Displaying items by tag: CO2

It’s been a good week for carbon capture in cement production with new projects announced in France and Poland.

The first one is a carbon capture and utilisation (CCU) collaboration between Vicat and Hynamics, a subsidiary of energy-provider Groupe EDF. The Hynovi project will see an integrated unit for capturing CO₂ and producing methanol installed at Vicat’s Montalieu-Vercieu cement plant in 2025. It aims to capture 40% of the CO₂ from the kiln exhaust stack at the plant by using an oxy-fuel method and installing a 330MW electrolyser to split water into oxygen and hydrogen for different parts of the process. The CO₂ will then be combined with hydrogen to produce methanol with potential markets in transport, chemicals and construction. The setup is planning to manufacture over 0.2Mt/yr of methanol or about a quarter of France’s national requirement. The project was put forward under a call for proposals by the Important Projects of Common European Interest (IPCEI) program. Pre-notification of its participation in the program has been received from the French government and it is currently being evaluated by the European Commission. Vicat’s decision to choose its Montalieu-Vercieu plant for this project is also interesting since it started using a CO₂ntainer system supplied by UK-based Carbon8 Systems there on an industrial scale in November 2020. This system uses captured CO₂ from the plant’s flue gas emissions to carbonate cement-plant dust and produce aggregate.

The second new project is a pilot carbon capture and storage (CCS) pilot by HeidelbergCement at its Górażdże cement plant in Poland. This project is part of the wider Project ACCSESS, a consortium led by Sintef Energi in Norway that aims to cut carbon capture, utilisation and storage (CCUS) costs and to link CO₂-emitters from mainland Europe to storage fields in the North Sea. The cement plant part in Poland will test an enzyme-based capture method using waste heat at the plant. Another part of the project will look at how the captured CO₂ can then be transported to the Northern Lights storage facility in Norway including the regulatory aspects of cross-border CO₂ transport. ACCSESS started in May 2021 and is scheduled to end in April 2025. It has a budget of around Euro18m with Euro15m contributed by the European Union (EU) Horizon 2020 fund.

HeidelbergCement also says that the second stage of its LEILAC (Low Emissions Intensity Lime And Cement) project at the Hannover cement plant is part of ACCSESS, with both testing of the larger-scale Calix technology to capture CO₂ and the connected transport logistics and bureaucracy to actually get it to below the North Sea. That last point about Calix is timely given that US-based Carbon Direct purchased a 7% stake in Calix in mid-September 2021 for around US$18m. Whilst on the topic of carbon capture and HeidelbergCement don’t forget that the group’s first full-scale carbon capture unit at Norcem’s Brevik cement plant, using Aker Solution’s amine solvent capture technology, is scheduled for commissioning in September 2024. Another carbon capture unit is planned for Cementa’s Slite plant in 2030 but the proposed capture method has not been announced.

Other recent developments in carbon capture at cement plants include Aalborg Portland Cement’s plan to capture and store CO₂ as part of the Project Greensand consortium. The overall plan here is to explore the technical and commercial feasibility of sequestering CO₂ in depleted oil and gas reservoirs in the Danish North Sea, starting with the Nini West Field. The project is still securing funding though, with an Energy Technology Development and Demonstration Program application to the Danish government pending. However, the Danish Parliament decided in December 2021 to set aside a special funding pool to support a CO₂ storage pilot project so this initiative seems to be making progress. If the application is successful, the consortium wants to start work by the end 2021 and then proceed with an offshore injection pilot from late 2022. How and when Aalborg Portland Cement fits in is mostly unknown but a 0.45Mt/yr capture unit at its Rørdal cement plant is tentatively planned for 2027. There’s also no information on the capture method although Aker Carbon Capture is also part of the Project Greensand consortium. Finally, also in September 2021, Chart Industries subsidiary Sustainable Energy Solutions announced that it had selected FLSmidth to help adapt and commercialise its Cryogenic Carbon Capture carbon capture and storage (CCS) system for the global cement industry.

