Displaying items by tag: heat

Türkiye: Medcem has completed testing of its new waste heat recovery (WHR) facility, which will recover 25% of the energy demand of the plant’s second rotary kiln line commissioned in 2024.

The 9.6MW facility uses an organic rankine cycle (ORC) system to generate electricity from a single heat source. The company says that this will lead to significant cost savings in energy expenses while also reducing CO₂ emissions.

US: Buzzi Unicem USA is among industrial partners collaborating with Electrified Thermal Solutions in the development of its Joule Hive Thermal Battery for industrial heat decarbonisation. The partners plan to launch a commercial-scale pilot of the battery in San Antonio, Texas, in association with the Southwest Research Institute. The project is supported by US$171m in funding from the US Department of Energy. The battery delivers heat of up to 1800°C from energy from renewable sources.

Buzzi Unicem USA president and chief executive officer Massimo Toso said “Cement production is known as a hard to abate industrial sector in large part because of the high temperatures required. Electrified Thermal Solutions’ Joule Hive Thermal Battery is the first industrial heat decarbonisation solution we have identified that could potentially enable us to cost-effectively and completely eliminate the use of fossil fuels in our heating processes and achieve our corporate decarbonisation goals.”

Electrified Thermal Solutions chief executive officer Daniel Stack said “We believe the breadth and depth of involvement from our industrial partners like Buzzi Unicem USA was critical to demonstrate to the Department of Energy just how valuable the Joule Hive Thermal Battery will be for industrial decarbonisation, and we are grateful for their partnership.” Stack added “Southwest Research Institute’s engineering support and world-class industrial demonstration facilities signalled to the Department of Energy that our technology will be developed, built, operated, tested and evaluated to the highest standards.”

Germany: Rohrdorfer Zement has fired up a pilot clay tempering unit at its Rohrdorf cement plant in Bavaria. The project has received Euro8.65m in funding from the German Federal Ministry for Economic Affairs and Climate Action and the EU. It is one of a number of industrial projects under the EU’s Euro800bn NextGenerationEU post-Covid-19 economic recovery instrument. Sources of heat for the pilot unit at the Rohrdorf cement plant include waste heat from the plant’s clinker line. If the pilot succeeds, the introduction of tempered clay into cement production at the site will follow. This will entail the construction of an on-site full-scale clay tempering plant. Rohrdorfer Zement says that this would reduce the plant’s CO₂ emissions by 16 – 18%, or by 30% if it achieves carbon neutral clay tempering through the use of green hydrogen.

Rohrdorfer’s dedicated Net Zero Emissions Labs team is working to turn the Rohrdorf cement plant carbon neutral by 2038. Other initiatives include the installation of carbon capture systems at the Rohrdorf plant and another in Austria, and participation in the H2-Reallabor Burghausen hydrogen partnership.

Regarding the latest pilot, Rohrdorf Net Zero Emissions Labs project leader Helmut Leibinger said “As a cement component, tempered clays make a significant contribution to CO₂ mitigation. With the pilot project of process-integrated tempered clay, we are taking not just a step in our decarbonisation roadmap, but a leap.”

Netherlands: Finland-based Coolbrook has completed the first test phase of the large-scale pilot of its RotoDynamic Heater (RDH) at the Brightlands Chemelot Campus in Geleen, Netherlands. The engineering company says that this has validated the RDH’s technical pathway up to industrial heat generation at temperatures suitable for cement plants. By developing and launching the technology, Coolbrook says that it will rely on a ‘comprehensive partnership ecosystem,’ including market leaders in technology and industry. It says that the RDH has the potential to eliminate 2.4Bnt/yr of CO₂ emissions – 30% of global industrial CO₂ emissions and 7% of all global CO₂ emissions.

