Tunstead lime plant. HeidelbergCement UK-subsidiary Hanson also ran a successful trial using hydrogen as part of the fuel mix at its Ribblesdale cement plant in 2021. The government-funded trial used a combination of hydrogen (39%), meat and bone meal (12%) and glycerine (49%) to reach a 100% alternative fuels substitution rate. In 2021 Hanson reported that fuel switching to hydrogen could help it reduce its 2050 CO₂ emissions by about 3%, or by -35kg CO₂/t of cement product.

Cemex appears to be a leader in using hydrogen in this way. The Mexico-based company started injecting hydrogen in 2019 and retrofitted all of its European cement plants with the technology to do so in 2020. It then said it wanted to roll this out to the rest of its operations. The project in the Dominican Republic is an example of this. In February 2022 it announced an investment in HiiROC, a UK-based company that has developed a method using thermal plasma electrolysis to convert biomethane, flare gas, or natural gas into hydrogen. The stated aim of this investment was to increase Cemex's hydrogen injection capacity in its cement kilns and to increase its alternative fuel substitution rate. Back in 2020 Cemex said that it planned to use hydrogen injection to contribute 5% of its progress towards its 2030 CO₂ emissions reduction target along with other measures such as increasing its thermal substitution rate and reducing its clinker factor.

As can be seen above there are a number of examples of hydrogen injection being used in cement plants in Europe and the Americas. However, there is very little actual data available publicly at this stage on how much hydrogen that the plants are actually using. For example, Cemex may have hydrogen injection equipment installed at all of its plants in Europe but it is unclear how many plants are actually using it. This is understandable though, given how commercially sensitive the fuel mix of a cement plant is and in Cemex’s case if it wishes to maintain a leader’s advantage in using a new technology.

It is interesting to see, in what has been released so far, the focus on doing deals with companies that supply electrolysis technology such as HiiROC and UTIS. A feasibility study ahead of the Hanson trial at Ribblesdale by the MPA, Cinar and the VDZ suggested that upgrading a kiln burner and adding all the necessary hydrogen storage and pipework could cost at least Euro400,000. However, this study also pointed out that the cost of hydrogen made a big difference to the cost of the CO₂ saving from using it as an alternative fuel. Hence the focus on the technology partners. It will be interesting to see how many more hydrogen injection projects are announced in the coming months and years and, crucially, who is providing the technology to supply the hydrogen.

For more information on the use of hydrogen in cement production see the proceedings from the 15th Global CemFuels Conference & Exhibition where presentations on the topic were given by Cemex and the VDZ

Argos USA announced this week that its integrated Roberta plant in Alabama is set to produce 100% Portland limestone cement (PLC) by June 2022. As part of the transition three of its terminals in North Carolina will also switch over at the same time. The company also expects that all of its plants will convert to PLC in 2023. Cement sites including Newberry in Florida, Harleyville in South Carolina and Martinsburg in West Virginia are already producing PLC.

The change by Argos marks the latest example in an ongoing trend of US-based cement companies moving entire plants to PLC production. In September 2021 LafargeHolcim US said that its integrated Midlothian plant in Texas was preparing to convert to full PLC production and that it would be the first plant in the US to do so. It later confirmed that the plant had done so by the end of 2021. In October 2021 GCC said that its Trident Plant in Montana would fully move to PLC in early 2022. Then in November 2021 Titan America said that its Pennsuco cement plant in Florida would make the change possibly by 2023. Moving into 2022 brought the news that LafargeHolcim US’ Ste. Genevieve plant in Missouri and its Alpena plant in Michigan had each transitioned to PLC production. Lehigh Hanson then rounded up the bunch earlier this month, at the start of February 2022, when it announced that a PLC was the primary product now coming out of its Mason City plant in Iowa. It even invited a US Member of Congress to celebrate!

The current expansionist phase of PLC usage in the US dates back to late 2020 when the Portland Cement Association (PCA) launched a dedicated website to promote the use of the blended cement by discussing its applications and benefits. It then released a new environmental product declaration in March 2021 and PLC received a mention in the PCA’s Roadmap to Carbon Neutrality when it was released a year later in October 2021. Lots of work went into PLC prior to 2020 though, both by the PCA and others. The first commercial production of PLC in the US started in 2005 and PLC gained its own blended cement specification in 2012. Notably, the PCA has been tracking the state acceptance of PLC by the Department of Transportation and it grew markedly during the 2010s.

The US is playing catch-up with PLC. In Europe its usage dates back to the 1960s. Cembureau, the European Cement Association, reported usage of around 30% in 2004. More recently in 2020, the VDZ, the German Cement Association, reported a similar figure domestically with the proportion of blended cement shipments including limestone, shale and multiple additives at 31.6%. In the US it is hard to gauge the scale of the current move towards PLC by producers, due to limited publicly available data. A PCA survey reported PLC production of 0.89Mt in 2016. If all the plants mentioned above convert fully to PLC and maintain their rated production capacity that would be something like 14Mt/yr of PLC in 2023 or 11% of the US’s total cement capacity. For comparison, the United States Geological Survey (USGS) reported total shipments of all blended cements at 3.3Mt in 2020 and a total of 5.4Mt for the first 11 months of 2021. Plus, remember that PLC is just one blended cement among others, like those that use slag or fly ash.

