Displaying items by tag: CO2

Canada: LafargeHolcim subsidiary Lafarge Canada, Svante and France-based Total have completed Phase 2 of the CO₂MENT carbon capture and storage (CCS) project at Lafarge Canada’s Richmond cement plant. The completed phase consisted of construction and installation of the CO₂MENT technology to capture and filter the flue gas. Lafarge Canada said that Phase 3, scheduled for construction over the next three years, will include the installation of a liquefaction unit, the development of an expansion project to further reduce emissions and a business case review for further expansion across the Lafarge network

Western Canada president and chief executive officer Brad Kohl said “This has been a turbulent year for business and people due to the Covid-19 pandemic with many large scale projects being put on hold, but the perseverance that the people working at the Richmond cement plant continue to show is evident in the success of Project CO₂MENT.” He added “To continue leading change in the building materials industry means we are always looking to partner with like-minded thought leaders such as Svante and Total. This partnership is showcasing our drive towards a net-zero future, and we are seeing this vision become a reality right now with the completion of this phase.”

France: Vicat started using a CO₂ntainer system supplied by UK-based Carbon8 Systems at its Montalieu-Vercieu cement plant in November 2020. It uses captured CO₂ from the unit’s flue gas emissions to carbonate cement-plant dust and produce aggregate, which can then be used to make products such as concrete. The system has particular relevance for a plant burning alternative fuels due to the additional chlorinated dust created compared to the use of conventional fossil fuels. The company says it is the first European cement producer to use the process at an industrial scale. Previously, Carbon8 Systems said that its CO₂ntainer would process and convert up to 12,000t of cement bypass dust in its first phase of operation.

Vicat Group scientific director Laury Barnes-Davin said, “We were drawn to Carbon8 Systems’ two-part technology: capturing the CO₂ that Montalieu emits, and using it to produce an aggregate that can be marketed in the construction industry. It opens up great potential for our operations not just in France but also in all the countries where we work across the globe.” The group hopes to reach a 100% alternative fuel substitution rate in France by 2024.

Spain: The Spanish cement association Oficemen has targeted a 43% emissions drop by 2030 across its entire value chain compared to 1990 levels. The objective has been published as part of the association’s sustainability roadmap to 2050. It is a tightening of the previous target of 27% by 2030. Oficemen intends to meet the tougher reduction by using the so-called 5C approach - clinker, cement, concrete, construction and built environment, and (re)carbonation – as detailed by Cembureau, the European Cement Association. Oficemen also revealed that it is working with the Spanish Technological Platform for CO₂ (PTECO₂) on identifying potential locations for storing captured CO₂. Hugo Morán, Secretary of State for the Environment, participated remotely with the launch event.

Oficemen also reports that Spanish cement consumption fell by 12% year-on-year to 12.2Mt in the first 11 months of 2020. Exports declined by 5%.

Italy: Caltagirone Group subsidiary Cementir Holding has announced the upcoming launch of its FutureCem grey cement product on 1 January 2021. The company says that it has 30% lower CO₂ emissions than normal ordinary Portland cement (OPC). It developed the product in collaboration with its Denmark-based subsidiary Aalborg Portland using 35% limestone and calcined clay to replace clinker. This resulted in a much more sustainable, high grade cement according to the company. It added that the low carbon benefits of FutureCem have been achieved without compromising strength and quality.

Chief sales, marketing and commercial development officer Michele Di Marino said that FutureCem is a ‘giant step’ on the way towards more sustainable cement production. “This is immensely important if we are to achieve our sustainability goals at Cementir Group,” said Di Marino. “But it is also an important contribution to the green transition of the concrete and construction industries in general. Thanks to the efforts of our research and development department in Aalborg, we are ready to begin distributing the FutureCem technology in Denmark and soon other subsidiaries in Europe will follow.” He added, “We have reached an important milestone in our innovation and sustainability efforts, but we are not done. Currently, we are incorporating the technology into more cement types in our product range. This includes white cement, and we have already introduced two white ultra-high performance concrete (UHPC) premix types with FutureCem technology.”

