Displaying items by tag: filters

Delegates at the Global CemCCUS Conference last week applauded when Anders Petersen, the Senior Project Manager Brevik CCS, Heidelberg Materials said that the Brevik cement plant will be capturing CO₂ and permanently storing it within the year. Rightly so. This moment will mark a historic milestone for the sector when it arrives. Net zero cement production is coming.

Last week’s event in Oslo delivered an overview of the current state of carbon capture in the cement and lime industries. It explored the practical challenges these industries face in capturing CO₂ emissions and - crucially – then working out what to do with them afterwards. Incredibly, delegates were able to view the construction site of Heidelberg Materials’ forthcoming full-scale carbon capture unit at its Brevik plant in Norway. On the same day as the tour, Holcim broke ground on the Go4Zero carbon capture project at its Obourg plant in Belgium.

The key takeaway at the conference was that a (dusty) bulk solids sector is starting to work with handling (clean) gases in a way it hasn’t before. This recurred repeatedly throughout the conference. Petersen summarised it well when he described Brevik as a meeting pointing between the cement industry and the petrochemical one. It looks likely at present that there will not be a single predominant carbon capture technology that the majority of cement plants will deploy in the future. Similarly, CO₂ storage infrastructure and sequestration sites differ. Utilisation plans are less developed but also offer various options. Yet, if carbon capture becomes common at cement and lime plants, then these companies will need to learn how to filter and handle gases regardless of the capture method and destination for the CO₂. So presentations on filtration and compressors were a revelation at CemCCUS.

The key obstacle remains how to pay for it all. By necessity, most of the big early projects have received external funding, mostly from governments. Although, to be fair, the private companies involved are often investing considerable amounts of their own money and taking risks in the process too. In the European Union (EU) CO₂ is being priced via the Emissions Trading Scheme and investments are being made via the EU Innovation Fund and other schemes. In the US the approach lies in tax breaks, on-shoring and investment in new sustainable technologies.

However, other countries have different priorities. Or as a South Asian contact told Global Cement Weekly at a different conference, “How can our government think about sustainability when it can’t feed everyone?” The world’s biggest cement producing countries are China and India, and then the EU and the US follow. Brazil, Türkiye and Vietnam are at similar levels or not far behind. The EU and the US represent about 9% of global cement production based on Cembureau figures for 2022. China and India cover 61% of production. Neither of these countries has announced a plan to encourage the widespread construction of carbon capture units. Once China ‘gets’ cement carbon capture though, it seems plausible that it will dominate it as it has in many other sectors such as solar panel production. Exporters such as Türkiye and Vietnam will have to adapt to the rules of their target markets.

The march by the cement and lime sectors towards carbon capture has been long, difficult and expensive. It also has a long, long way to go. Yet, the next decade promises to be exciting as new technologies are developed and tested, full-scale projects are commissioned and CO₂ pipelines, sequestration sites and usage hubs come online. The next key milestones to look out for include the first full-scale installations using other capture methods (such as oxy-fuel kilns), the first CO₂ pipeline network that hooks up to a cement plant, the first land-based sequestration site, the first industrial hub that uses CO₂ at scale to manufacture a product, new government policies in China and India, and the first large unit that is funded entirely from private finance. To end on a positive note, a Cembureau representative at the Global CemCCUS Conference reckoned that Europe will be able to capture 12Mt/yr of CO₂ by 2030. If it happens, this will be a major achievement and a serious statement of intent towards net zero for the sector.

This short recap of the event barely touches the surface of what happened so be sure to read the full review of the 1st Global CemCCUS Conference.

The 2nd Global CemCCUS Conference will take place in Hamburg in May 2025

UK: Aggregate Industries subsidiary Lafarge Cement has begun installing a new Euro10m bag filter system at its 1Mt/yr Cauldon cement plant in Staffordshire. The project is due for delivery in early 2024. The system consists of 2080 fabric bags to remove particulates from the plant's flue gases. It will replace the plant's existing electrostatic precipitation system. The company says that the system will triple the removal rate of particulates, reducing them to 10mg/Nm³ from 30mg/Nm³.