Recent developments show that a large change is coming towards the US cement market in the update of blended cements. It’s been a long time coming but the last six months have seen brisk increases in PLC production at scale. The exact data is not available but one might expect something around triple the current number of production plants making PLC if the US market heads towards European levels. This rough estimate doesn’t take into account existing partial PLC production levels. At the same time the US cement sector should see a fall in its emissions due to PLC’s 10% reduction in CO₂ emissions compared to ordinary Portland cement

Germany: The German Cement Works Association (VDZ) has lobbied national and European Union governments for ‘appropriate and reliable’ framework conditions for the industry’s to realise its sustainability objectives. Its Environmental Data of the German Cement Industry 2020 report set out the sector’s agenda under three overlapping headings: climate neutrality by 2050, preservation of primary raw materials and air pollution control. The VDZ said that government support for the necessary ‘unprecedented’ reduction in CO₂ emissions will be especially vital in the area of renewable power and the creation of a functioning CO₂ infrastructure.

VDZ president Christian Knell said “The often bureaucratic and complex processes involved in approval procedures and applications for funds to finance necessary investments are a cause for concern.”

Germany: The German Cement Works Association (VDZ) has published a study entitled ‘Decarbonising cement and concrete: a CO₂ roadmap for the German cement industry,’ detailing the planned transformation to cement industry-wide carbon neutrality by 2050.

The study says that a decarbonisation scenario based on conventional reduction measures would cut carbon dioxide (CO₂) emissions by 36% between 2019 and 2050. Chief executive officer (CEO) Martin Schneider said that the sector is already “reaching the limits of its potential for any further reduction in the volume of CO₂, particularly as the process-related emissions specifically associated with clinker production cannot be lowered by employing conventional means." As such, the association proposed a “completely new approach to the production of cement and its use in concrete” in order to realise full climate neutrality. It proposes that cement producers help to reduce concrete’s clinker factor, capturing the remaining CO₂ from necessary cement production.

Schneider said, "We have placed the decarbonisation of cement and concrete at the heart of our activities. It will be essential to achieve an integrated approach, incorporating the entire construction value chain.” In order for this more radical scenario to work, he added, “Another essential factor will be to involve society as a whole in this process."

There has been good news from the German Cement Works Association (VDZ) this week. Following a strong start to the year, the association expects cement consumption in 2020 to remain similar to the level, 28.7Mt, reported in 2019. VDZ president Christian Knell acknowledged the difficulty in making forecasts, this year of all years, but said that the association remained positive since demand had held up so well. He noted the continued operation of construction sites, despite the local coronavirus-related lockdown from March 2020, and the ‘quick action’ of politicians.

Graph 1: German cement deliveries, 2015 – 2019: Source: German Cement Works Association (VDZ).

The year certainly started well, with a 33% year-on-year increase in domestic cement deliveries to 1.43Mt in January 2020 from 1.07Mt in January 2019. This was due in part to good weather, although it also looks good because 2019 started badly compared to 2018. Yet, the VDZ’s assessment has been supported by the results of the main producers operating in the country. HeidelbergCement reported that Germany bucked the trend of its Western and Southern Europe Group area in the first half of 2020 with a ‘positive market development’ whereas deliveries declined significantly everywhere else. Similarly, LafargeHolcim noted a ‘resilient’ performance in Germany. Buzzi Unicem released a more detailed assessment, with shipments of hydraulic binders down in April and May 2020 but then back up with a recovery in June 2020. Overall its cement plants reported a slight decline in sales for the first half of the year. Concrete production grew however, by 6% year-on-year, possibly aided by the plants that the group purchased in 2019.

Germany’s success appears to be down to two factors. The first, as Knell mentioned above, is that it was able to keep much of its construction industry open through its lockdown. Dieter Babiel, the head of Hauptverband der Deutschen Bauindustrie – the main German construction industry association - reckoned that the industry was operating at about 80% capacity in May 2020 compared to the situation in other large European countries like France, the UK, Spain and Italy where building sites totally closed at the height of local lockdowns before gradual reopening. Bauindustrie has since reported falling monthly order intake as coronavirus-effects on the general economy filter through to construction. The other reason is that the country has managed to control its outbreak better compared to other European countries. It has reported the third most cases in Europe but its fatality rate is only 4% compared to 14% in the UK, Italy and France. This has been attributed to strong public health measures and high levels of testing, particularly with respect to elderly residential care.

It’s not all plain sailing though since the International Monetary Fund (IMF) has projected a 7.8% decline in Germany’s gross domestic product (GDP) in 2020. Likewise, the VDZ is predicting weakening construction markets and cement demand in the fourth quarter of 2020. It cited falling orders and requests for building permits as mounting evidence for this trend. From here a gloomier outlook is foreseen for 2021 as construction budgets for commercial and government projects are cut. At the same time uncertainty in the labour market is expected to drag down the residential market. With this in mind the VDZ is predicting cement demand to drop by 3 – 5% in 2021.

To end on an upbeat note, if the VDZ’s forecasts are accurate, then the German cement sector looks like it might weather the coronavirus-downturn better than other industries. It knows a downturn in construction is coming and it can prepare for it.

Germany: The Verein Deutscher Zementwerke (VDZ) has forecast domestic cement consumption of 28.7Mt in 2020, consistent with the 2019 level. The impacts of the coronavirus lockdown were offset by “a good start to the year, not least due to the weather conditions” and “the continued operation of construction sites in March thanks to the quick actions of politicians.”

The organisation said that the situation was unprecedentedly unpredictable with orders and building permits currently in decline. It expects demand to partly tail off in the fourth quarter of 2020, falling by between 3 - 5%, as companies postpone or discard planned developments in the face of restricted budgets. It said, “Nonetheless, the government’s economic stimulus pacts will undoubtedly provide a positive impetus through such initiatives as public infrastructure and multi-family housing projects.