Displaying items by tag: CCUS

Spain: The Spanish cement manufacturers' association, Oficemen, has signed a two-year co-operation agreement with utilities provider Enagás. Under the agreement, the pair will explore decarbonisation techniques and solutions, including the development of infrastructure for transporting captured CO₂, as well as hydrogen and oxygen. Oficemen members reduced their total CO₂ emissions by 44% between 1990 and 2022. Europa Press News has reported that Oficemen believes that carbon capture and storage (CCS) will be crucial in realising the industry’s 2050 climate neutrality goal. Oficemen became the first industrial association in Spain to publish a net zero roadmap in 2020.

Italy: Utilities provider Snam says that it has begun selecting partners for its upcoming Ravenna carbon capture and storage (CCS) transport network. The network will connect hard-to-abate industrial facilities in Ravenna with 500Mt of CO₂ storage space in the Mediterranean Sea. The total cost of infrastructure for the project is Euro350m.

CEO Stefano Venier said "The cement industry will be a central partner in this project. A partnership with Heidelberg will be announced in a few days."

UK: Aggregate Industries has engaged energy engineering firm Petrofac to investigate a carbon capture project at its Cauldon cement plant. Petrofac is currently conducting early engineering assessments to identify CO₂ capture opportunities at the plant in Staffordshire. This includes technology selection for any future project. Upon commissioning, a carbon capture system will support the storage of up to 600,000t/yr of CO₂ from the Cauldon cement plant under the Irish Sea as part of the cross-industry Peak Cluster carbon capture and storage (CCS) project.

Aggregate Industries decarbonisation manager Luke Olly said "Aggregate Industries is excited to be launching this carbon capture study, as we are aiming to fully decarbonise our cement plant by 2030. This technology is an important part of our strategy."

Petrofac head of business development energy transition projects, Alex Haynes, said "We’re looking forward to working with Aggregate Industries UK in finding a way to reduce the carbon footprint of its cement products."

It has been a busy week for carbon capture in the cement sector with Global Cement covering five stories. However, increasingly, the topic has become a regular feature in the press as the industry bends to the demands of the carbon agenda. This week’s selection is notable because three of the stories cover North America.

Holcim US announced that it is working with Ohio State University and GTI Energy to design, build and test engineering-scale membrane carbon capture technology at the Holly Hill cement plant in South Carolina. The information builds on an earlier release from the US Department of Energy’s (DOE) Office of Fossil Energy and Carbon Management (FECM) in late December 2023 about the project. It has a total budget of US$9m, with US$7m supplied by the DOE. It plans to build a 3t/day CO₂ capture unit that uses a method intended to retain 95 - 99% of CO₂ from cement kiln gas with a purity exceeding 95%. The new information at this stage is that GTI Energy is involved. Specifically, it will support the development of the pilot skid for site deployment.

The other two stories from North America are worth noting because they both concern commercial equipment or technology suppliers joining up to work together. First, 10 companies - Biomason, Blue Planet Systems, Brimstone, CarbonBuilt, Chement, Fortera, Minus Materials, Queens Carbon, Sublime Systems, and Terra CO₂ - announced they were launching the Decarbonized Cement and Concrete Alliance (DC2). The group’s principal aim is to lobby the US government toward using new low-carbon cement and concrete products in public infrastructure. It also intends to look at advocacy and public sector engagement including expanded tax credits, development of standards for novel cements, consistent ecolabeling and accounting, and customer demand support. DC2 was formally launched in January 2024 but it follows previous work by the companies in the area. The other related story was a memorandum of understanding that Aker Carbon Capture and MAN Energy Solutions have also signed this week to jointly pursue opportunities related to carbon capture, utilisation and storage (CCUS) and CO₂ compression in the North American market. These two companies have worked on the full-scale CCUS unit at Norcem’s Brevik cement plant, which is due to be commissioned later in 2024. They are likely intending to capitalise on the publicity that is likely to be generated once it officially starts up.

