Displaying items by tag: CO2

World: The total volume of CO₂ emissions released during cement production have more than doubled over the past 20 years, a study has revealed. In 2021 CO₂ emissions from the manufacture of cement came to 2.6Bnt, more than 7% of all emissions, according to Robbie Andrew, a greenhouse gas emissions scientist at the CICERO Center for Climate Research in Norway and the Global Carbon Project. In 2001 the CO₂ emissions from cement production were just 1.2Bnt.

Driven by China, the global cement sector’s CO₂ emissions have now more than tripled in the 30 years since 1992, recently increasing by 2.6% a year. The drivers are not just that more cement is being made, but that the CO₂ intensity of production has risen by 9.2% per tonne, according to the International Energy Agency. This is due to a switch from production in mature markets to developing ones, with China again a dominant factor.

Pakistan: DG Khan Cement has despatched a shipment of 50,000t of cement for Houston, US, from Karachi. The Balochistan Times newspaper has reported that the shipment is the first of 12 consignments of the same size under an order for 600,000t of low-alkali cement. If successful, the order may double to 1.2Mt. The producer is using jumbo bags to transport the product on its 42-day journey overseas.

Marketing director Fareed Afzal said that Pakistani businesses need to diversify their export markets and strengthen foreign currency reserves. He added that DG Khan Cement continues to reduce its products' carbon footprints by using renewable energy, waste heat recovery (WHR) and alternate fuels (AF).

Australia: Adbri is part of a consortium of eight Australian industrial manufacturers, developers and port operators collaborating with AGL Energy on a feasibility study for a green hydrogen plant at the site of the latter’s Torrens Island power plant in South Australia. AFR Online News has reported that any future hydrogen plant established by the partners would rely on solar and wind power, which has large potential in the region.

The South Australian government previously launched its first US$414m green hydrogen project in Whyalla in March 2022.

Pakistan: Fauji Cement says that its sustainability initiatives across its three cement plants reduced CO₂ emissions by 215,000t in the 2022 financial year. The Pakistan Today newspaper has reported that clinker factor reduction in reduced-CO₂ products such as Askari Green cement and Pamir cement eliminated 89,900t-worth of emissions, 42% of total reductions. Waste heat recovery (WHR) plants eliminated 79,400t of emissions (37%), solar power plants eliminated 31,500t (15%), alternative fuel (AF) substitution eliminated 8030t (3.5%) and reforestation eliminated 600t (2.5%).

Belgium: Holcim Belgium hopes to complete its Obourg cement plant’s Go4Zero oxyfuel kiln conversion and carbon capture installation project by 2025, in order to achieve carbon neutrality at the plant by 2030. The producer says that the plans involves establishing a new 135m-high cooling tower, instead of a 145m-high tower as previously planned.

In an effort to rally local support, Holcim Belgium will begin offering virtual reality (VR) tours of the upgraded plant plans in September 2022.

Chief executive officer Bart Daneels said “We would like to start this project, which will be a world premiere in the cement industry.”

Coolbrook has been in the news recently with collaboration deals struck with Cemex and UltraTech Cement. First the Finland-based company officially launched its Roto Dynamic Heater (RDH) technology with a memorandum of understanding signed with Cemex in May 2022. Then, this week, it signed a similar agreement with UltraTech Cement.

The specifics of either agreement are unknown but the target is clearly to build an industrial pilot of an electric kiln – or something like it - at a cement plant. Coolbrook says it has run a pilot of its RDH technology in Finland. Further tests are now scheduled to continue for two years starting from September 2022 at the Brightlands Chemelot Campus at Geleen in the Netherlands. Commercial scale demonstrations are scheduled from 2022 with the hope of commercial use from 2024. Links with Cemex and UltraTech Cement seem to suggest progress. At the same time Coolbrook will be testing its RotoDynamic Reactor (RDR) technology, which promises to electrify the steam cracking process used in plastic manufacturing.

Publically available details on the RDH technology are light. In its promotional material Coolbrook says that it can achieve process temperatures of up to around 1700°C. This is crucial to achieve full clinker formation in a cement kiln. Reaching this temperature with non-combustion style kilns, such as solar reactors, has previously been a problem. Notably, Synhelion and Cemex said in February 2022 that they had managed to produce clinker using concentrated solar radiation. Retrofit possibilities and compact equipment size are also mentioned in the promotional material for the RDH. The former is an obvious attraction but size of equipment footprint is increasingly emerging as a potential issue for cement plants looking to reduce their CO₂ emissions. Rick Bohan from the Portland Cement Association (PCA) presented a summary of the potential and problems of emerging carbon capture and utilisation/storage (CCUS) technologies for cement plants in the US at the Virtual Global CemCCUS Seminar that took place on 14 June 2022. He noted that installing CCUS equipment makes cement plants start to look different (more like petrochemical plants in the view of Global Cement Weekly) and that they may require more space to install it all.

