Displaying items by tag: CO2

Nigeria: Dangote Cement says that it raised the thermal substitution rate of alternative fuels (AF) in its group cement production by 25% year-on-year in the first half of 2022. It co-processed 67,200t of locally-sourced waste in its operations during the half.

Chief executive officer Michel Puchercos said “Although significant increases in energy and AGO costs are impacting production, we are strengthening our efforts to ramp up the usage of AF. Our on-going Alternative Fuel Project aims to leverage waste management solutions, reduce CO₂ emissions and source material locally.”

Mexico: Cemex’s consolidated sales grew by 9% year-on-year to US$7.85bn in the first half 2022 from US$7.2bn in the same period in 2021. It sold 32.1Mt of cement, down by 4% from 33.6Mt. Its cement sales volumes rose by 4% in its US and by 1% in Europe, the Middle East, Africa and Asia, but fell by 10% in Mexico and by 3% in South and Central America and the Caribbean. The group says that record levels of alternative fuel usage and a lowered clinker factor helped it to reduce its total CO₂ emissions by 3% year-on-year in the reporting period.

Chief executive officer Fernando González said “I am pleased that our pricing strategy is yielding results and has fully offset inflationary costs in the second quarter of 2022. With improved supply chain dynamics and continued success of our pricing and cost containment strategies, we remain confident we can recover 2021 margins. 


US: National Cement Company of Alabama has reported that the new kiln line at its Ragland cement plant will reduce the plant’s CO₂ emissions by 40%. Its energy consumption will also fall by 30% as a result of the upgrade. The new line includes a 78m-high homogenisation silo, vertical crusher, five-stage preheater and automated clay storage system. AF used in the kiln will include waste tyres, woodchip and sawdust. The new kiln will help in the Ragland cement plant’s transition to 100% Portland limestone cement (PLC) production by 2023, further diminishing its carbon footprint.

Vicat CEO Guy Sidos said "Our ambition is to use AF in all our cement plants around the world. In addition to eliminating fossil fuel energy and replacing it with recycled regional waste, our investments contribute directly to local development. We are proud of the modernisation and transformation of our Ragland site, which was our very first acquisition outside France in 1974."

Spain: Cemex España has signed a 10-year renewable energy supply deal with Acciona Energía. The producer expects the contract to cover 30% of its power consumption. It used 30% renewable energy in 2021, and is aiming to achieve 55% renewables use by 2030.

Cemex Europe, Middle East, Africa and Asia president Sergio Menendez said "Increasing clean energy consumption plays a key role within our decarbonisation plan." He concluded "This agreement shows commitment to our clean energy transition, adding to the success of similar agreements in other geographies."

Philippines: Cemex subsidiary Solid Cement is installing a new US$356m, 1.5Mt/yr line at its Antipolo cement plant. When operational in April 2024, the line will increase the plant’s capacity by 79% to 3.4Mt/yr. Over the first four months of the project since March 2022, Solid Cement invested US$197m in silos and mechanical installation. The new 1.5Mt/yr line will use Low Temperature Clinker technology to reduce its CO₂ emissions, and will also recycle waste hot gases for raw materials drying.

Solid Cement is building the plant using 6000t of its own Vertua reduced-CO2 cement, which it says will further reduce its net carbon footprint by 564t.

Philippines president and CEO Luis Franco said “We will maintain our active role in supporting the development of this nation, as we have done in the past 25 years.”

Canada: The provincial government of Alberta has signed a contribution agreement for US$3.87m in funding towards Lafarge Canada’s planned carbon capture installation at its Exshaw cement plant. The cost of the system is US$20.9m. Offshore Energy News has reported that it is one of 11 carbon capture projects in the province which Alberta Minister of Energy Sonya Savage said will be operational by 2030. Ultimately, project partners plan to establish a CO₂ sequestration hub and transport network connecting the capture sites of various industry partners.

Colombia: Federación Interamericana del Cemento (FICEM) and the Global Cement and Concrete Association (GCCA) have announced their next steps to accelerate the decarbonisation of cement production in Latin America and the Caribbean. The partners have named Colombia as the region’s first Net Zero Accelerator host country. The initiative works to identify barriers to decarbonisation and to recommend policy changes to make an immediate impact. Along with fellow Net Zero Accelerator host countries Egypt, India and Thailand, Colombia brings the total coverage of the initiative to 10% of global cement capacity.

GCCA chief executive officer Thomas Guillot said “The urgency of addressing climate change becomes clearer every day. Last year, our industry made a breakthrough Net Zero global commitment to reduce our carbon footprint, and we are now driving action in Latin America to make real change in one of the regions predicted to use the most concrete and cement in the coming decades. Our Roadmap Accelerator programme, previewed today by our members and affiliate (FICEM) at Latin America and the Caribbean Climate Week, highlights the tailored policies and tools we will use to ensure that Net Zero concrete and cement is achieved by 2050.”

