Displaying items by tag: CCUS

Germany: The Catch4Climate project has moved into the planning stage of its oxyfuel pilot plant at the Mergelstetten cement plant. The group, comprising Buzzi Unicem’s subsidiary Dyckerhoff, HeidelbergCement, Schwenk Zement and Vicat, signed a letter of intent with the state’s prime minister and transport minister in Stuttgart in mid-November 2020.

The consortium intends to build and operate its own demonstration plant on a semi-industrial scale, to use the oxyfuel process to capture CO₂. In the future, the captured CO₂ will be used to produce so-called ‘reFuels’, climate-neutral synthetic fuels such as kerosene for air traffic, with the help of renewable electrical energy.

The cement producers formed CI4C – Cement Innovation for Climate in late 2019. The aim of the Catch4Climate project is to create the basis for a large-scale application of CO₂ capture technologies in cement plants enabling the later use of CO₂ as a raw material in other processes such as a carbon capture and utilisation/storage.

Germany: Cemex Zement has announced the start of carbon-neutral building materials development at its 1.9Mt/yr Rüdersdorf, Brandenburg cement plant. Called Vision Rüdersdorf, the project consists of, “the comprehensive investigation of various approaches to breakthrough technologies in order to prevent process-related carbon dioxide (CO₂) from entering the atmosphere, but to use it for beneficial purposes. The investigation areas can be divided into capture, storage or use of CO₂. This will help towards Cemex’s target of 55% CO₂ emissions reduction across Europe by 2030 and its commitment to deliver carbon-neutral concrete by 2050.

Chief executive officer (CEO) Rüdiger Kuhn said, “For years, sustainable success has been achieved here in the reduction of fossil fuels and in the selection of alternative recipe ingredients for cement. The experienced team is always looking for possible improvements. When it came to determining the best possible CO₂ emission values, the Rüdersdorf plant was always at the forefront of the European cement industry and has thus also earned an excellent reputation in the global Cemex organisation.”

In order to realise Vision Rüdersdorf, the producer has partnered with companies from other industries. Managing director and plant manager Stefan Schmorleiz said, “In an interesting approach, the CO₂ that we capture is used as a raw material for downstream processes in the chemical industry. Another approach is to innovate in the storage of CO₂. With these efforts, and our commitment to review and invest in these technologies, Cemex Zement is making a contribution to the decarbonisation of the cement industry.”

Norway: The Norwegian government has introduced a bill to parliament to allow funding for industrial scale implementation of HeidelbergCement’s carbon capture and storage (CCS) project at its 1.2Mt/yr Brevik plant in Porsgrunn, Telemark. If enacted, the legislation will provide for the majority of required funding.

HeidelbergCement chair Dominik von Achten, “We are very pleased with the proposal of the Norwegian government. This allows us to continue the pioneering work that we started together with our partners in Brevik. The CCS project in Norway is an important cornerstone in our climate strategy. It will enable us to significantly reduce otherwise unavoidable greenhouse gas emissions related to the cement production process.”

Mexico: Cemex subsidiary Cemex Ventures has signed an agreement with US-based carbon capture and storage (CCS) specialist Carbon Clean for the development of a CCS solution for under US$30/t of carbon dioxide (CO₂) captured. Cemex cement plants will host the products during pilot testing. Cemex Ventures head Gonzalo Galindo said, “The ambitious target of making carbon capture technology accessible and more efficient would be an unprecedented achievement for the cement sector, opening a door of opportunities for further developments.”

US: LafargeHolcim says that Department of Energy institution National Energy Technology Laboratory has awarded US$1.5m of federal funding to the company’s CO₂MENT Colorado project. The project aims to capture 2.0Mt/yr of carbon dioxide (CO₂) from the company’s 1.9Mt/yr Portland cement plant in Florence, Colorado for sequestration underground by Occidental.

The group said, “With the successful completion of the initial scoping study in June 2020 and confirmation of Department Of Energy funding, the partnership has committed to the next project phase.”

Japan: A proposal by Mitsubishi Group on researching CO₂ injection into concrete has been approved for a grant from the New Energy and Industrial Technology Development Organisation (NEDO). This joint project between Mitsubishi Group, Kajima Corporation, and Chugoku Electric Power aims to improve the existing technology so that it can be applied to the reinforced and cast-in-place concretes used in building construction. At present the group said that current carbon-recycling techniques are mainly used for unreinforced concretes, such as concrete blocks.

Mitsubishi Group has already been involved in the development of concrete projects that take advantage of carbon-recycling, including a zero-emission concrete called CO₂-SUICOM. It added that carbon capture, utilisation and storage (CCUS) technologies, including carbon-recycling, are an excellent opportunity for the company to use its strengths between industries that both emit and use CO₂.

France: UK-based Carbon8 Systems has announced plans for the commercial implementation of its carbon capture and use (CCU) system at Vicat’s Montalieu integrated cement plant in France. It follows successful demonstration projects at cement plants in the UK and Canada.