CEO Joonas Rauramo said “Sharing our partners’ and customers’ sense of urgency to achieve net zero, we take determined actions to execute our strategy and progress towards the commercial launch of our electric technology. We are proceeding with first commercial agreements, while continuing to build our organisation and supply chain for industrial scale operations.”

Japan: Tokuyama Corporation has installed ABB’s Expert Optimizer automated optimisation system in the kiln line of its Nanyo cement plant. The system controls the line’s calciner, kiln and cooler processes. The supplier says that the technology will reduce the Nanyo cement plant’s thermal energy consumption by 3%.

Tokuyama Corporation "We selected ABB's Expert Optimizer to equalise operations and improve operational efficiency. As expected, we have significantly reduced the number of the operator manual operations normally spent on manual tasks.” It added “We believe that this solution will also support our young operators in learning the know-how of our operations efficiently."

Spain: Switzerland-based Synhelion and Cemex España plan to build a new clinker plant near Madrid. The plant will use Synhelion’s synthetic fuel to produce clinker from clay and crushed sand at 1200°C. The fuel consists of a gas produced from green hydrogen and captured CO₂, using solar heat. La Tribune de Genève Online News has reported that Synhelion’s thermochemical reactor further helps to capture CO₂ emissions from clinker production. A study by the Swiss Federal Institute of Technology Lausanne indicated that this can halve the cost of carbon capture at cement plants, to below Euro85/t.

Mexico/Switzerland: Cemex and industrial solar heat specialist Synhelion have achieved constant clinker production on an industrially viable scale using only solar heat. The partners say that this confirms the technology's potential for industrial-scale implementation.

Cemex chief executive officer Fernando A González said “I am convinced we are getting closer to the technologies that will enable net-zero CO₂ cement and concrete production. The solid progress I see here proves that solar cement is not just a dream: it is achievable through continued collaboration, and backed up by rigorous research and testing.”

India: Prism Cement has taken delivery of a pendulum cooler supplied by Germany-based IKN at its Prism cement plant in Maharashtra. The new equipment will replace the 6.1Mt/yr plant's existing air beam technology cooler. The supplier says that this will help to improve the efficiency of waste heat recovery (WHR) processes at the plant.

Greece/US: Titan Cement Group has made new venture capital investments in two US-based disruptive technology suppliers. The cement producer enlarged its investment in energy storage specialist Rondo Energy, which has developed the Heat Battery. The technology enables cement plants and other industrial operations to access a constant supply of electricity using captive renewable energy sources. It also invested in venture capital firm Zacua Ventures, which handles a portfolio of companies involved in developing optimisation, automation and Construction 4.0 technology, including products relevant to the cement industry.

Titan Group Chief Sustainability and Innovation Officer Leonidas Canellopoulos said “We are committed to embracing innovation and fresh perspectives. By engaging with advanced construction and green technology startups through direct and indirect investments, as well as collaborations, we intend to forge more partnerships in the sector.”

Thailand: US-based Rondo Energy and Siam Cement Group (SCG) plan to expand the production capacity of a heat battery storage unit at a SCG plant to 90GWh/yr. Once complete the site will reportedly have a production capacity larger than any current heat battery-supported manufacturing facility worldwide and will save up to 12Mt/yr of CO₂. The SCG site already has a capacity of 2.4GWh/yr.

SCG’s executive vice president Thammasak Sethaudom said “Rondo offers an innovative solution to reduce the carbon emissions from industrial process heat used in factories worldwide. SCG can use Rondo’s technology to lower our own carbon emissions and SCG Cleanergy can partner with Rondo to help our customers cut emissions.” He added “We also realised that we can leverage our 70 years of technical expertise in the refractory business and supply chain.”

Rondo heat batteries consist of refractory bricks capable of storing renewable energy as heat. The heat energy can then be returned to an industrial process as hot air or steam. SCG invested in Rondo Energy in 2022.

This story was amended on 4 July 2023, after a previous version erroneously stated the location of the plant as Ukraine. Global Cement apologises for this error.