Cauldon cement plant manager Thierry Davila said “The installation of the new system will help us provide a step change in our efficiency and effectiveness, and optimise kiln performance. The plant and our operations will hugely benefit from up-to-date technology, which will result in more consistent running of the site, but also it will improve environmental performance and benefit the local community. The new filter system will mean less dust and emissions into the atmosphere and a reduction in pollutants, which is hugely positive and in line with our approach to sustainability.”

Syria: Abdul Qader Jokhadar, the Minister of Industry, has cited using Iran-based expertise in developing filtration system in cement plants to reduce emissions as an example of how the two countries can cooperate. Jokhadar met with Morteza Shahmirzaei, the director of the General Company for Petrochemical Industries and deputy to the Oil Minister of Iran, to discuss industrial development, according to the Syrian Arab News Agency. Other areas of collaboration include manufacturing electric batteries, agricultural machinery, tyres and optical cables.

Germany: Hengst Filtration has appointed Norbert Gregor as the group director of Hengst Group and the managing director of Industrial Air Filtration. He assumes his duties in a dual leadership role with Merete Gotfredsen, who leads the Process Air Filtration segment as its managing director. Both report directly to Peter Wink, Group Vice President for Industrial Air Filtration.

Gregor is a business economist who holds more than 25 years of management experience with a specialism in marketing and sales. From 2014, he was Vice President for DACH (Germany, Austria and Switzerland) and Eastern Europe at the Sweden-based filter specialist Camfil. In 2019, he moved to the Helsa Group as its chief executive officer, for which he was the managing director and realigned the two business units for molecular filtration (Helsatech) and elastomer technology (Helsacomp), which he sold to Mann+Hummel after a reorganisation. There, as Global Vice President, he was responsible for the post-merger integration of Helsa for two years, creating the new molecular filtration segment for the Life Science division for Mann+Hummel.

Argentina: Loma Negra has completed the replacement of an electrostatic filter at its integrated Zapala cement plant in Neuquén with a new baghouse filter. The Gaceta Mercanil newspaper has reported that the company said that the new product has the benefit of being able to work without an electricity supply. Additionally, it is able to operate at higher inlet temperatures than the previous filter, reducing water consumption by approximately 50%. Work began in early 2019 and the total investment cost of the project was US$7m.

Nigeria: LafargeHolcim subsidiary Lafarge Africa plans to invest US$8m on an upgrade to the electrostatic precipitator filters at the bagging plant at its Ewekero cement plant. The Punch newspaper has reported that the upgrade requires a six-month shutdown of the unit’s kilns to make the changes. Chief executive officer Khaled El-Dokani said that the investment ‘underscores the company’s commitment’ to sustainability.

Russia: Iskitimcement has completed the modernisation of the grinding plant at its 2.1Mt/yr integrated Iskitimcement plant in Novosibirskskaya following the installation of a closed-circuit dynamic separator and bag filter supplied by Christian Pfeiffer at a cost of US$3.69m. Iskitimcement director general Vladimir Skakun said that the upgrade aims, “to provide customers with separated cement that surpasses the quality of products produced with open-circuit grinding.”

The company said that the closed-circuit unit has increased productivity and reduced the temperature of cement. Dust emissions have fallen by over 90%, bringing the plant in line with current environmental strictures. “We are ready to meet the customers’ demand for quality products even at the peak of the construction season,” said Skakun.

Iskitimcement says that it is planning a modernisation of its stacks with the installation of new filters by 2024.

Canada: Albarrie says that there has been no interruption in any provision of products to its customers. Its production capabilities are not affected by novel coronavirus and it is implementing travel restrictions and health guidelines in line with government and World Health Organisation (WHO) advice. Key features include heightening risk assessments for employees, improved workplace hygiene, bolstered information technology support to allow home working and the cancellation of all nonessential domestic and international travel. Albarrie produces textile products including filtration products used by the cement industry.

Bulgaria/Panama: Germany’s Venti Oelde has increased its sales presence in Europe and Central America. Its has appointed a new sales representative in Bulgaria, as well as one in Panama to cover countries including Mexico, Belize, Costa Rica, El Salvador, Guatemala, Honduras, Nicaragua, and Panama. The company manufactures industrial products including fans and filters.