The company’s CO₂ntainer product will be deployed directly onsite at the plant and integrated into Vicat's existing industrial processes. It will capture CO₂ directly from the plant's flue gas emissions and use this as part of its Accelerated Carbonisation Technology (ACT) process. This accelerates the carbonation of cement bypass dust into lightweight aggregates. In its first phase of operation it will process and convert up to 12,000t of cement bypass dust.

HeidelbergCement released their sustainability report for 2019 this week. Every large cement producer publishes one but this one is worth checking out because of the company’s ambition to become CO₂ neutral. Other companies are heading the same way but few of them have such developed and public plans.

Sustainability reports are often a hodgepodge of non-financial reporting bringing together environment, health and safety, community and other topics. Multinational companies cover a wide range of jurisdictions and combining reporting in these kinds of fields can be beneficial. Typically they are members of various bodies like the Global Reporting Initiative (GRI) or the Global Cement & Concrete Association (GCCA) that give various levels of conformity between reports. Yet, the wider focus of sustainability reports gives companies a chance to promote what they are doing well, away from balance sheets.

One highlight of HeidelbergCement’s report is its progress towards reducing its specific CO₂ emissions per tonne of cement and its recognition by the Science Based Targets (SBT) initiative towards this goal. So far it has achieved a reduction of around 22% from 1990 levels to 599kg CO₂/t (net) with a target of a 30% reduction or 520kg CO₂/t by 2030. There is a lot more going on in the report but it’s led by the vision, ‘to offer CO₂-neutral concrete by 2050 at the latest.’ It plans to achieve this by increasing the proportion of alternative CO2-neutral raw materials and fuels, developing lower clinker cement types and capturing and utilising CO₂ emissions. A focus on concrete is worth noting given the pivot by building materials manufactures towards concrete in recent years.

Back in the present, HeidelbergCement is roughly in the middle of the pack of major European multinational cement producers with its specific CO₂ emissions for cement in 2019. LafargeHolcim reported 561kg CO₂/t and Cemex reported 622kg CO₂/t. This is a bit of a moving target since corporate acquisitions and divestments can change both the starting point and the apparent current progress. HeidelbergCement’s acquisition of Italcementi in 2017 or CRH’s purchase of Ash Grove did exactly that. The other thing to consider is that these companies manufacture a lot of cement. The actual gross CO₂ emissions from a multinational cement producer are immense. LafargeHolcim, one of the world’s largest multinational producers, emitted 113Mt of CO₂ in 2019 from process and fuel sources whilst making cement. To put that into context, estimates for total global CO₂ emissions range from 33 – 36Gt for 2019. The cement industry’s entire share was estimated by the International Energy Agency (IEA) to be 4.1Gt in 2018.

Where this sustainability report starts to become really interesting is where it talks about CO₂ capture and utilisation. Its plans in this department are more mature than many of its competitors with various initiatives at different levels of development, mostly in Europe. Norcem, its Norwegian subsidiary, recently signed an agreement with Aker Solutions to order a CO₂ capture, liquification and intermediate storage plant at its integrated Brevik cement plant. The deal is dependent on government support but it’s a serious proposal. As reported previously from the Innovation in Industrial Carbon Capture Conference 2020, HeidelbergCement is actively preparing to hook up with CO₂ transport and storage infrastructure. The driver is CO₂ pricing from initiatives like the European Union (EU) Emissions Trading Scheme (ETS). With the EU preparing for the next phase of the ETS and talk of the European Green Deal gathering pace, before the coronavirus outbreak at least, CO₂ prices in Europe look set to rise. HeidelbergCement is positioning itself to benefit from being the first major cement producer to head into CO₂ capture and storage/utilisation with a variety of methods intended for different CO₂ prices and regional requirements.

HeidelbergCement doesn’t mention the coronavirus pandemic in its latest sustainability report. The report covers 2019 after all, before all of this happened. These reports do include health and safety information of employees, so this may be something to look out for next year. However, Cemex did mention the coronavirus in relation to its climate action plans this week. Essentially it wants to maintain its plans as a ‘fundamental component’ of its efforts to recover from the health crisis. This chimes with media talk around so-called ‘green-led’ government-backed relief programmes. Governments are the ones who are likely to be handing out the money, probably in the form of infrastructure projects. So it’s the perfect opportunity for them to encourage change from the companies bidding for this funding. Sustainability reports and the information behind them will be a useful tool in accessing this cash.

Germany: Schwenk Zement has announced plans for the production of sustainable aviation fuel (SAF) from cement kiln CO₂ emissions. The World Ethanol and Biofuels Report has reported that Schwenk Zement’s integrated 1.0Mt/yr Allmendingen, Baden-Württemberg plant will receive a pilot SAF plant in late 2020.

Japan: Taiheiyo Cement has partnered with JFE Steel and the Global Institute for Environmental Technology to develop a carbon capture and storage system. The system will use wet alkaline earth metals extracted from steel slag to produce carbonates from exhaust gases at cement and steel plants. The partners are investigating the possibility of using these carbonates, specifically calcium carbonate and magnesium carbonate, as additives in cement production at Taiheiyo Cement’s plants. Taiheiyo Cement president Masafumi Shigehara said, “With the effects of climate change becoming apparent both in Japan and overseas, the importance of global warming counter-measures is increasing.”