Displaying items by tag: landfill
Update on construction and demolition waste, October 2023
25 October 2023Cementos Molins has been celebrating the first anniversary this week of its alternative raw materials unit at its Sant Vicenç dels Horts plant near Barcelona. It has processed 75,000t of waste since September 2022 when the site started up. More is yet to come as the unit has a production capacity of up to 200,000t/yr. The facility receives waste in coarse, granular, powder and sludge formats. Waste from concrete plants is crushed and screened to produce recycled aggregate. Industrial and construction waste is dosed and homogenised to produce alternative raw materials for cement production.
Global Cement Weekly has covered construction and demolition waste (CDW) a couple of times already so far in 2023. A number of cement producers are investing in the sector - including Holcim, Heidelberg Materials, CRH, Cemex – by developing technology, buying up other companies, setting up internal CDW divisions and so on. Holcim and Heidelberg Materials have been the more obviously active participants over the past six months based on media coverage. In September 2023 Holcim France commissioned the Saint-Laurent-de-Mûre alternative raw materials plant and Holcim Group invested in Neustark, a company promoting technology to sequester CO2 in CDW. In August 2023 Lafarge Canada also completed the first stage of a pilot project to use CDW in cement production at its St. Constant plant in Quebec. Heidelberg Materials meanwhile announced in October 2023 that a forthcoming upgrade to its Górażdże cement plant in Poland would include a new CDW recycling unit and in September 2023 it launched a CDW division for its subsidiary Hanson UK.
Previously we have described how the European Union (EU) has set recovery targets for CDW. However, McKinsey & Company published research in March 2023 setting out the economic case for cement and concrete companies looking at CDW. It estimated that “an increased adoption of circular technologies could be linked to the emergence of new financial net-value pools worth up to roughly Euro110bn by 2050.” It is not a certainty and there is risk involved, but adopting circular practices is one way to reduce this risk. It then went on to predict that recirculating materials and minerals could generate nearly Euro80bn/yr in earnings before interest, taxation, depreciation and amortisation (EBITDA) for the cement and concrete sectors by 2050. The biggest portion of this could come from using CDW in various ways such as a clinker replacement or as an aggregate in concrete production, or the use of unhydrated cement ‘fines.’ Capturing and using CO2 and increasing alternative fuels (AF) substitution rates would have a financial impact but not to the same scale.
Graph 1: CO2 abatement cost via circular technologies for cement and concrete sectors. Source: McKinsey & Company.
Graph 1 above puts all of the McKinsey circular technology suggestions in one place with the prediction that all of these methods could reduce CO2 emissions from cement and concrete production by 80% in 2050 based on an estimated demand of 4Bnt/yr. The first main point they made was that technologies using CO2, such as curing ready-mix or precast concrete, can create positive economic value at carbon prices of approximately Euro80/t of CO2. Readers should note that the EU emissions Trading Scheme CO2 price has generally been above Euro80t/yr since the start of 2022. The second point to note is that using CDW could potentially save money by offering CO2 abatement at a negative cost through avoiding landfill gate fees and reducing the amount of raw materials required. This is dependent though on government regulation on CO2 prices, landfill costs and so on.
Cement producers have been clearly aware of the potential of CDW for a while now, based on the actions described above and elsewhere, and they are jockeying for advantage. These companies are familiar with the economic rationale for AF and secondary cementitious materials (SCM) in different countries and locations. CDW usage is similar but with, in McKinsey’s view, existing CO2 prices, landfill costs, and regulatory frameworks all playing a part in the calculations. Graph 1 is a prediction but it is also another way of showing the path of least resistance to decarbonisation. It is cheaper to start with AF, SCMs and CDW rather than barrelling straight into carbon capture. The beauty here is that cement and concrete sold, say, 50 years ago is now heading back to the producers in the form of CDW and it still has value.
