Displaying items by tag: Alternative Fuels

Canada: Pond Biofuels has set up a bioreactor pilot plant at St Marys cement plant in St Marys, Ontario. The raw smokestack gas from the cement plant is recycled to grow algae in a third-generation 25,000L bioreactor at the on-site pilot plant. The resulting algae can be used for bio-oil, food, fertiliser and sewage treatment.

The algae consume CO₂, NO_X and SO_X from the smokestack gas. Every 1kg of algae produced prevents 2kg of CO₂ from being emitted into the atmosphere. The St Marys Cement Plant produces 720,000t/yr of cement and 540,000t/yr of CO₂. Currently, Pond Biofuels only uses a small portion of the total CO₂ output.

"We consider ourselves a carbon recycling technology," said Steve Martin, founder of Pond Biofuels.

The algae thrive in light filled, CO₂-rich conditions, which are provided in the bioreactor. The light comes from custom-designed red LED lights that flash continuously. The rapid flashing fools the algae into thinking the days are very short, so it grows very fast. "The algae evolve quite quickly; we can get four, five, six generations of algae in a day," said Martin.

Proving the production of algae at commercial scale is important, but the other important part is finding a market for the algae. "Between 10 – 20% of it is oil that be used for producing biodiesel," said Martin. It could also be used a coal replacement, a soil amendment or even animal feed and it can be easily dried using waste heat from the cement plant.

Namibia: Namibia's Ohorongo Cement plant plans to use blackthorn as biofuel for cement production. The company sources some 30% of its energy requirements from biofuel and plans to raise this figure to 80%.

"In the long term we will be very competitive," said Ohorongo Cement's chairman, Gerhard Hirth. Not having to rely on coal and oil imports, Ohorongo Cement will be able to keep energy costs down while making a positive contribution to the environment.

Hirth has invested US$340m in the 600,000t/yr capacity Ohorongo Cement plant. Some 500,000t/yr is sold on the domestic market and the rest is exported to Botswana, Zimbabwe and Zambia. Ohorongo Cement employs 330 people directly and 2500 indirectly.

Ohorongo Cement is currently under threat from a new market player. In order to side-step the 60% levy on cement imports into the country, a Chinese cement producer has recently begun operations at its own plant in Namibia. According to Hirth, Ohorongo Cement has lost more than Euro30m and is undertaking legal proceedings against its rival.

Canada: Lafarge is moving ahead with an attempt to use plastic waste instead of coal at its Brookfield cement plant in Nova Scotia. Scarth MacDonnell, Brookfield's plant manager, appeared before Colchester County council to inform them of the plant's intent to use plastic waste as a low-carbon fuel.

"We think we have found a solution to the very real problem of plastics that build up in landfills," said MacDonnell. "We hope to get 30% substitution of coal." MacDonnell added that the emissions are safe and meet or exceed provincial and federal government standards.

The plant will submit an application to Nova Scotia's Department of Environment for an industrial trial replacing coal with shredded plastics. It will also host an open house on 17 July 2014 for people who want to learn more about and talk about the idea.

MacDonnell said that a study by the province's Department of Natural Resources indicates that there is 79,000t/yr of plastic going into landfills in Nova Scotia and that a study by Dalhousie University states that using plastics reduces carbon dioxide emissions up to 34% and other greenhouse gas emissions can be reduced by as much as 98%.

Colombia: Cemex is pursuing alternative energy sources, including landfill biogas, wind and solar energy, for its operations in Colombia. It has planned some US$50m of projects for the next five years. The company will look for partners among financial entities and investment funds, according to Edgar Angeles, Cemex's vice president of operations for Central, South America and the Caribbean.

Since the elaboration of Colombia's law on renewable energy, Cemex has been studying projects of this type. The law allows companies to invest in their own power supply and to sell any surplus on the wholesale market. Cemex wants to guarantee 100% of its power supply, compared to 65% now. It already has three small hydroelectric stations and a gas-fired plant in Colombia's Junin, Bucaramanga and Ibague municipalities.