Coolbrook hasn’t been the only organisation looking at kiln electrification. The installation with the most available information on kiln electrification has been the Decarbonate project, led by the VTT, formerly known as the Technical Research Centre of Finland. The project has built a pilot rotary kiln with a length of 8m inside a shipping container. It has a production capacity of around 25kg/hr. The system reportedly uses fixed radiant heating coils around the kiln, surrounded by insulation materials. Early results presented to the 1st Virtual Global CemPower Seminar in late 2021 were that the kiln started up, sufficient calcination was occurring and the system was operated continuously for three days at a temperature of 1000°C with no problems reported. Further research was scheduled to carry on into 2022 with longer trials planned for three different materials.

HeidelbergCement’s subsidiary in Sweden, Cementa, completed a feasibility study on implementing electrified cement production at its Slite plant in 2019. It then said that it was conducting further study with electricity producer Vattenfall as part of CemZero project. This consists of three projects running to 2025. Namely: heat transfer with plasma in rotary kilns; direct separation of carbon dioxide from calcination of carbonate-based raw materials in the production of cement clinker and burnt lime; and carbon dioxide-free products with electrified production - reactivity of cement clinker with secondary additives. HeidelbergCement has since announced plans to build a full scale 1.8Mt/yr carbon capture and storage (CCS) plant at the Slite cement plant by 2030.

How this would fit with any kiln electrification plans is unknown. However, one attraction of moving to an electrical kiln, for all of the projects above, is to cut out the 40 – 50% of a cement plant’s CO₂ emissions that arise from the fuel that is burnt. Taking a kiln electric also makes CO₂ capture easier. Much of the remainder of the CO₂ released comes from the decomposition of limestone during calcination when clinker is created. Substitute out fossil or alternative fuels and the flue gas becomes much purer CO₂.

It is early days for cement kiln electrification but progress is happening both commercially and scientifically. The next step to watch out for will be the first pilot installation at a cement plant. One point to finish with is a comment that Rick Bohan made at the IEEE-IAS/PCA Cement Industry Technical Conference that took place in May 2022: carbon capture is expected to double a cement plant’s energy consumption. Kiln electrification is one potential route for cement production to reach net zero. CCUS is another. If one or both occur then a low carbon future could be a high energy one also.

Watch out for Global Cement’s forthcoming interview with Coolbrook in the September 2022 issue of Global Cement Magazine

For more on CCUS, download the proceedings pack for the Virtual Global CemCCUS Seminar 2022

For more on Synhelion and Cemex read the interview in the December 2020 issue of Global Cement Magazine interview

Turkey: OYAK Cement has detailed its progress towards net zero CO₂ cement production in its Integrated Report 2021. The report's focus is sustainability and digitalisation. Under itsCement 4.0 CO₂ emissions reduction initiative, OYAK Cement has proceeded with efficiency improvements at its cement plants.

OYAK Cement is committed to net zero CO₂ cement production by 2050 and reductions in line with the Paris Agreement to limit global climate change to 1.5°C by 2030.The producer is collaborating withthe Science-Based Targets Initiative (SBTi) to realise its emission reduction goals.

Canada/US: Holcim North America has invested in Blue Planet to support the development and commercialisation of its mineralisation technology. Blue Planet’s process sequesters CO₂ with building waste feedstock such as recycled concrete, cement kiln dust (CKD) and slag to produce new aggregate products. Each tonne of Blue Planet’s aggregate can mineralize up to 440kg of captured CO₂. Lafarge Canada, Holcim US, and Blue Planet will start a multi-year collaboration to help identify potential to use the mineralisation technology to further lower the carbon footprint of the companies’ cement, aggregates and concrete operations, with the potential to expand to other operations in the Holcim Group around the world.

“This is an important step for us in North America. Our vision is to transform our St Constant Plant in Montreal into a carbon campus that ultimately advances commercialisation of mineralisation technologies, including Blue Planet’s products,” said David Redfern, president and chief executive officer, Lafarge Canada. “We look forward to advancing our Net Zero strategy by leveraging mineralization technology that allows us to use the CO₂ from our own cement plants to produce carbon neutral or carbon negative sand and gravel products.”

Signapore: Researchers at the Nanyang Technological University in Singapore (NTU Singapore) have successfully used bacteria to combine two abundant waste streams into clinker-free biocement. NDTV news has reported that the scientists developed the material from by combining calcium ions with urea in a mixture of industrial carbide sludge and urine. The process takes place at room temperature, reducing CO₂ emissions while also offering waste management benefits.

The NTU Singapore team is presently testing the biocement on artificial beaches. It will subsequently investigate other possible large-scale applications around Singapore.

US: The Global Cement and Concrete Association (GCCA) hosted chief executive officers (CEO)from across the global cement industry at its CEO Gathering in Atlanta, Georgia, on 9 June 2022. The event explored the best ways for the sector to progress towards net zero CO₂ emissions. Speakers included: UN special advisor on climate Selwin Hart, US Department of Energy assistant secretary for fossil energy and carbon management in the Brad Crabtree, architecture firm Gensler CEO Diane Hoskins, Chair of Oil and Gas Climate Initiative (OGCI) executive chair Bjorn Otto and climate economist Gernot Wagner.

GCCA CEO Thomas Guillot said “To achieve net zero and enable the delivery of the sustainable built environment of the future, there needs to be ongoing engagement and deeper collaboration between our industry and government in the years ahead. Targeted government policy will be vital to removing barriers and to expediting our industry’s decarbonisation plans.”