Canada: The district council of Capital Regional District (CRD) says that it expects to resume sending biosolids to Lafarge Canada's Richmond cement plant in early June 2023. This follows a reported reduction in production at the unit in 2023 and 2022, according to the Times Colonist newspaper. The 1.1Mt/yr cement plant previously used biosolids supplied by the CRD as an alternative fuel in its cement production. However, during the current hiatus the biosolids have been sent to landfill instead.
The Richmond cement plant is the site of the CO2MENT carbon capture and utilisation project. The project proceeded to its third phase, which consists of a capture capacity expansion and the installation of a liquefaction plant, in May 2023.
Lehigh Cement’s Picton plant to use alternative fuels
01 September 2022Canada: Lehigh Cement has initiated the administrative process to begin the use of alternative fuels (AF) in cement production at its Picton cement plant in Ontario. Under the company’s plans, the plant will substitute 200t/day of AF for coal and petcoke at the plant. Possible AF sources include excess seed from farm feed production in Ontario. The Picton cement plant previously reduced its CO2 emissions per tonne of cement by 20% through assorted sustainability initiatives.
Picton plant manager Carsten Schraeder said that the move will support Canada’s 2030 emission reduction plan, and also take pressure off landfill sites.
US: Eco Material Technologies has won a contract with Georgia Power to mine 600,000t/yr from the energy company’s Plant Bowen ash dump in Cartersville, Georgia. Eco Material Technologies will use the ash to produce its 99% reduced-CO2 building materials, including an alternative cement with 20% greater compressive strength than ordinary Portland cement (OPC) after 28 days, according to the company.
Grant Quasha, CEO of Eco Material Technologies, said "As the largest partnership of its kind in the US, this project will not only use material from landfills and ash ponds, but also keep millions of tonnes of CO2 from going into the atmosphere."
Titan Group receives Platinum Zero Waste to Landfill certification for all its Greek cement plants
12 July 2021Greece: Eurocert has awarded Platinum Zero Waste to Landfill certificates to all three of Titan Group’s cement plants in Greece. The producer said that the certification ‘reaffirms the excellent environmental performance’ of its Kamari, Patra and Thessaloniki cement plants. It says that the plants achieved the highest waste management certificate through effective waste prevention and proper management to avoid landfill.
Greece general manager Angelos Kalogerakos said “Titan is clearly committed to contributing substantively, through its operation and products, to the zero-waste goal. The Platinum Zero Waste to Landfill certification endorses and rewards the good practices that we have systematically applied for many years and that we have adopted in order to minimise our footprint and ensure a sustainable future for coming generations. We want to make all of our partners part of this commitment, aiming for a reliable and sustainable supply chain.”
Greece: Titan Cement group has accelerated its efforts towards sustainability with new environmental, social and governance (ESG) targets. The targets include an updated CO2 emissions reduction target of 35% by 2030 compared to 1990 levels, zero workplace fatalities and a cement industry top-three lost time injury frequency rate, increased female leadership participation and 70% supplier sustainability in line with the producer’s own ESG standards by 2025. It also set a water consumption target of 280L/t of cementitious material produced and 50% certified Zero Waste to landfill production by 2025.
Chief sustainability officer Leonidas Canellopoulos said, “We are building on our strong track record on sustainability and aspire to increase our positive impact on people, society, and the environment. We are committing to ambitious targets that aim to generate more value for all our stakeholders and set the foundations for sustainable growth in a carbon-neutral and digitalised world.”
MPA Cement publishes 2019 Sustainable Development Report
17 January 2020UK: The Mineral Products Association (MPA) Cement’s five members – Breedon Cement, Cemex UK, Hanson Cement, Lafarge Cement and Tarmac – saw their direct CO2 emissions per tonne of cement rise by 0.6% year-on-year to 633kg in 2018 from 629kg in 2017. Refuse-derived fuel rates in 2018 were 43.2%, down by 0.5% from 43.8Mt in 2017. The industry achieved its seventh consecutive year in which producers sent zero process waste to landfill. Overall sales fell by 1.0% year-on-year.