Displaying items by tag: municipal solid waste

Iraq: Eggersmann Anlagenbau has expanded its refuse-derived fuel (RDF) production facility in Sulaymaniyah, operated by Ecocem Environmental Solution, part of the Faruk Investment Group. The expansion includes a new Eggersmann TEUTON ZS 55 single shaft shredder and four additional lanes for biological drying using the CONVAERO system. This system is integral to the Eggersmann RDF process, which converts municipal solid ‘waste’ into high calorific value RDF used by the regional cement producers Gasin Cement Company and Bazian Cement Company. The facility, which has a capacity of 1100t/day of RDF, will see an increase with the expansion. The Eggersmann FUEL process utilises biowaste in RDF production, improving both the quantity and quality of the fuel through biological drying in the CONVAERO system, relying on the natural warmth of the composting process. This method reduces methane emissions at landfill sites by integrating biomass into the fuel, according to the company.

Business development manager at Eggersmann, Eugen Becker, said "A particularly high quality substitute fuel is being produced with the Eggersmann FUEL process in Sulaymaniyah, whose net calorific value can be precisely tailored to the customer’s needs over the adjusting of the drying period. This quality makes a noticeable economic difference."

India: Fornnax has introduced the SR-MAX2500 shredder, designed for municipal solid waste (MSW). The machine features hydraulic motors and a unique cutter design, aiming to serve large-scale recyclers and cement plants.

Jignesh Kundaria, CEO and director of Fornnax, said "With the SR-MAX2500, we're poised to transform the waste management landscape in India and beyond. Our goal is to line up MSW recycling industries with a robust, efficient and sustainable solution.”

The SR-MAX2500 is engineered for India, accommodating the specific challenges of highly contaminated local waste. The company says that the shredder will enhance efficiency, reduce operational costs and minimise downtime.

Indonesia: Indocement Tunggal Prakarsa has acquired a 20% stake in Amita Prakarsa Hijau, a company that specialises in the recycling of industrial and municipal refuse and biomass-derived materials into alternative fuel for the cement industry. The deal is valued at US$120,000 and was completed on 8 October 2024.

Energy has been the theme for a couple of cement news stories of note from Egypt this week. The first concerns the government’s impending plan to centralise distribution of mazut (heavy fuel oil) to cement plants to help them cope with ongoing power shortages. Earlier in the week Cemex signed a deal with the Assiut Governorate to operate a second municipal solid refuse processing unit in the country. The company’s first Regenera facility, in Mahala, started operations in May 2024. Another story from mid-September 2024, along the same theme, covered the inauguration of an 18MW waste heat recovery (WHR) unit at Heidelberg Materials Egypt's Helwan Cement plant.

The wider story is that the country has faced so-called load shedding, or power rationing, since mid-2023 due to falling gas production, rising energy demand and negative currency exchange effects making it harder to buy fuel imports. The power cuts were extended in duration in July 2024 due to a heat wave. The government then said in late September 2024 that it is making investments to prevent domestic power cuts in 2025.

The cement stories mentioned above show some of the ways cement companies cut their energy costs. Two potential ways of doing this are to increase the use of alternative fuels (AF), such as municipal solid waste, or to install a WHR unit. Titan Cement, for example, reported AF thermal substitution rates of above 40% in Alexandria and above 30% in Beni Suef in the first half of 2024. The local press hasn’t reported power shortages amongst the country’s cement producers, but the plans to control the distribution of mazut suggest that either ‘something’ has happened or the government is trying to avoid ‘something.’ Readers may recall that producers have periodically faced step changes in power supplies over the years. In the mid-2010s, for example, lots of plants switched from heavy fuel oil and gas to coal. The energy price fluctuations following the start of the Russia - Ukraine war in 2022 then saw the price of coal rise.

However, what the foreign-owned producers have complained about in the first half of 2024 is the declining exchange rate of the Egyptian Pound. Cementir, Cemex and Titan Cement all noted this. However, Titan reckoned that International Monetary Fund and European Union investment had actually eased the economic situation in the first half of the year leading to an increase in the number of large construction projects.

One effect of the currency problems upon the cement market has been a focus on exports. At the start of September 2024 the Federation of Egyptian Industries said that national cement consumption in 2024 was expected to drop by 4% year-on-year to 45Mt. However, exports were projected to rise to 15Mt. The first and second most popular destinations so far in 2024 have been the Ivory Coast and Ghana. Yet, exports to Libya, the third biggest external market, may have had the biggest effect. These have been blamed for creating a shortage of trucks that was causing delays to the local construction sector. The round-journey from Egypt to Libya can take up to 12 days. This has left building sites bereft of raw material deliveries because all the trucks are elsewhere! Vicat acknowledged the growing importance of imports for its business in Egypt in its half-year report for 2024. It said that ‘sluggish’ domestic market conditions “were more than offset by growth in cement and clinker volumes for export to the Mediterranean and Africa regions.”

