Displaying items by tag: Spain

Taiwan Cement has just commissioned a 107MWh energy storage project at its Yingde plant in Guangdong province, China. Subsidiary NHOA Energy worked on the installation and has been promoting it this week. The battery storage works in conjunction with a 42MW waste heat recovery (WHR) unit, a 8MWp solar photovoltaic unit and a proprietary energy management system. It is expected to store about 46,000MWh/yr of electricity and save just under US$3m/yr in electricity costs.

NHOA Energy, formerly known as Engie EPS before Taiwan Cement bought a majority stake in it, claims it is one of the largest industrial microgrids in the world. We can’t verify this for sure, but it is definitely large. For comparison, the 750MW Vistra Moss Landing Energy Storage Facility in California often gets cited as the largest such facility in the world. This is run by a power company, as are many other large battery energy storage systems. In its annual report for 2022 Taiwan Cement said it was planning to using NHOA’s technology to build seven other large-scale energy storage projects at sites in Taiwan including its integrated Suao, Ho-Ping and Hualien cement plants.

The aim here appears to be supplying renewable electricity to the national grid in Taiwan. Taiwan Cement is diversifying away from cement production, with an aim to derive over 50% of its revenues from other activities besides cement by 2025. In 2022 cement and concrete represented 68% of its sales, while its electricity and energy division, including power supply and rechargeable lithium-ion batteries, represented 29%. The company is also not using its own batteries at the Yingde plant. Instead it is using lithium iron phosphate batteries supplied by Ningde Times. This is worth noting, as the cement producer’s batteries are used in vehicles.

Global Cement regularly reports news stories on cement plants that are building photovoltaic solar power arrays. However, so far at least, energy storage projects at scale have been rarer. One earlier example of an energy storage system loosely associated with a cement plant includes the now decommissioned Tehachapi Energy Storage Project that was situated next to the Tehachapi cement plant in California. That project tested using lithium ion batteries to improve grid performance and integrate intermittent generation from nearby wind farms. It is also worth noting that Sumitomo Osaka Cement’s sister company Sumitomo Electric is one of the world’s larger manufacturers of flow batteries, although no installation at a cement plant appears to have happened yet. In simple terms, flow batteries are an alternative to lithium ion batteries that don’t store as much energy but last longer.

More recently, Lucky Cement in Pakistan started commercial operation of a 34MW solar power plant with a 5.59MWh energy storage unit at its Pezu plant in Khyber Pakhtunkhwa in late 2022. Reon Energy provided the equipment including a lithium-ion based battery approach to the storage. Then, in March 2023, Holcim US said that it was working with TotalEnergies to build solar power capacity and a battery energy storage unit at the Florence cement plant in Colorado. TotalEnergies will install, maintain and operate a 33MW DC ground-mounted solar array and a 38.5MWh battery energy storage system at the site. Operation of the renewable energy system is expected to start in 2025.

Away from electrical batteries, the other approach to energy storage at cement plants that has received attention recently from several quite different companies has been thermal batteries. The two prominent groups using them at different scales are Rondo Energy and Synhelion. The former company has developed its Heat Battery technology, which uses refractory bricks to absorb intermittent renewable energy and then supply the energy back as a steady stream of hot gas for use in a cement plant mill, dryer, calciner or kiln. Both Siam Cement Group (SCG) and Titan Cement have invested in Rondo Energy. In July 2023 SCG and Rondo Energy said that they were planning to expand the production capacity of a heat battery storage unit at a SCG plant to 90GWh/yr. Synhelion, meanwhile, has been working with Cemex on using concentrated solar power to manufacture clinker. It achieved this on an ‘industrially viable scale’ in August 2023. It has since been reported that the companies are working on building a small scale industrial plant at Móstoles near Madrid by 2026. Crucially for this discussion though, the process also uses a thermal energy storage unit filled with ceramic refractory material to allow thermal energy to be released at night, and thus ensure continuous operation.

The examples above demonstrate that some cement companies are actively testing out storing energy at scale. Whilst this will not solve the cement sector’s process emissions, it does potentially start to make using renewable energy sources more reliable and reduce the variable costs of renewable power. Whether it catches on remains to be seen. Most of these kinds of projects have been run by power companies and that is where it may stay. It is instructive to note that Reon Energy was the only company to state that its battery-based energy storage system has a life-span of 8 - 12 years. Our current vision of a net-zero future points to high electrical usage but it may be shaped by how good the batteries are… from our phones to our cars to our cement plants.

