Displaying items by tag: Alternative Fuels

Canada: As it awaits industrial approval from the Province to burn tyres at its Nova Scotia cement plant, Lafarge Canada says it has spent US$830,000 to install emissions monitoring systems. The company says its new equipment measures plant emissions such as sulphur dioxide, nitrogen oxides, carbon monoxide, carbon dioxide, oxygen, and total hydrocarbons every 10 seconds.

Rob Cumming, Lafarge's environment director, says the company's proposed one year pilot project at its Brookfield plant will allow it to gather the scientific evidence needed to assure the public that it is safe to use scrap tyres as a replacement for coal.

In October 2017, the Environment Department said it was reviewing the company's application and would make a decision on the project within 60 days. The project has drawn criticism from residents near the plant, environmental groups and Nova Scotia's NDP, which has called on the Liberal government to ban tyre burning.

Canada: The New Democratic Party has called for a ban of burning tyres in Nova Scotia. The opposition political party held a news conference with opponents of the government's decision in July 2017 to approve a one-year pilot project allowing Lafarge Canada to burn tyres for energy at the company's Brookfield cement plant, according to the Canadian Press newspaper. No tyres have been burned at the plant so far as the cement producer waits for industrial approval of the project from the provincial government.

Mark Butler of the Ecology Action Centre said the government’s decision was based on a Dalhousie University engineering study that was too narrow in its focus and wasn't peer reviewed. However the government has said that it used several technical studies to inform its decision. A group of local residents also started legal action in August 2017 on the grounds that the project violated the province's Environment Act.

Ireland: On 29 August 2017 an oral hearing began to hear submissions regarding plans by Irish Cement to use alternative fuels for energy in its plant in Limerick. The company is seeking to move away from using fossil fuels as a main source of material in its cement kiln in Mungret and to use recovered waste and tyres instead.

A number of local residents and members from action group Limerick Against Pollution (LAP) held a protest outside the hearing. LAP spokesperson Tim Hourigan said that residents were concerned about the possible release of toxins from the proposed process and that they were opposed to it going ahead. The hearing was also attended by local businessman and racehorse owner JP McManus, who said he was ‘concerned’ about the plans.

Representatives from Irish Cement told the hearing that the proposal would improve the long-term viability of the plant as well as help to reduce CO2 emissions and the plant’s reliance on imported fossil fuels. The hearing is expected to last until Friday 1 September 2017.

Canada: A group of residents close to the Lafarge Canada Brookfield plant has launched a court challenge arguing the Nova Scotia government's approval of a plan to burn tyres as an alternative fuel at the plant violated the Environment Act.

In his application for a judicial review, lawyer William Mahody wrote that Environment Minister Iain Rankin didn't properly assess the impact of emissions from the Lafarge plant in Brookfield on surrounding areas, stating that was a ‘strong potential for adverse effects’ on surface water, human health and wildlife from the project. The plan has run into criticism from environmental groups, municipal councils and area residents, who prevented a similar proposal a decade ago.
Nova Scotia’s waste diversion agency has shifted a supply of at least 280,000 tyres per year to Lafarge and recently approved the company's environmental application for a one-year pilot project to incinerate the tyres as fuel.

Lafarge says it can't comment on the judicial review. However, Robert Cumming, the environmental director at Lafarge, says research conducted off-site by a Dalhousie University engineer suggests the use of scrap tyres will lower the plant's CO2 emissions. "Our pilot project seeks to validate this evidence gathered from scientific reports and in Dalhousie University laboratories. The research team and Lafarge have committed to sharing the results with the community."

Germany: Bernd Scheifele, the chairman of HeidelbergCement, has admitted that his company needs to take action to improve its overall sustainability management following its acquisition of Italcementi. Following the purchase both its specific gross CO₂ emissions per tonne of cementitious material and its alternative fuels mix fell. However, specific emissions of NO_x and SO_x fell, although specific dust emissions rose in the reporting period. The cement producer also improved accident frequency despite increasing its workforce to 15,781 in 2016 from 9560 in 2015.

Netherlands: Alternative fuels specialist N+P Recycling has celebrated its 25th anniversary and the opening of its new headquarters in Nieuw-Bergen, Limburg. Company chief executive officer (CEO) Karel Jennissen presided at the event and Manon Pelzer, the mayoress of Nieuw-Bergen, was also in attendance.

200 guests attended the opening that included a guided tour of the new premises. At a ceremony marking the anniversary Karel Jennissen, with his wife Karin, presented the history of the company. Their three sons Lars, Stijn and Jens then gave guests a personal insight into their own experiences with the firm. This was followed the next day by a general tour of the facility for the local community with around 1000 members of the public.

A full report will be published in the September 2017 edition of Global Cement Magazine, including a visit to the company’s 80,000t/yr Subcoal production facility in Farmsum.