Back in North America the DC2 Alliance noted in its press release the DOE’s release of its Pathways to Commercial Liftoff: Low-Carbon Cement report in September 2023. Although it is similar to many other varied sector roadmaps, including the Portland Cement Association’s Road to Net Zero that was released in 2021, this document is well worth reading due to its details and local market context. The headline figure, for example, is that following a set of pathways to fully decarbonise the US cement industry would cost US$60 - 120bn by 2050. Doing so would involve reducing the clinker factor, improving energy efficiency, increased use of alternative fuels, using CCUS, using alternative feedstocks and adopting alternatives to traditional cement production methods.

Graph 1: US active cement kilns by capacity and age. Source: PCA survey data used in Department of Energy Pathways to Commercial Liftoff: Low-Carbon Cement report.

One other interesting tidbit to consider from the report is an analysis of the age of the US cement sector’s kilns versus their production capacity as shown in Graph 1 above. The largest 10 kilns in the country account for 22% of the country’s total capacity and these were all built after 2000. Then, the next 44% of the national capacity comes from 38 kilns out of a total of 120 kilns at 98 cement plants. The report itself does not make this assertion but the implication is that retrofitting CCUS units at one third of the country’s clinker lines would capture the CO2 being emitted from two-thirds of the sector’s production capacity. This is not to say that this could actually work technically, logistically or economically. Yet seeing the scale of the challenge presented in this way is fascinating and one starts to have thoughts about how a retrofit roll-out of CCUS units might actually be approached.

Whether the cement sector adopts CCUS at scale remains to be seen but demonstration projects are definitely coming in both Europe and North America. The DOE report from September 2023 suggests that decarbonisation will cost a lot of money. No surprises there and, as ever, there is rather less detail on who will actually pay for this. One thing that might help here, that the DOE report mentions frequently, is the 45Q carbon capture tax credit scheme, which was introduced by the Trump administration in 2020. Regardless of the potential bill for consumers of cement though, the suppliers are clearly taking note of the investment potential as evidenced by all the non-cement plant CCUS news stories this week.

The 1st Global CemCCUS Conference will take place 13 - 15 May 2024 in Norway and it will include a plant tour of the Norcem Brevik cement plant and CCS project

North America: Aker Carbon Capture and MAN Energy Solutions have signed a Memorandum of Understanding (MoU) to explore carbon capture, utilisation and storage (CCUS) and CO₂ compression opportunities in North America. The collaboration will combine Aker Carbon Capture's amine capture technology with MAN Energy Solutions’ compressor technology to provide standardised and modularised solutions, with optimised energy consumption and delivery time. Both parties are currently participating in the Brevik capture and storage project with Heidelberg Materials Northern Europe in Norway. Rystad Energy has forecast potential capture capacity across North American industries of 200Mt/yr by 2030.

Aker Carbon Capture head of North America Jonah Margulis said "This agreement will strengthen our position to remove and reduce carbon emissions from industries and energy solutions, which is supported by strong incentives from the US government."

MAN Energy Solutions head of sales and project management, carbon capture and storage, Marco Ernst said "We are delighted to work with Aker Carbon Capture, which appreciates our comprehensive expertise in compressor solutions in general and in the area of CO₂ compression in particular. We feel encouraged by the high level of interest in our technical solution concepts that we are on the right path towards sustainable decarbonisation of the industries that have previously had particularly high emissions."

Switzerland: Carbon capture and storage (CCS) equipment developer and supplier Neustark says it plans to more than double the number of its CO₂ storage sites in Austria, France, Germany, Switzerland and the UK to 34 from 14. Neustark’s process turns mineralised captured CO₂ and existing mineral waste streams into useful limestone. Building materials producers lease Neustark’s storage sites to produce reduced-CO₂ alternatives such as recycled concrete. The sites currently have a total storage capacity of 5000t. Existing customers include Holcim.