Belgium: Carmeuse has signed a joint development agreement with France-based energy transition specialist ENGIE and John Cockerill for a carbon capture and utilisation (CCU) project in Wallonia. It will concentrate CO₂ from a new type of lime kiln and combine it with ‘green’ hydrogen to produce ‘e-methane.’ The hydrogen will be produced by a 75MW electrolyser plant powered by renewable electricity. The company said, “The produced e-methane will be suitable for injection into the national natural gas grid. This renewable e-methane can be used by industrial users or as an alternative fuel in the transport sector, thus allowing these sectors to decarbonise.”

Construction is due to begin in 2022 for commissioning of the installation in 2025. Its total investment cost is Euro150m. The partners have applied for funding from the EU Innovation Fund and Important Project of Common European Interest (IPCEI) fund. The project’s estimated CO₂ emissions reduction over 10 years is 900,000t

Chief executive officer (CEO) Rodolphe Collinet said, “We are delighted to join forces with John Cockerill and ENGIE for the development of this very exciting and strategic project. It is a major step forward in our ambition to become CO₂-neutral by 2050. This project is a very concrete and important example of Carmeuse’s strong commitment and contribution to sustainable development.”

Norway: The Norwegian Parliament has voted in favour of the government’s proposed grant of funding for industrial scale implementation of full-scale carbon capture and storage (CCS) at HeidelbergCement subsidiary Norcem’s Brevik cement plant. Work on the project is expected to start immediately, with the goal of starting CO₂ separation from the cement production process by 2024. The end result will be a 50% cut of emissions from the cement produced at the plant. The group said that the installation will contribute to its CO2 emissions reduction target of 30% between 1990 and 2025.

Norcem chair and HeidelbergCement Northern Europe regional general manager Giv Brantenberg said, “HeidelbergCement highly appreciates the successful cooperation with the Norwegian authorities. The Brevik CCS project clearly shows the importance of industry and public sector to find common solutions in the fight against climate change.”

HeidelbergCement chair Dominik von Achten said, “We are delighted about the final approval of the Norwegian parliament for our breakthrough CCS project in Norway.” He added, “To meet national and international climate targets, CO₂ separation is an important cornerstone. Our CCS project in Brevik will pave the way for our industry and other sectors.”

Germany: The German Cement Works Association (VDZ) has published a study entitled ‘Decarbonising cement and concrete: a CO₂ roadmap for the German cement industry,’ detailing the planned transformation to cement industry-wide carbon neutrality by 2050.

The study says that a decarbonisation scenario based on conventional reduction measures would cut carbon dioxide (CO₂) emissions by 36% between 2019 and 2050. Chief executive officer (CEO) Martin Schneider said that the sector is already “reaching the limits of its potential for any further reduction in the volume of CO₂, particularly as the process-related emissions specifically associated with clinker production cannot be lowered by employing conventional means." As such, the association proposed a “completely new approach to the production of cement and its use in concrete” in order to realise full climate neutrality. It proposes that cement producers help to reduce concrete’s clinker factor, capturing the remaining CO₂ from necessary cement production.

Schneider said, "We have placed the decarbonisation of cement and concrete at the heart of our activities. It will be essential to achieve an integrated approach, incorporating the entire construction value chain.” In order for this more radical scenario to work, he added, “Another essential factor will be to involve society as a whole in this process."

Italy: The Italian cement and concrete association Federbeton says that investments in sustainable technologies in domestic cement production totalled Euro110m between 1 January 2017 and 31 December 2019. This reduced carbon dioxide (CO₂) emissions by 311,000t in 2019 alone, up by 12% year-on-year from the reduction in 2018. An increased alternative fuel (AF) substitution rate of 6.7% in 2019 contributed to the reduction, up by 0.7% from 6.6%. Producers’ full-year AF consumption was 1.6Mt.

