Displaying items by tag: Buzzi

Brazil: Companhia Siderúrgica Nacional (CSN), Huaxin Cement and Votorantim Cimentos have all bid for InterCement’s Brazilian business, Valor Online News has reported. The source stated that Votorantim Cimentos is leading a consortium alongside Italy-based Buzzi and concrete producer Polimix Concreto, however the Brazilian cement market leader denied this, stating that its offer is ‘individual and independent.’ Both Votorantim Cimentos and CSN Cimentos are reportedly considering making initial public offerings (IPOs).

Votorantim Cimentos said “The company clarifies that it is not part of nor leads any consortium within the auction process. To date, its offer remains under evaluation by the respective seller and, therefore, no documents have been signed with any counterparty that generate an obligation or firm commitment for the acquisition of the assets that were the subject of the offer.”

Valentine’s Day last week included some ‘hot’ news for the cement sector with the announcement that Electrified Thermal Solutions is preparing to build the first commercial-scale pilot of its Joule Hive thermal battery (JHTB) in San Antonio, Texas. The company is working with the Southwest Research Institute on the project along with Buzzi Unicem USA, 3M and Amy’s Kitchen as industrial partners. Advisors include Imerys. The project update follows the award of a US$5m grant from the US Department of Energy (DOE) in late January 2024.

The funding description from the DOE’s Industrial Efficiency & Decarbonization Office reports that the end goal is to “turn intermittent renewable electricity into constant industrial grade heat” that can replace fossil fuel usage. Electrified Thermal Solutions aims to test its JHTB thermal energy storage system, which uses electrically conductive refractory bricks, to convert and store electricity as heat at temperatures higher than 1700°C. The JHTB power ranges between 1 - 200MW of thermal output, with duration up to tens of hours, enabling ‘very affordable’ high temperature energy storage and on-demand heat. Notably, it can charge and discharge simultaneously, allowing a continuous heat supply.

Electrified Thermal Solutions is not alone in targeting the cement sector. As Global Cement Weekly has covered previously energy storage is a growing topic of interest with a few large-scale electrical battery units running at cement plants in Pakistan and Taiwan. The other big name in thermal batteries for cement production is Rondo Energy. Both Electrified Thermal Solutions and Rondo Energy are using modular three-dimensional arrays of refractory bricks to store thermal energy and then release it, although they are likely to have key proprietary differences. However, Rondo Energy appears to be further along the industrial adoption process so far. Titan Cement and Siam Cement Group (SCG) invested in Rondo Energy in 2022. Then in July 2023 SCG and Rondo Energy said that they were planning to expand the production capacity of a heat battery storage unit at an SCG plant from 2.4 GWh/yr in mid-2023 to 90GWh/yr. For more information on Rondo Energy read the feature by CEO John O’Donnell in the January 2023 issue of Global Cement Magazine.

The reason that this matters, as partly explained above, is that fossil fuels contribute about one third of the CO₂ emissions created by heating up the kiln in cement production to make clinker. This is dropping globally due to the uptake of alternative fuels, but burning alternative fuels emits gross CO₂, however you account for the emissions. Mass adoption of thermal batteries by the sector could potentially cut out this double-accounting and reduce that third down to the carbon footprint of the refractory bricks used. This would then create knock-on issues concerning what to do with the waste streams instead but that is not a problem for the cement sector. These are worries for another day, as we first need to see how thermal batteries work at scale at a cement plant.

A recent feature in the Economist considered whether the mass adoption of electrical power from renewable sources might be an increasingly viable path to decarbonising industry. Geopolitics, faster-than-expected growth in renewables and new technology are all doing their bit to make this possible. As with so much of the carbon agenda it may alter the very concept of the traditional cement production line or at least the speed of change. Just imagine how a future cement plant might look, decked out with a electrical micro-grid, a heat battery, an oxy-fuel kiln, a carbon capture unit and either a chemical plant or gas pipeline junction. Will it happen? Who knows… but it is an exciting time for the cement sector.

US: Buzzi Unicem USA is among industrial partners collaborating with Electrified Thermal Solutions in the development of its Joule Hive Thermal Battery for industrial heat decarbonisation. The partners plan to launch a commercial-scale pilot of the battery in San Antonio, Texas, in association with the Southwest Research Institute. The project is supported by US$171m in funding from the US Department of Energy. The battery delivers heat of up to 1800°C from energy from renewable sources.

Buzzi Unicem USA president and chief executive officer Massimo Toso said “Cement production is known as a hard to abate industrial sector in large part because of the high temperatures required. Electrified Thermal Solutions’ Joule Hive Thermal Battery is the first industrial heat decarbonisation solution we have identified that could potentially enable us to cost-effectively and completely eliminate the use of fossil fuels in our heating processes and achieve our corporate decarbonisation goals.”

