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Netherlands: Van Aalst says that NACC Alicudi is the world’s first cement carrier equipped with International Maritime Organization (IMO) Tier III compliant diesel engines driving the bulk handling system. Converted in 2017 with a Van Aalst dry bulk handling system, the vessel became a 120m self-discharging cement carrier, with a cement handling system based on compressors and vacuum pumps, driven by Tier III Scania engines. This has created a ‘unique’ vacuum-pressure system for pneumatic conveyance of cement, fly ash and granulated slag.
Directly after completion of the conversion, the NACC Alicudi entered the trade for a three-year contract on the east coast of the US and Canada, an area that has been a NOx Emission Control Area (ECA) for new built and converted vessels since January 2016. Van Aalst says that this approach fits well with the environmental policies of both NovaAlgoma Cement Carriers and McInnis Cement. The high emission standards of the vessel will enable a shift to the US Gulf of Mexico, Puerto Rico and Hawaii.
Chief executive of Dadabhoy Cement Industries dies
Written by Global Cement staff
10 October 2018
Pakistan: Mohammad Amin Dadabhoy, the chief executive of Dadabhoy Cement Industries, has died. The company operates an integrated plant at Nooribad in the Dadu District of Sindh.
Riding the IPCC rollercoaster
Written by David Perilli, Global Cement
10 October 2018
One graph the United Nations’ (UN) Intergovernmental Panel on Climate Change (IPCC) report on Global Warming of 1.5°C didn’t include this week was what happens if the world just doesn’t bother. It’s probably just as well since warming of 1.5°C is likely to happen between 2030 and 2052 at the current rate of climate mitigation efforts. If they had included such as diagram, it likely would have had a ominous red line hurtling skywards like a rollercoaster track just before the screams start.
The giant paper study is really about comparing and contrasting the different impacts and responses to a 1.5°C and a 2°C rise. One taste of what the higher rise threatens is, “limiting global warming to 1.5°C instead of 2°C could result in around 420 million fewer people being frequently exposed to extreme heatwaves, and about 65 million fewer people being exposed to exceptional heatwaves."
The cement industry gets a look-in with an acknowledgment that the sector contributes a ‘small’ amount (5%) of total industrial CO2 emissions. It then breaks the entire industrial sector’s mitigation strategies down to (a) reductions in the demand, (b) energy efficiency, (c) increased electrification of energy demand, (d) reducing the carbon content of non-electric fuels and (e) deploying innovative processes and application of carbon capture and storage (CCS).
Speaking generally, phasing out coal, electrification and saving energy in mechanisms like waste heat recovery is predicted to get industry only so far. Yet from here even skirting over 1.5°C but below 2°C is ‘difficult to achieve’ without the, “major deployment of new sustainability-oriented low-carbon industrial processes.” Such new process include full oxy-fuelling kilns for clinker production, which have not been tested at the industrial scale yet. Likewise, CCS is seen as a major part of keeping warming below 2°C with a target of 3 Gt CO2/yr by 2050. Some reality is present though when the report says that the development of such projects has been slow, since only two large-scale industrial CCS projects outside of oil and gas processing are in operation and that cost is high. It even posits a value of up to US$188t/CO2 (!) for the cost of CO2 avoided from a Global CCS Institute report.
None of this is new to cement producers. The real debate is how to get there without wiping out the industry. In his address to the recent VDZ conference, Christian Knell, the president of the German Cement Works Association (VDZ), highlighted that meeting climate change goals was leading to ‘considerable’ costs for the cement industry. He then called for policy-related support to on-going research projects into CO2 mitigation technology.
The bit that the IPCC doesn’t go into is how much those five steps to the industrial sector will cost cement producers and, vitally, who will pay for it. For example, taking a cement plant’s co-processing rate to 70% and building a waste-heat recovery system, might cost around US$30m. The Low Emissions Intensity Lime And Cement (LEILAC) Consortium’s Calix’s direct CO2 separation process pilot at the Lixhe cement plant in Belgium has funding of about Euro20m. Rolling all three of these measures out to the world’s 2300 cement plants would cost over US$100bn and it would take more than a decade. Beware, the financial figures here are rough estimates and may be way out. The point remains that the implementation costs will not be trivial.
Industry advocates have started in recent years to push back against the climate lobby by highlighting the essential nature of concrete to the modern world. The IPCC barely mentioned this aspect of cement’s contribution to society suggesting recycling, using more renewable materials, like wood, and resorting to the mitigation strategies detailed above. Building new cities out of wood is not inconceivable but CCS seems more likely to solve the climate problem at this stage. Manufacturing the cement that becomes concrete may create CO2 emissions but it has also built the modern world and raised living standards universally. No cement means no civilisation. There is, at present, no alternative.
Instead of leaving this discussion at an impasse, it is worth reflecting on the last week in the industry’s news. An Indian cement company is importing fly ash, several companies are opening or preparing cement grinding plants, a coal ash extraction pilot project is running, a waste heat recovery unit has opened at a plant in Turkey and a producer is getting ready to co-process tyres as a fuel in Oman. All of these stories are proof that change is happening. The trick for policymakers is to keep prodding the cement sector in this direction without disrupting the good things the industry does for people’s lives through sustainable housing and infrastructure.
The November 2018 issue of Global Cement Magazine will include an exclusive article by Mahendra Singhi, the CEO of Dalmia Cement, about his company’s CO2 mitigation efforts.
The 2nd FutureCem Conference on CO2 reduction strategies for the cement industry will take place in May 2019 in London, UK.
India: Shree Cement has ordered a TRT 5000/8.0 Triplex dryer from Germany’s Gebr. Pfeiffer. The dryer will be used to dry flue gas desulphurisation (FGD) gypsum from a captive coal-power plant for use in cement plants. In the planned dryer plant the moisture of the FGD gypsum will be reduced to a residual moisture of <2%. Artificial gypsum from the dryer will be used at other cement grinding plants in the country. The 50t/hr dryer will be installed at the end of 2018 and is expected to start commercial operation in mid-2019.
Gebr. Pfeiffer is also planning to partially calcine the gypsum in future installations of the dryer. The TRT Triplex dryer uses the uniflow principle, where both material and hot gasses flow in the same direction and pass through the dryer tubes from the centre outwards. Testing at the Gebr. Pfeiffer test station have yielded ‘positive’ results and further installations in other plants are being considered.
India: NCL Industries’ cement production rose by 36% year-on-year to 1.02Mt in the half year to the end of September 2018 from 0.75Mt in the same period in 2017. Its cement despatches increased by a similar amount to 1.02Mt from 0.75Mt. The company operates in cement, cement-based boards, ready-mixed concrete, prefabricated structures and hydroelectric power.