The wider picture of the cement sector in Egypt remains one of overcapacity with integrated capacity estimated above 70Mt/yr. The government introduced cement production quotas in mid-2021 and this stabilised prices (and profits). The recent state of the local economy may have strained this, but the latest round of external investment appears to have buoyed things for now. Although the effects of the Israeli military action in Lebanon may have unforeseen consequences upon neighbouring markets. In the meantime, cutting energy costs and growing exports offer two ways for producers to raise their profits.

Egypt: Cemex has signed an agreement with Assiut Governorate to operate its second Regenera facility in Egypt. This facility processes about 7,000t/month of municipal solid refuse, treating it to generate alternative fuels before compost production, thereby ensuring minimal residual materials go to landfill. The Assiut agreement follows the first Regenera facility in Mahala, which began operations in May 2024. Cemex has invested over US$2.5m in an alternative fuel dryer at the Assiut plant.

India: Nuvoco Vistas has commissioned feeding systems for alternative fuel (AF) in the pyro-process sections of its Nimbol and Risda cement plants. The systems will handle municipal solid waste, including unrecyclable plastic.

Managing director Jayakumar Krishnaswamy said "As part of our Protect Our Planet agenda, we view the AF projects as an important step towards fulfilling our commitment to sustainable cement manufacturing and reducing the environmental impacts. The successful completion of this project demonstrates our commitment to reducing carbon emissions, maximising waste consumption and demonstrating responsible resource management practices.” He added "This along with, other themes under Protect Our Planet agenda, is enabling Nuvoco to build robust partnerships with several stakeholders, and contribute to society at large.”

Indonesia: Indocement Tunggal Prakarsa has engaged Japan-based environmental consultancy Amita Holdings to support a two-year feasibility study to investigate ways to make its cement production carbon neutral. The study will commence with trials of industrial wastes as alternative raw materials and municipal solid waste as refuse-derived fuel. Amita Holdings says that it is in the process of building a recycling-based society in Indonesia, in partnership with Indocement Tunggal Prakarsa.

Amita Holdings supported the establishment of the community-led Meguru waste sorting facility in Central Java. Two of Indocement Tunggal Prakarsa’s cement plants – the 18Mt/yr Citeureup cement plant and 4.1Mt/yr Paliman cement plant – are situated in neighbouring West Java.

Mexico: Cemex's waste management subsidiary Regenera has signed a deal with the municipal council of Huajuapan de León to receive the latter's sorted non-recyclable municipal solid waste (MSW). Under the deal, Regenera will receive up to 6000t/yr of MSW, which it will supply to Cemex's Tepeaca cement plant in Puebla.

Thailand: ThyssenKrupp Polysius says that it has successfully supplied and installed a Prepol SC alternative fuels (AF) system at a 12Mt/yr cement plant in Thailand. The system will supply the plant's four lines with 4000t/day of AF.

ThyssenKrupp Polysius' Asia Pacific CEO Lukas Schoeneck said "Asia Pacific, with its tremendous municipal solid waste (MSW) problem, is ideal when it comes to replacing coal with AF. The Prepol SC technology significantly reduces the need to treat MSW before using the inherent calorific value. Additionally, it helps to further reduce the ambitious CO₂ limit targets in the region."

Colombia: Cemex has announced the launch of the Tunjuelo Circularity Centre at its former Tunjuelo quarry near Bogotá. Having rebuilt parts of the 50m-deep quarry with demolition waste, Cemex will now work on its ecological restoration, while continuing to receive excavation waste for reconstruction of the ground. It will meanwhile divert demolition waste deliveries for recycling in aggregate production. In Bogotá, Cemex has launched an initiative for urban construction partnerships in collaboration with local authorities. It will also collect municipal solid waste (MSW) there for use in its cement production and collect its used plastic cement bags for recycling in building materials production.

Cemex’s Colombia and Peru president Alejandro Ramírez said "This is a pioneering model for Cemex in the construction materials industry globally, which we aim to position as a benchmark for circularity within the sustainable development of large cities in Colombia and the world. A piece of land that supplied materials for Bogotá's development for decades has received construction and demolition waste for its redevelopment and was transformed into a green area to the south of the city, an epicenter of the circular economy and an opportunity for urban development for the capital city of Colombia."