Electrified Thermal Solutions chief executive officer Daniel Stack said “We believe the breadth and depth of involvement from our industrial partners like Buzzi Unicem USA was critical to demonstrate to the Department of Energy just how valuable the Joule Hive Thermal Battery will be for industrial decarbonisation, and we are grateful for their partnership.” Stack added “Southwest Research Institute’s engineering support and world-class industrial demonstration facilities signalled to the Department of Energy that our technology will be developed, built, operated, tested and evaluated to the highest standards.”

Italy: Buzzi recorded consolidated sales of Euro4.32bn in 2023, up by 8.1% from Euro4.32bn in 2022. This came in spite of a 7% year-on-year drop in the company’s cement sales volumes, to 26.3Mt. In its domestic market of Italy, Buzzi raised its sales by 13% to Euro818m. In the US, sales grew by 9.5% to Euro1.74bn, in Mexico by 33% to Euro1.03bn, in Germany by 9.2% to Euro872m, in the Czech Republic and Slovakia by 1.8% to Euro205m, in Poland by 11% to Euro157m and in Ukraine by 43% to Euro85.6m. On the other hand, Buzzi’s sales fell by 5.6% in Luxembourg and the Netherlands, to Euro214m, by 2% in Russia to Euro285m, and by 1.6% in Brazil to Euro394m.

The company said “The increasingly evident effects of monetary restriction, the worsening of consumer and business confidence, and the uncertainties dictated by the growing geopolitical tensions in Ukraine and the Middle East continue to weigh on the international economic framework. In fact, in the last part of 2023, global economic activity weakened further, with international trade contracting in the third quarter.”

Ukraine: The Antimonopoly Committee of Ukraine (AMCU) has launched an investigation into Ireland-based CRH's acquisition of certain Central-Eastern European assets of Italy-based Buzzi Unicem. The assets in question include two Ukrainian cement plants. The AMCU will assess the potential impacts of the consolidation on the cement market in Ukraine. The parties concluded the deal in June 2023, and expected to conclude it in September 2024. The AMCU first rejected CRH's application to it in September 2023, but subsequently agreed to reopen its examination of the deal in October 2023.

US: Buzzi Unicem USA’s Maryneal cement plant in Texas hit a production record of 1.03Mt of clinker and 1.18Mt of cement in 2022. The figures were more than 4% over the year’s budgeted figures. The plant says it achieved the result through consistent communication and a positive culture. Managers at the unit also shared updated production figures at daily meetings, kept all employees actively engaged and created an encouraging atmosphere. The plant has set new goals for 2023.

Antonio Corea Cruz, Operations Manager at the plant, said, “We’ve implemented strategies to keep reliable assets which allow the team members to work on continuous improvement. This affects the efficiency and productivity of all aspects of the plant.”

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.

US: Buzzi Unicem USA has challenged penalties worth US$62,500 and denied that it failed in its duty to protect an employee who died after falling into the Mississippi River while working on a barge at the Natchez terminal in Mississippi in February 2023. The Occupational Safety and Health Administration (OSHA) cited multiple alleged safety violations by the Buzzi subsidiary in a report published in mid-August 2023.

Buzzi Unicem USA said “The company strongly contends that it did not violate the regulations set forth in the citations regarding personal floatation devices and guardrails, and therefore timely filed notice with OSHA that it is contesting the alleged violations contained in these citations (as well as certain aspects of the other citations).” It continued “The company objects to any characterisation by OSHA that the citations are a final determination that the company violated any OSHA regulation or caused the death of our valued employee.”

US: The Occupational Safety and Health Administration (OSHA) of the US Department of Labor has found that Buzzi Unicem USA failed in its duty to implement safe practices, after a 50-year-old employee died at work in February 2023. The victim was working on a Mississippi River barge belonging to Buzzi Unicem USA subsidiary River Cement Sales when he fell overboard, leading to his death. OSHA concluded that Buzzi Unicem USA had committed multiple serious safety violations. Those connected to the tragedy in February 2023 included failures to ensure that workers wore personal floatation devices and to install guardrails. The administration said that the failures ‘cost a worker his life.’ Safety inspectors proposed a fine of US$62,500 for the breaches.

Italy: Alpacem subsidiary W&P Cementi has concluded a deal to buy Buzzi’s Fanna cement plant in Friuli-Venezia Giulia. The plant has a clinker capacity of 660,000t/yr. As a part of the deal, Buzzi will obtain a 25% stake in Alpacem’s Austrian subsidiary Alpacem Zement Austria. Alpacem said that the deal expands the companies’ existing strategic partnership into the Austrian market. The parties expect to conclude the deal, pending the approval of competition authorities, in 2024.

Alpacem chief executive officers Bernhard Auer and Lutz Weber said “We are pleased to be expanding the strategic partnership. There are many future challenges in the cement sector that we can solve better together than we can individually.”