Neustark CEO Johannes Tiefenthaler said “Neustark is scaling up rapidly, and we’re well on track to achieve our aim of permanently removing 1Mt of CO₂ by 2030. Our global goal is a series of reliable, region-specific CCS facilities that can be replicated anywhere, offering immediate sustainability benefits to local supply chains.”

Latvia: Schwenk Latvija plans to build a 750,000t/yr carbon capture system at its 2Mt/yr Brocēni cement plant. The producer has hired Norway-based Capsol Technologies to conduct a CapsolEoP carbon capture feasibility study at the plant. Schwenk Latvija is a member of the CCS Baltic Consortium, which achieved provisional inclusion on the European Commission’s list of Projects of Common Interest in November 2023.

Schwenk Northern Europe CEO Reinhold Schneider said “Checking the best carbon capture methods and how they can be integrated with our production process is a crucial task for us on the way to carbon neutrality, and likely the major investment direction for the coming decade. To that end, we are excited to investigate the energy consumption and the scale of equipment required for carbon capture at the Brocēni plant, if potentially partnering with Capsol for this challenge.”

Capsol Technologies CEO Jan Kielland said “We are excited to work with Schwenk, one of the most innovative building materials producers in Europe, which has constantly improved its processes to reduce emissions since operations started at the Brocēni plant’s new kiln line in 2010” He added “With this feasibility study, we are taking another step towards building a position as the preferred carbon capture technology provider for cement.”

Capsol’s project pipeline includes 10 large-scale cement projects in the sales engineering and engineering studies phase. The total CO₂ capture capacity of these projects is 11Mt/yr.

Germany: Switzerland-based CO₂ mineralisation technology developer Neustark says that it sees major potential for recycling concrete from construction and demolition waste (CDW) to produce carbon-negative products using its process in Germany. Neustark inaugurated its first German plant, and 12th overall, at Marzahn in Berlin in late 2023. Capital Online News has reported that the start-up estimates that Germany generates 60Mt/yr of CDW concrete, but only recycles 600,000t/yr (1%). This contrasts with international CDW concrete recycling rates as high as 15% in Switzerland and the US.

The start-up, founded at the Federal Institute of Technology Zurich in 2019, currently absorbs 10kg/t of CO₂ in its recycled materials, but aims to reach 60kg/t. Its investors include Holcim.

UK: The World Cement Association (WCA) marked the achievement of an ‘historic’ global consensus for decarbonisation at the COP28 climate change conference in the UAE in December 2023 with a new call to global cement producers and suppliers. The association called on all participants in the industry to help promote developments in reduced-CO₂ cement production through enhanced connectivity and communication. It said that technologies like alternative raw materials and alternative fuels (AF), efficiency-enhancing process changes and carbon capture and utilisation (CCU) are widely applied, but unequally, applied in the global cement industry.

Regarding the disparity between different markets, the WCA said “This imbalance underscores the critical need for more research and development funding in emerging markets, where there is real demand for this kind of support as a crucial enabler of progress.” It added “We will join hands with our members and stakeholders to advance the low-carbon and sustainable development of the industry and contribute to building a clean, safe and beautiful world.”

Japan: Sumitomo Osaka Cement, Sumitomo Corporation, JFE Steel, Kawasaki Kisen Kaisha and Woodside Energy have signed a memorandum of understanding (MOU) to jointly conduct a business feasibility study looking at setting up a CO₂ hub in the Setouchi and Shikoku regions. It will examine how CO₂ can be collected from different industries, transported to a hub port and then shipped to Australia for sequestration. A signing of the MOU was held at the ASEAN-Japan Economic Co-Creation Forum in the presence of Minister of Economy, Trade and Industry Ken Saito.

Sumitomo Osaka Cement operates two integrated plants in the Setouchi and Shikoku regions at Ako and Kochi respectively.