India: According to the latest data from the Gujarat Pollution Control Board (GPCB), the utilisation of hazardous waste as an alternative fuel and raw material (AFR) in cement kilns has increased by a factor of 35 since 2009 – 2010 from 15,693t/yr to 543,569t/yr in 2013 - 2014.

This follows the GPCB's measures to strike a balance between the disposal of toxic hazardous wastes, environmental protection and economic interests. Safe disposal of toxic hazardous waste posed a major challenge before the state pollution regulator took up disposal through cement kilns under controlled conditions.

In 2011 Gujarat State generated 109Bnt/yr of incinerable waste, 1107Bnt/yr of land-fillable waste and 577Bnt/yr of recyclable hazardous waste. These included plastic waste, spent carbon, tar, mixed waste liquid, pharmaceutical waste, tyre chips, agricultural waste, solid waste, chemical gypsum, iron sludge, copper slag and fly ash.

The GPCB encouraged major industrial clusters and cement plants to provide waste collection centres and pre-processing facilities for hazardous waste for co-processing. "It is a recovery of energy and material from waste," said Hardik Shah, member secretary of the GPCB. "The challenging task was to convince the top management of cement plants." The GPCB facilitated cement makers with access to its data on the waste generated in the State via Extended Green Node (XGN) software, which ensured the supply of suitable wastes.

"This involves some additional investment, but in the long run it repays as there are savings on fuel costs," said an Ambuja Cement spokesperson. Ambuja has invested US$16.7m to set up a pre-processing facility of solid/semi-solid waste at its Ambujanagar plant in Junagadh District, Gujarat State.

Similarly, Sanghi Industries is in the trial phase for using hazardous waste. "From a legal standpoint, we need to get clearance from the GPCB for co-processing any new waste material in our plant," said Alok Sanghi, director of Sanghi. "We have submitted the results of the trials conducted and are awaiting clearance from them." Sanghi has been doing trials for last 18 months.

"The use of alternative fuel in Indian cement industries has been limited," said GPCB's Shah. "The thermal substitution rate (TSR) in the cement industry is less than 1% in India as against 10% in Japan and 40% in European nations. The GPCB has set a target of three years to achieve a TSR of 10% by using AFR."

Egypt: Omar A Mohanna, Chairman of Suez Cement, has announced that the company intends to alter its energy mix to use 20% of its energy from waste recycling and 80% from coal during 2014. He added that the Ministry of Environmental affairs has not announced its position on the use of coal, according to AlAhram News. Previous energy supply shortages have reduced production at Suez Cement to 50%.

In related news, the CEO of the Misr Beni Suef Cement Company revealed that his company has received an official letter from the Egyptian government informing the company that the natural gas supply to their facilities will be completely cut in May 2014. The letter added that the government will supply enough Mazut to the company to operate one production line.

Egypt: Arabian Cement Company has announced that its initial public offering (IPO) is expected to take place before the end of the second quarter of 2014, with trading on the Egyptian Stock Exchange to start around 21 May 2014. The company plans to sell a 22.5% stake.

Arabian Cement Company has also invested US$35m to shift from using 100% natural gas to 70% coal and 30% alternative fuels. It expects to use coal within the next three to four months once the government issues the company with the necessary license. The company produced 4Mt of cement in the 2013 fiscal year from a capacity of 5Mt/yr. It expects no growth in the 2014 fiscal year on the back of energy shortages.

UK: Saxlund International Ltd, a subsidiary of Opcon AB, is preparing to commence construction on the materials handling contract won late in 2013 for Hope Construction Materials' Hope Valley cement plant in Derbyshire, UK.

As part of Hope's move to replace fossil fuels with more sustainable solutions, Saxlund will provide an alternative fuel system for the use of Solid Waste Fuel (SWF). Saxlund's scope includes supplying the design, manufacture and delivery of a push floor storage system, reclaim conveyor, process tower with drum magnet, star screen and feed into the weighing and pneumatic injection system to the main burner on both kilns.