All of this tells the cynics in the audience that a large international climate change meeting is coming up very soon. Most cement companies will likely want some good news to show off when the 2021 United Nations Climate Change Conference (COP26) dominates the media agenda in November 2021. Other observations to point out include that none of the projects above are full-scale industrial carbon capture installations, most of them are consortiums of one sort of another and that they are all subsidised or want to be. While hydrogen and CO₂ networks get built this seems inevitable. Yet, we’re not at the stage where cement companies just order carbon capture units from a supplier, like they might a new clinker cooler or silo, without the need for long lists of partners. When this changes then carbon capture looks set to flourish.

On a final note, the UK is currently experiencing a shortage of commercially-used CO₂. The reasons for this have nothing to do with the cement industry. Yet consider the constant doom-and-gloom about record global CO₂ emissions and the sheer amount of effort going into reducing this by the projects mentioned above and others. Life has a sense of humour at times.

For a view on the CO₂ sequestration permitting process in the US look out for the an article by Ralph E Davis Associates, in the forthcoming October 2021 issue of Global Cement Magazine

Italy: The Italian cement association Federbeton has launched its comprehensive plan for cement industry decarbonisation in line with the EU’s European Green Deal target of a 55% reduction in CO₂ emissions between 1990 and 2030 and carbon neutrality by 2050. The strategy entails Euro4.2bn of total new investments andEuro1.4m/yr of extra operating costs across the industry. This will cover the adoption of transition technologies and the large-scale application of carbon capture and storage (CCS). The association says that while some such actions, such as alternative fuel (AF) substitution,are immediately available, others require further development. The sector’s primary fuel is petcoke, mainly imported from the Gulf of Mexico. As such, Federbeton has identified the 100% replacement of all fossil fuels with ‘low-carbon impact’ alternatives as a means of reducing the industry’s carbon footprint by 12% achievable in the short term. Renewable green hydrogen use can cut a further 3% of CO₂ emissions, an energy transition to renewable sources can cut 5%, clinker factor reduction can cut 10%, alternative raw materials in clinker can cut 6%, CCS can cut 43%, supply chain and logistics changes can cut 16% and the optimisation of construction can cut the remaining 5%.

President Roberto Callieri said “The cement and concrete supply chain wants to be one of the protagonists of the ecological transition.” He added “Only with adequate and immediate support tools will it be possible to prevent the impoverishment of the industrial fabric, preserve the competitiveness of the supply chain and prevent relocation. Last but not least, a new environmental culture must be shared, based on dialogue and no longer on the preconceived opposition to any choice of industry.”

France: Vicat’s Montalieu-Vercieu cement plant will host a carbon capture and storage (CCS) installation and methanol plant under a joint project by Vicat and Groupe EDF subsidiary Hynamics known as Hynovi. The project aims to achieve 40% carbon capture at the plant. A 330MW electrolyser will convert captured CO2 to methanol through oxycombustion. Commisioning of the entire system is scheduled for 2025. The partners said that Hynovi may subsequently be taken up by cement plants globally.

Guatemala: Cemex Latam Holdings plans to invest US$25m in installing a new mill at its 500,000t/yr Guatemala City grinding plant. The company says that the mill will increase the plant’s capacity by 80% to 900,000t/yr.

Cemex South America, Central America and Caribbean president Jesus Gonzalez said "This investment reinforces Cemex's commitment to Guatemala's development and reflects our confidence in the favourable outlook of the economy in the country and the region." Gonzalez added “We are excited about expanding our offer of products and solutions to the market which contribute to sustainable construction, like Vertua, our family of net-zero and low carbon products."

France: Hoffmann Green Cement Technologies has launched H-Iona clinkerless cement, its first cement to be made available to retail customers in bagged form. Dow Jones Institutional News has reported that H-Iona cement production’s CO2 emissions are 150kg/t, according to the producer. It claims that this is just 17% that of ordinary Portland cement (OPC). Hoffmann Green Cement Technologies produces H-Iona, primarily from ground granulated blast furnace slag (GGBFS) and gypsum, heat-free at its fully automated Bournezeau plant.

Co-founder Julien Blanchard and David Hoffmannsaid "By launching H-Iona, the lowest carbon cement on the European market, Hoffmann Green Cement is following its continuous innovation approach.” They added “This is the first low-carbon cement to have received CE marking. Thanks to this ground breaking technology, we are democratising access to low-carbon cement.”