Japan: Sumitomo Osaka Cement has formulated a set of medium-term goals and long-term policies in order to enable it to achieve carbon neutrality, in line with the Japanese government’s target, by 2050. These consist of a 30% reduction in energy-derived carbon dioxide (CO₂) emissions intensity between 2005 and 2030 and efforts toward carbon neutrality in energy and process-derived emissions by 2050. These efforts include: “reduction to the limit of fossil energy, development and introduction of process-derived CO₂ emission reduction technology, carbon-free electric power, technology development and supply expansion related to low-carbon cement and concrete products, development and supply of innovative bonding materials and development and introduction of innovative technology related to carbon capture, utilization and storage (CCUS).”

There were mixed feelings evoked by HeidelbergCement’s good news last week that its French subsidiary Ciments Calcia is to set to spend Euro400m on a modernisation project. Sadly, this came with the bad news that the integrated plants at Gargenville and Cruas will be downgraded into a grinding plant and a terminal respectively, and there will be a review of the company’s headquarters in Guerville. All of this will cut 160 jobs but create 20 new ones.

Make no mistake, this is serious money to invest. Euro300m alone will go towards an upgrade of the integrated Airvault cement plant in the former Poitou-Charentes administrative region. HeidelbergCement didn’t say it in its press release but French press reported that the pyroprocessing line at Airvault will be rebuilt starting in 2022 with commissioning scheduled for 2025. If correct then this certainly suits an investment on this scale for a single plant. Smaller investments in the region of Euro25 – 50m were also said be earmarked for the integrated plants at Bussac-Forêt, Beaucaire and Couvrot. These are serious commitments to HeidelbergCement’s production base in France.

Generally speaking, the French cement and construction market has done as well as expected for a country forced to implement two coronavirus lockdowns so far in 2020. Half-way through the year the major cement producers were reporting sales declines of around 10% year-on-year with business picking up again over the summer. Vicat, for example, reported a 9% fall in sales volumes in the first half followed by ‘solid business growth’ in June 2020. LafargeHolcim, CRH and HeidelbergCement all reported a similar situation for their local subsidiaries.

Looking at the wider construction industry, in October 2020 analyst company GlobalData stuck by its forecast of a contraction of construction output by 11.6% in France in 2020. It noted a 35.5% quarter-on-quarter rebound in the third quarter, although it reckoned output was still down by around 5% in the quarter year-on-year, using French National Institute of Statistics and Economic Studies (INSEE) data. With a second national lockdown initiated in late October 2020, it said that INSEE expected a contraction in the fourth quarter of 2020 even with construction sites being allowed to stay open. This follows a peak of cement production above 20Mt in the late 2000s before hitting a low of around 15.5Mt in 2015 and a gradual recovery since then, according to data from the French cement industry union (SFIC).

Ciments Calcia’s upgrade at Airvault is noteworthy for the whole of Europe because it is one of only a few new pyroprocessing line projects in the last decade. The last major one was the new 4000t/day line at HeidelbergCement’s Burglengenfeld plant in Germany that was commissioned in 2018. The trend since then has generally been one of integrated plants slowly closing as markets shrank following the 2008 financial crisis, international clinker levels boomed and environmental measures tightened. Dominik von Achten, chairman of the managing board of HeidelbergCement, addressed this last point directly with the announcement of the Airvault project when he said, “This is why we focus our initiatives on the main CO₂-emitting plants in France.” The competitors to the larger established cement producers in France are certainly thinking about CO₂. Alongside the general European trend of fewer new clinker production lines has been rise in France of the smaller cement producers with grinding and/or reduced-clinker factor models like Cem’In’Eu, Hoffmann Green Cement Technologies and Ecocem. Anyone spending Euro300m on a clinker kiln spewing out CO₂ would do well to consider how much the CO₂ price might be in fifty years time.