"We've worked hard to expand our portfolio in this sector and to provide clients with some of the best solutions in the market," said Rob Leighton, business development manager for Alternative Fuel Systems at Saxlund. "It's good to work with clients like Hope, who are doing as much as they can to run their businesses as efficiently and sustainably as possible. With increasing costs of fossil fuels and the increasing range of waste-derived fuels available, Hope is keen to use more and more alternative fuels in order to reduce their energy costs and improve environmental performance where possible."

Three news stories this week cover the gamut of fuels used by the cement industry in North America.

First we had an example of the changing trends in fossil fuel usage when TruStar Energy announced a deal to supply compressed gas to Argos USA. Then we moved to an example of recycled fuels used in co-processing when chemical waste firm ChemCare trumpeted its 100 million gallon milestone (that's 379,000m³ to the rest of the world) in supplying fuel-quality waste to the Lafarge co-processing subsidiary Systech Environmental. Finally, Cemex rounded off the main fuels groups with renewables, when it released pans to build a US$600m wind farm project in north-east Mexico.

Obviously fossil fuels still dominate in kilns north of the Darian Gap, as they do almost everywhere else, and fuel buyers wouldn't be doing their job properly if they weren't searching for the next best deal. Yet the range here shows a dynamic industry.

Jan Theulen from HeidelbergCement pointed out one example in the US at the recent Global CemFuels Conference held in Vienna. Here, rising landfill prices are increasing opportunities for alternative fuels use alongside changing US Environmental Protection Agency (EPA) permitting for solid recovered fuel. Alternative fuels consultant Dirk Lechtenberg, in an interview with Global Cement Magazine in February 2014, singled out the US as one country that is developing its alternative fuels use. As he explained, "Even though the fossil fuel prices are quite low in the US, the industry is developing supply chains for alternative fuels to be more independent with their fuels sourcing."

This race between cheaper fossil fuels in the US (via shale gas) and increasing development in alternative fuels is fascinating. Specifically: why is it happening now? Gas prices have fallen and demand for cement is returning in the US. The annual mean Henry Hub natural gas spot price in the US fell from US$8.86/million BTU in 2008 to a low of US$2.75/million BTU in 2012. This compares to up to US$15/million BTU in Japan and US$9/million BTU in Europe.

Public environmental pressure made manifest by the policies of the EPA and general increased knowledge about co-processing may be factors for the surge in alternative fuels investment. Long lead times for alternative fuels schemes may be another. Planners making a decision about what fuels mix to pursue in 2008 at the start of the recession might well have bet on alternatives to spread their risk. Yet the cause could be something else, as shale gas takes over higher paying industries, such as electrical generation, and the cement industry continues to be priced out of the leftovers.

Ultimately what burns in a cement kiln comes down to price. Depending on how the shale gas market plays out in North America it would be ironic if 'frackers', the bogeymen of current environmentalists, inadvertently cleaned up the cement industry.

US: Chemical distributor Univar has shipped 379,000M^₃ (100 million gallons) of fuel-quality waste from its waste chemical business, ChemCare, to Systech Environmental, a subsidiary of Lafarge. The two companies have been in partnership in waste management since 1989.

"We are committed to responsible waste management for our ChemCare customers, including the recycling of materials wherever possible. Our 25 year partnership with Systech has been an outstanding reflection of this, enabling the responsible disposal of waste while providing an alternative fuel source for cement kilns," said Greg Vas Nunes, vice president of ChemCare. Systech Environmental added that the arrangement had prevented the generation of 800,000t of CO₂.

ChemCare provides waste management service that collects both hazardous and non-hazardous waste products at customer locations in the US and Canada. It then works with partners in the waste disposal business to transport these materials to licensed third-party treatment, storage and disposal facilities.

Systech Environmental processes hazardous and non-hazardous industrial waste for use as fuel in cement kilns. It is actively processing or marketing fuels at 16 cement plants in the US.