Image 1: Karel Jennissen of N+P Recycling

Image 2: Karel Jennissen N+P Recycling with his sons Lars, Stijn and Jens

Saudi Arabia: Saudi Electricity Company (SEC) has signed a co-operation agreement with Al Safwa Cement Company to reuse carbon ash and oil residues byproducts that result from the burning of heavy fuel in power generation plants. They will be used as an alternative source of energy at the cement plant, instead of being landfilled.

Khalid Bin Abdulrahman Al Tuaimi, the executive vice president for the generation at SEC, pointed out that SEC was the first company to adopt this policy. "This will reduce the dependence of the cement plant on heavy fuel, thereby reducing dependence on oil, which is a key element of the Kingdom Vision 2030 to restructure the national economy," he said.

Spain: Cementos Cosmos has stopped exports from its Niebla cement plant due to an increase in the price of petcoke. The subsidiary of Brazil’s Votorantim has also implemented a Temporary Regulation of Employment from June 2017 to May 2018 that will enable it to suspend workers or reduce working hours, according to the Huelva Información newspaper. The cement producer says it is waiting for planning permission to install a dosing system for waste fuels that will cut it fuel bill. However, the local community has opposed attempts to use alternative waste fuels previously.

Lots of fascinating information has been emerging in recent weeks about changes in the Chinese cement industry as the larger producers have published their annual financial results. One example is the focus on using alternative fuels to fire up kilns. As explained below, the spotlight on co-processing is state-mandated and this is why the producers are now keen to promote their adherence. Even so, as ever with China, the scale of the change is staggering.

For example, Anhui Conch reported that it had completed 15 waste treatment projects and one sludge treatment project in 2016. In addition it had three projects still undergoing construction at the year-end. The group said that it co-processed 600,000t of domestic waste in its cement kilns in 2016. All of this was achieved by a company that says it only started co-processing municipal waste from its first project in 2010. China Resources Cement’s (CRC) progress was slower but it managed to start a co-processing project at its plant in Binyang County, Guangxi in December 2015 and a sludge project in Nanning City, Guangxi in July 2016. New projects at Tianyang County, Guangxi and Midu County, Yunnan are being built at present, with completion expected by the end of 2017.

Long held rumours about production overcapacity in China came to head in 2015 with the National Bureau of Statistics in China (NBSC) reporting that sales dropped in 2015 following a decade of steady growth. Then the results of most of major producers followed this by falling in 2015. CRC presented a good history of what happened next in the Chinese cement industry in its results report [LINK]. In brief, in 2016 the Chinese government implemented supply-side structural reforms focusing on production efficiency, reiterating attempts to stop new production capacity being built and pushing environmental reforms. Throughout the year various government offices released guidelines to encourage market consolidation, cut obsolete production capacity, increase co-processing rates and decrease the energy needed to produce each tonne of clinker.

Graph 1: Cement sales in China, 2012 – 2016. Source: National Bureau of Statistics in China.

Whether or not any of this has helped the Chinese cement industry to overcome the problems it faced in 2015 is unclear. As Graph 1 shows, Chinese cement sales started to rise again slightly to 2.35Bnt in 2016 from 2.31Bnt in 2015. Sales revenue from some of the major cement producers presents a more varied picture as can be seen in Graph 2. Anhui Conch’s revenue rose by 9.7% year-on-year to US$8.12bn in 2016, China National Building Material Company’s (CNBM) revenue rose by 1% to US$14.8bn and CRC’s revenue fell by 4.2% to US$3.3bn. CRC may have suffered here from its relative business concentration in southeast China. Both Anhui Conch’s and CNBM’s results seemed to look patchy in mid-2016 when they released their half-year reports, but both sales and profits seemed to pick up sharply in the second half of the year.

Graph 2: Sales revenue from selected major Chinese cement producers. Source: Company annual reports.

As the current set of structural reforms kick in within the Chinese cement industry it will be interesting to see what happens next. From plans to cut 10% of local clinker production capacity by 2020 to ambitious environmental aims the sector barely has time to catch its breath. The question is whether the major producers balance sheets are being helped more by a recovering local market or by the reforms. Either way the uptake of alternative fuels is encouraging.

China: Huaxin Cement’s sales revenue rose by 1.9% to US$1.96bn in 2016 from US$1.93bn in 2015. Its cement and clinker sales rose by 5% to 52.7Mt and its net profit rose sharply to US$65.6m from US$14.9m. It attributed its result to following government-promoted supply side reforms such as cutting production costs. The cement producer noted that its had increased its usage of alternative fuels in the second half of the year following an increase in the cost of coal.

During the reporting period Huaxin Cement put its 3000t/day Tajikistan Sughd clinker production line into operation. It also purchased 15 cement plants from LafargeHolcim, including four grinding plants, located in Yunnan, Chongqing and Guizhou provinces. Altogether the new cement and clinker production capacity is expected to reach 10Mt and 15Mt respectively. The company also added that it had 25 alternative fuels co-processing projects operating or under construction with a capacity of 5Mt/yr.