India: Shree Cement has given details of its US$67.8m solar power plant project plans. Projects Tiger News has reported that the producer intends to install 106MW-worth of solar power capacity across several Indian cement plants before October 2022. The company expressed its commitment to reducing its carbon footprint and fossil fuel dependence.

UK: Cemex UK has relaunched its used pallet collection service. The scheme aims to reduce timber waste in its supply chain, according to the company. It forms part of its Future in Action – Committed to Net Zero CO2 climate action strategy. Its partner ELM will collect stockists’ pallets free of charge for refurbishment and return to Cemex UK. It will reuse all repaired pallets and recycle those damaged beyond repair.

Packed cement sales manager Graeme Barton said “We want to make life easier for our merchants to work with us to reduce waste. We’d like to make pallet recovery part of the standard delivery process, as many pallets still end up in landfill. It is increasingly costly to dispose of pallet waste and there is far greater value to be gained by recycling and reuse. Rising timber costs, combined with pallet shortages, means there is a heightened need to conserve and maintain pallets throughout the supply chain. Recovery is considerably more cost effective than buying new replacements.” He added “Pallets are a standard format in transporting building products and contribute a significant financial and environmental cost which needs to be captured by the user. We saw a similar situation with supermarkets and plastic bags, but we’d rather not wait for legislation to enforce this; we’d really like to make a difference now with preventative action. The pallet recovery service is regenerative by design and aims to support the key principals of the circular economy to benefit business, society and the environment. If we all pull together it will have a significant impact across the whole supply chain.”

China: Anhui Conch has signed a CO₂ trading agreement with Shanghai Environmental Energy Exchange (SEEE). The deal takes place within the context of Shanghai’s CO₂ trading pilot scheme. Anhui Conch says that it will not only facilitate the promotion of carbon allowance asset scheduling and carbon asset market transactions, but also provide accreditation and CO₂ management system certification. It says that SEEE will help it to better assume the role of a leading enterprise in the ‘dual-carbon’ field of the cement industry.

Anhui Conch says that it is focusing on developing a full-process carbon footprint monitoring system. It has begun researching the utilisation possibilities of captured carbon with academic partners.

Mexico: Cemex has launched a sustainability-linked financing framework. It says that it is the ‘most comprehensive’ such framework in the building materials sector. The framework further aligns Cemex’s corporate sustainability commitments to its financing strategy, as part of its ‘Future in Action’ program. It establishes Cemex’s guiding principles when issuing new sustainability-linked financing instruments, including public bonds, private placements, loans, derivatives, working capital solutions and other financing instruments. Sustainalytics, an independent company that specialises in providing environmental, social and corporate governance research, ratings and data to institutional investors and companies, validated the framework’s alignment with the Sustainability-Linked Bond Principles, the International Capital Market Association’s Climate Transition Finance Handbook and the Loan Market Association’s Sustainability-Linked Loan Principles.

“Climate change is one of the biggest challenges of our time, and we will continue to address it as a fundamental component of our business strategy,” said Maher Al-Haffar, Cemex's chief financial officer. “Cemex is committed to increasing the role sustainable finance plays in its capital structure by potentially linking the cost of financial instruments to the achievement of targets, directly aligning our corporate finance strategy to sustainability commitments and further contributing to a low-carbon future.”

Cemex has included three key performance indicators in the framework: net CO₂ emissions per tonne of cementitious product, clean electricity consumption and alternative fuels rate. All of them were qualified by Sustainalytics and deemed aligned with the company’s climate action strategy. Cemex currently has a 2030 target of reaching below 475kg/t of CO₂ for cementitious products.

Germany/Brazil: Researchers at the Martin Luther University Halle-Wittenberg in Saxony-Anhalt and the University of Pará in Pará have produced a cement alternative with 66% reduced CO₂ emissions. A type of calcium sulphoaluminate cement, it replaces up to 60% of limestone in clinker with overburden from bauxite mining. Researchers demonstrated that the resulting product conforms to all standards for commercial Ordinary Portland Cement. The results of the research have been published in ‘Sustainable Materials and Technologies.’