Displaying items by tag: UK
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.
Cemex UK supplies by-pass dust to farmers
24 October 2023UK: Cemex UK says that it has collected 130,000t of by-pass dust (BPD) from its Rugby cement plant in Warwickshire since 2015. The producer supplies the BPD to the agriculture sector, where it can replace traditional fertilisers and lime due to its high lime and potassium content. Additionally, Cemex UK has sponsored research into this and other circular economic uses of BPD, including an on-going study which claimed the Carbon Journey Award at the Eco Innovation North West Awards 2023.
Cemex’s Europe regional head of sustainability Paul Fletcher said “We are very proud of our partnership with Silverwoods and the considerable positive impact their innovation and expertise has had on our ability to reuse BPD for other applications. We believe it leads the way in our industry and presents real potential to be adapted elsewhere across our operations. Not only does it benefit the environment by reducing the amount of materials that need to be disposed of, but it generates a product that has a value for farmers and helps cut the use of traditional materials.” He added “This partnership demonstrates that to deliver true circularity, more industrial by-products, including those from different sectors of the economy, need to be used as secondary resources, rather than primarily be seen as waste. If this is to be achieved, a new perspective is needed to boost circular economy practices, with regulations and permitting supporting this proactively.”
Fernando Gonzalez appointed as president of the Global Cement and Concrete Association
18 October 2023UK: Fernando Gonzalez has been appointed as the president of the Global Cement and Concrete Association (GCCA). He has been the association’s vice-president since 2018 and succeeds outgoing president Jan Jenisch.
Gonzalez has called for industry and governments around the world to establish a "robust regulatory framework" that can further accelerate the cement and concrete sector's decarbonisation efforts. He said "It is a great honour to be president of the GCCA - cement and concrete are the world's essential building materials. As an industry, we've gone beyond the commitment phase to taking decisive action today to reduce our CO2 emissions."
Gonzalez is the chief executive officer (CEO) of Cemex. He has worked for the company since 1998. On the operational side, he has led various regions of Cemex, including Europe, Asia and South Central America and the Caribbean, and has held corporate positions in strategy, planning, business development and human resources. He was appointed Executive Vice President of Planning and Development in 2009, chief financial officer in 2011, and has been the company's CEO since 2014.
UK: First Graphene and Breedon Group have entered into a development and commercialisation agreement. Together, the companies aim to enhance Breedon Cement’s CEM II Portland limestone cement (PLC) through the use of First Graphene’s graphene enhanced grinding aids and cement admixtures. Breedon will provide increased access to cement production lines in order to optimise the understanding of the processing environment and operating conditions.
Breedon Group’s Hope cement plant in Derbyshire previously conducted a 24-hour graphene-enhanced cement production trial on 28 June 2023.
UK: Holcim subsidiary Aggregate Industries has installed Driver Status Monitoring Systems supplied by Spillard Vehicle Safety Systems in the cabins of its Cauldon cement plant truck fleet. The systems use cameras and AI software to detect signs of tiredness, as well as mobile phone use, lane deviation, not wearing a seatbelt and smoking. In the case of tiredness, this triggers an alarm which continues to sound until the vehicle comes to a stop.
Cement supply chain manager Matt Owen said “Health and safety is a massive priority for us as a company and the industry, so anything that can serve to continuously improve our approach to it is very welcome. Driver fatigue is always a potential issue across any business involved in transport and fleet, so we’re delighted to be utilising the latest technology with our partners to ensure that everyone gets safely home from work.”
Use of ground granulated blast furnace slag avoided 408Mt of CO2 emissions over 22 years in EU and UK
05 October 2023EU/UK: EUROSLAG says that the use of ground granulated blast furnace slag (GGBFS) in cement production in the EU and UK between 2000 and 2022 has generated a cumulative reduction in CO2 emissions of 408Mt. GGBFS replaced 716Mt-worth of raw materials over the period.
EUROSLAG Chair Thomas Reiche said "Resource conservation through secondary raw materials, especially in the construction sector, and lower emissions of climate-damaging CO2, are of outstanding ecological and economic importance. The use of ferrous slags makes an important contribution to this. EUROSLAG is working multilaterally to master the enormous challenges in the coming years, above all the transformation of the steel industry, through research and adjustments to national and European regulations.”
Tarmac and Cambridge Electric Cement participate in trial melt of Cement 2 Zero carbon neutral cement project
03 October 2023UK: The Cement 2 Zero project has successfully concluded its first trial melt of recovered cement paste in an electric arc furnace at the Materials Processing Institute’s Teesside campus. The project uses the paste as flux for electric steel recycling. Cambridge Electric Cement (CEC) has demonstrated that the ‘slag’ from this process can be ground into fine clinker that, when mixed with gypsum and supplementary cementitious materials (SCMs), produces net zero CO2 cement. The Cement 2 Zero project to produce CEC’s cement at an industrial scale launched in March 2023, with US$7.85m in funding from UK Research and Innovation. Tarmac will grind the clinker from the project’s trial melts for testing in order to obtain certification and specification as a usable cement product.
Hanson UK becomes Heidelberg Materials UK
02 October 2023UK: Germany-based Heidelberg Materials has introduced customers and investors to Heidelberg Materials UK, its UK subsidiary formerly known as Hanson UK. The latest rebrand signifies increasing collaboration across the group’s geographies as a global business with one voice. Heidelberg Materials UK will launch rebranded packaging for its cement and other products in early 2024 and transition its branding across its sites and vehicles by October 2025.
Heidelberg Materials UK CEO Simon Willis said “The construction sector faces global challenges such as climate change and the digitalisation of our industry; challenges we are better placed to meet as a strong, united group. Having a single brand name and identity sends a clear and consistent message to our increasingly global customers.” Willis added “It will allow us to work together to lead the field in driving down carbon emissions; promote the circular economy by recycling and reusing construction waste; develop digital solutions to provide added value to our customers and develop sustainable and innovative building materials.”
James Whitelaw to head Hanson UK’s new recycling line
20 September 2023UK: James Whitelaw will take on the role of managing director in Hanson UK’s newly-established recycling business line. He will be responsible for identifying opportunities to grow organically using the company’s existing capabilities and for integrating new acquisitions.
Whitelaw has held management roles in Hanson UK since 2001 and most recently served as aggregates managing director. Former concrete managing director Brian Charleton will replace him in this role, while Gordon Napier, previously concrete regional director, joins Hanson UK’s executive team as the new concrete managing director.
Hanson UK launches construction and demolition waste recycling business
20 September 2023UK: Hanson UK has launched a recycling business line to process construction and demolition waste. The business will supply recycled materials for use in Hanson UK’s operations.
CEO Simon Willis said “Promoting circularity by recycling, reusing and reducing the use of primary raw materials is crucial to reaching net zero. The development of a separate recycling business line will allow us to provide the most sustainable products to our customers through circularity and innovation, to enable building more with less. It is another significant step towards achieving our aim of being the industry leader in the supply of sustainable, circular products.”