It’s been a good week for carbon capture projects in Europe with the announcement of who the European Union (EU) has selected for a grant from its Innovation Fund. 17 large-scale projects have been pre-selected for the Euro1.8bn being doled out in the second round of awards. On the cement and lime sector side there are four projects. These include projects at Holcim’s Lägerdorf cement plant in Germany, HeidelbergCement’s Devnya Cement plant in Bulgaria, Holcim’s Kujawy plant in Poland and Lhoist’s Chaux et Dolomites du Boulonnais lime plant in France. Large-scale in this instance means projects with capital costs over Euro7.5m. To give readers some sense of the scale of the projects that the EU has agreed to pay for, if the funding was shared out equally between the current bunch, it would be a little over Euro100m per project. This is serious money.

Devnya Cement’s ANRAV carbon capture, utilisation and storage (CCUS) project in Bulgaria has received little public attention so far so we’ll look a little more closely at this one first. No obvious information is available on what capture technology might be in consideration at the plant. HeidelbergCement’s leading experience in carbon capture technology at cement plants gives it a variety of methods it could use from a solvent scrubbing route to something less common. What the company has said is that, subject to regulatory approval and permitting, the project could start to capture 0.8Mt/yr of CO₂ from 2028.

What has also been revealed is that the project is linking up via pipelines to a depleted part of the Galata gas field site in the Black Sea. Oil and gas company Petroceltic Bulgaria is a partner and the aim of the project is to start a CCUS cluster in Eastern Europe. with the potential for other capture sites in Romania and Egypt to join in. This is noteworthy because much of the focus for the burgeoning cement sector CCUS in Europe so far has been on usage on local industrial clusters or storage in the North Sea.

The other new one is the Go4ECOPlanet project at Holcim’s Kujawy plant in Poland. Lafarge Cement is working with Air Liquide on the project. The latter will be providing its Cryocap FG adsorption and cryogenics technology for direct capture of flue gas at the plant. The transportation of the CO₂ is also interesting here as it will be by train not pipeline. Liquid CO₂ will be despatched to a terminal in Gdańsk, then transferred to ships before being pumped down into a storage field under the North Sea.

Turning to the other two grant recipients, the Carbon2Business project plans to capture over 1Mt/yr of CO₂ using a second generation oxyfuel process at Holcim Deutschland’s Lägerdorf cement plant. This project is part of a larger regional hydrogen usage cluster so the captured CO₂ will be used to manufacture methanol in combination with the hydrogen. Finally, Lhoist’s project at a lime plant in France is another team-up with Air Liquide, again using the latter’s Cryocap technology. The capture CO₂ will be transported by shared pipeline to a hub near Dunkirk and then stored beneath the North Sea as part of the D'Artagnan initiative. Around 0.61Mt/yr of CO₂ is expected to be sequestered.

The key point to consider from all of the above is that all of these projects are clear about what is happening to the CO₂ after capture. The days of ‘carbon capture and something’ have thankfully been left behind. CO₂ transportation infrastructure is either being used or built and these cement plants will be feeding into it. This will inevitably lead to questions about whether all these new CO₂ networks can support themselves with or without EU funding but that is an argument for another day.

Finally, in other news, four residents from the Indonesian island of Pulau Pari started legal proceedings against Holcim last week for alleged damages caused by climate change. Industrial CO₂ emissions are unquestionably a cause of this along with other sources but what a court might think about this remains to be seen. Yet, it is intriguing that the plantiffs have decided to go after the 47th largest corporate emitter rather than, say, one of the top 10. Regardless of how far the islanders get this is likely not to be last such similar attempt. If the case does make it to court though it seems likely that Holcim will mention its work on CCUS such as the two projects above. Only another 200-odd cement plants in Europe to go.

Germany: Cemex Deutschland’s carbon capture partner Carbon Clean has hired US-based engineering company KBR to carry out installation of the planned 100t/day CycloneCC carbon capture system at the producer’s Rüdersdorf cement plant in Brandenburg. KBR will provide front-end engineering design (FEED) services for the project.

KBR global technology solutions president Jay Ibrahim said "Reaching net zero targets requires expertise from different industries to work together, and we make a powerful team. Hopefully, it will be the first of many such projects."

Germany: Holcim Deutschland announced a planned upgrade to its Lägerdorf cement plant’s kiln on 14 July 2022. The producer will install a second generation oxyfuel kiln, which uses an air separation unit to supply oxygen directly, emitting CO₂-rich flue gas. A new carbon capture system will supply captured CO₂ to a synthetic hydrocarbons plant, which will produce methanol for other industrial applications. The upgrade will result in the capture of 1.2Mt/yr
of CO₂ emissions and make Lägerdorf one of the world’s first carbon neutral cement plants, according to Holcim Deutschland.

The project, called Carbon2Business, was among four cement plant projects and 13 other EU-wide projects to win a share of a US$1.81bn EU Innovation Fund funding pot. CEO Thorsten Hahn acknowledged that the awarding of funds was ‘good news for Holcim and all partners working with us to decarbonise cement.’ He said “Climate change means cement change.”