Displaying items by tag: Alternative Fuels

Germany: A major clean-up operation is underway at Heidelberg Materials’ Burglengenfeld plant in Bavaria following a fire on 17 August 2025. The fire began in the plant’s waste plastic fuel storage hall and was attended by more than 340 firefighters, who managed to prevent it spreading to other areas of the plant. Waste plastic is the Burglengenfeld plant’s main fuel.

The damage is nevertheless considerable, amounting at least to ‘ hundreds of thousands of Euros,’ according to plant manager Bernhard Reindl. He also announced that a structural engineer will inspect the hall's structure in the coming days. It is already clear that the roof will have to be at least partially dismantled and replaced.

However, despite the disruption, cement production has been able to continue, with lignite being used on a temporary basis until the waste plastic fuel facility is repaired. The kiln is reported to be operating at 80% of its usual capacity.

How the fire in the warehouse started remains unclear, but Reindl suspects a smouldering fire, similar to a considerably smaller one that affected the same building in October 2024. Burglengenfeld police station has begun an investigation into the cause.

Mexico: Moctezuma inaugurated a US$12m alternative fuels storage system at its Tepetzingo cement plant in Morelos, after two years of engineering, planning and execution. The facility will process over 150,000t/yr of waste, including end-of-life tyres, municipal solid waste and non-recyclable materials, which will replace fossil fuels in cement production, with a goal of 30% substitution by 2030. The company said that the benefits of the project include saving thousands of tonnes of waste from landfill and mitigating methane emissions.

The producer, the Morelos government and the Ministry of Sustainable Development are also developing a circular economy centre in Jiutepec with an additional investment of US$1.6m. The facility will collect, shred and convert up to 3000t/month of tyres into alternative fuels.

Costa Rica: Holcim Costa Rica has issued its first sustainability report, which states that it reduced CO₂ emissions by 19% between 2018 and 2024. During the last year, the company prevented the release of more than 4600t of CO₂ thanks to improvements in thermal efficiency. It also processed more than 72,000t of municipal and industrial waste as energy or alternative fuel in cement production and reused more than 90% of the industrial water consumed at its cement plant. It reported that it has reached gender equality within its executive team, with 50% female and 50% male leadership.

Holcim Costa Rica’s 2030 goals include achieving a 32% reduction in primary CO₂ emissions from cement plant operations, a 5% reduction in electricity consumption and a 21% reduction in logistics emissions, while reaching a net positive impact on biodiversity, and reducing the use of fresh water.

Portugal: Cimpor has reported the successful installation of a new KHD Pyrorotor combustion chamber at its Alhandra plant. It described the upgrade as a key milestone in the modernisation of Kiln 7 and in the company’s energy transition process.

The combustion chamber measures 3.4m in diameter and 10m in length, and weighs 146t. It will allow the replacement of fossil fuels with alternative fuels, enabling a thermal substitution rate of up to 80%. Its installation required a technically demanding operation, carried out using a 400t crawler crane. The work is part of a wider structural upgrade of Kiln 7, which also includes the modernisation of the existing kiln to a production capacity of 3600t/day, a new preheater tower with a five-stage cyclone, the installation of a Pyroclon calciner, a new clinker cooler and a new vertical raw mill.

Cimpor says that the investment will contribute directly to the reduction of the plant’s CO₂ emissions, fully aligned with the company’s decarbonisation goals and reinforcing the company’s commitment to the targets set out in its Recovery and Resilience Plan.

Japan: Cement producers used 21.9Mt of post-consumer materials and by-products in the 2024 financial year, down by 3% year-on-year, marking the third consecutive annual decline, according to the Japan Cement Association.

Coal ash and blast furnace slag, which together make up over 50% of the total, both declined, although post-consumer plastics increased for a fourth consecutive year.

Cement production, including clinker for export, also fell by 3% to 45.7Mt. The amount of byproducts used per tonne of cement dropped from 480kg in 2023 to 478kg, but remained above 400kg for the 21st year in a row.

Argentina: The La Metropolitana recycling plant in Donovan despatched 14.1t of end-of-life tyres for industrial co-processing at Cementos Avellaneda’s La Calera plant. The facility uses the tyres as an energy source under a circular economy model. The initiative is promoted by the Ministry of Environment and Sustainable Development to support environmental protection and proper waste management.

Australia: Boral’s Berrima Cement Works celebrated a milestone of using more than 100,000t of alternative fuels in cement manufacturing at its facility during the 2025 financial year, according to a post by the producer on Linkedin. The facility displaced over 80,000t of coal. The fuels included high-biomass waste and tyres, which were diverted from landfill.

Boral said that it has achieved over 30% thermal energy substitution in the plant’s kiln, with successful trials reaching 45%. With recent upgrades such as the chlorine bypass and further infrastructure investment, the company targets 60% substitution in coming years.

Colombia: Holcim Colombia has invested US$2m to modernise its co-processing platform at its Nobsa cement plant in Boyacá. The upgraded facility will process 100,000t/yr of waste into alternative fuels for the cement plant, raising thermal substitution to 40% in the short term, with a target of 70% by 2030.

CEO of Holcim Colombia Martín Costanian said “This project realises our dream of optimising the crushing circuit and scaling our capacity to replace fossil fuels with more sustainable and truly circular solutions.”

The system renovation includes the addition of a shredder with a nominal capacity of 10t/hr, as well as new transfer systems and a modern dosing system capable of feeding up to 20t/hr of alternative fuels to the kiln. The waste used will consist of paper, cardboard, plastics and biomass.

Manager of Geocycle José Méndez said “This project represents true circularity and a solution for the thousands of pieces of waste that end up in landfills each year.”

Togo: Cement producers in Togo have committed to reduce CO₂ emissions by 2050 by lowering the clinker factor and increasing the use of alternative fuels. At a meeting in Lomé on 30 June 2025, manufacturers set out a roadmap that includes large-scale adoption of limestone calcined clay cement (LC3) to reduce clinker content from 65% to 40%, potentially cutting emissions by up to 40% without sacrificing performance, according to the Togo First newspaper.

The strategy also involves replacing coal with agricultural or municipal waste. Industry data shows that cement production generated 0.9Mt of CO₂ in 2023, which could rise to 1.8Mt by 2050 without intervention. Manufacturers are seeking regulatory support to help deliver the roadmap, which aligns with Togo’s Paris Agreement commitments.

New Zealand: Fletcher Building will begin using hard-to-recycle plastics and wood as alternative fuels in its cement production process during 2025, as part of its ‘front-end firing project’, according to The Post newspaper. The company aims to be 100% coal-free by 2030. It said wood pellets and shredded tyres currently substitute for 50% of coal. The new additions will raise this to 70–80%. Fletcher Building began burning wood pellets in 2003, construction waste in 2010 and tyres in 2023. Fletcher Building said it plays a “significant role in waste diversion for New Zealand."