For more information on Rondo Energy read the January 2023 issue of Global Cement Magazine

Spain: Cement consumption in Catalonia fell by 11% in August 2023, while production fell by 2.7%, and exports by 32.7%, according to regional cement association Ciment Català. During the 12 months, to 31 August 2023 consumption decreased by 2.9% to 2.24Mt, while production fell by 4.4% to 3.15Mt and exports fell by 3.7% to 1.74Mt. Ciment Català’s president, Salvador Fernández, attributed these declines to the poor economic situation in the autonomous region, a lack of investment and ‘the challenges of the decarbonisation process,’ according to Europa Press.

Spain: The Spanish cement association (Oficemen) has elected Alan Svaiter as its president. He will take charge of various cross-sectoral initiatives aimed at helping the local cement industry to meet present and future challenges. These include recovering its higher activity levels and advancing its net zero strategy. He succeeds Cemex’s director general of strategic planning, Europe, Middle East, Africa and Asia, José Manuel Cascajero, in the role.

Svaiter has held the position of chief executive officer (CEO) of Votorantim Cimentos España since January 2018. Prior to that, he worked in Brazil as Votorantim Cimentos’ supply chain director from 2014 and the CEO of its ready-mix concrete subsidiary Engemix from 2010. Earlier, he held management roles at logistics groups VarigLog and Vale.

Spain: A cross-industry group of companies has launched All4Zero, a platform to speed up development of renewable fuels and the CO₂ capture in Spain. Representatives from steel-maker ArcelorMittal, oil producer Repsol and cement producer Holcim launched the platform on 6 September 2023 in Madrid, describing All4Zero as "a unique industrial technological innovation hub in Spain, of a private, multi-sector and non-profit nature, which will promote disruptive technologies in the field of renewable fuels, circular materials, CO₂ capture and conversion or renewable hydrogen, among others.” All partners share the common objective of net zero operations by 2050.

All4Zero will focus on the scale-up of early-stage technologies developed by private companies, universities, research centres and start-ups, and will allow them to validate their technological developments in real industrial environments, thus bridging the gap between ideas and implementation. Participants will be able to participate in technical conferences and carry out concept tests in the facilities provided by the industrial partners.

Europe: Six cement plants were reportedly issued around Euro88m in free European Union emissions allowances (EUA) from 2019 to 2022 despite the clinker kilns at the units being idle or running at low levels. Research by the Oil Price Information Service (OPIS) has revealed that plants operated by Buzzi, Cementos Portland Valderrivas (CPV), Cemex, Holcim and Votorantim Cimentos all benefited from the scheme despite only emitting 36,370t of CO2. The companies would then have been able to use the subsidy to cover emissions costs at other plants or sell the permits. OPIS identified five plants in Spain and one in Germany.

Spain: Cemex España has bought two new quarries near Madrid. The producer said that the quarries will strengthen its limestone reserves. It added that they include ‘all necessary elements’ for it to increase its services to the Madrid market.

Cemex’s Europe, Middle East, Africa and Asia regional president Sergio Menéndez said “These acquisitions strengthen our existing network and enable us to better serve a growing market with high-quality, sustainable and circular products. We are excited to be part of Madrid’s growth, which contributes to improving the quality of life of its residents and setting an example for more sustainable and circular cities.”

Spain: Residents of Cartagena, Murcia, have protested Cemex’s plans to begin mining pozzolan at new sites locally. The Murcia Plaza newspaper has reported that the protestors are calling for a mining ban, in line with their interpretation of the area’s Rural Area of Special Environmental and Social Sensitivity designation.

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.

Brazil: Votorantim Cimentos recorded consolidated sales of US$2.59bn during the first half of 2023, up by 51% year-on-year from US$2.37bn in the first half of 2022. The group reported that cement demand was ‘strong’ in the US and ‘stable’ in Spain, however the Brazilian and Canadian markets were ‘challenging.’ Its costs also rose, by 4.2% to US$2.1bn from US$2.02bn. Despite this, Votorantim Cimentos’ net profit grew by a factor of 11, to US$112m from US$10.1m.

Spain: Cementos Molins’ sales totaled Euro705m in the first half of 2023, up by 16% year-on-year from first-half 2022 levels. The producer said that increased cement volumes and prices across all regions contributed to the growth. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 36% to Euro179m, while its net profit rose by 40% to Euro80m. The company noted the favourable impact of the comparison with the first half of 2023, which was marked by market slowdown, high inflation and supply chain disruptions.
 
Chief executive officer Julio Rodríguez said "We have continued on the path of sustainable and profitable growth throughout the first half of 2023. It has been a truly positive second quarter in terms of our economic results, but also very encouraging thanks to the progress we are making in terms of sustainability. We have achieved important milestones in our Sustainability Roadmap 2030, including the launch of new low-carbon footprint cements and concretes. Furthermore, we inaugurated a new solar park in San Luis, Argentina."