Displaying items by tag: CO2

UK: CemFree cement-free concrete has been applied volumetrically for the first time in a 52m3 repair to the Woodford West Viaduct on the M25 London ordbital motorway in Essex. The reason behind the choice of method was the unavailability of batching plants at night, which was the only time that a team of Jackson, DB Group and Axtell employees working on behalf of Connect Plus were permitted to perform the work on the UK’s busiest road. CemFree said that 9.4t of CO2 emissions were cut by comparison to the same project undertaken with ordinary Portland cement (OPC). Jackson director of highways Paul Watson said, “We hope this marks a turning point on the M25 and the wider Highways sector for using low carbon alternatives.”

Cemfree uses 95% ground granulated blast furnace slag (GGBFS) and a 5% alkali activator, removing the need for cement. This gave CO2 emissions of 114kg/t, which the company says is 77% lower than conventional (OPC).

If you needed a sign that the cement industry has become serious about carbon capture it was the presence of two organisations offering CO₂ transport and storage capacity in northern Europe at last week’s Innovation in Industrial Carbon Capture Conference 2020 (IICCC). Both Norway’s Northern Lights and the Rotterdam CCUS (Project Porthos) were busy at their stands during the event’s exhibition. Meanwhile, Cembureau, the European Cement Association, said that it will work on finding other potential storage sites for CO₂ and on identifying existing gas pipelines that could be converted. The industry is planning what to do about CO₂ transport and storage.

As with the previous IICCC event in 2018 the heart of the programme was the Low Emissions Intensity Lime And Cement (LEILAC) project. Since then Calix’s 60m tall pilot Direct Separation Calciner unit has been built at the HeidelbergCement cement plant in Lixhe and has been tested since mid-2019. Early results look promising, with CO₂ separation occurring, calcined material produced and the tube structure and mechanical expansion holding up. Problems with thermocouples failing, blockages and recarbonation at the base of the tube have been encountered but these are being tackled in the de-bottlenecking phase. Testing will continue well into 2020 and plans for the next demonstration project at another cement plant in Europe are already moving ahead. LEILAC 2 will see industry partners Cimpor, Lhoist, Port of Rotterdam and IKN join Calix, HeidelbergCement and other research partners to work together on a larger 0.1Mt/yr CO₂ separation pilot scheduled for completion in 2025.

Alongside this HeidelbergCement presented a convincing vision of a carbon neutral future for the cement industry at the IICCC 2020. It may not be what actually happens but the building materials producer has a clear plan across the lifecycle chain of cement. It is researching and testing a variety of methods to capture CO₂ process emissions, is looking at supply chains and storage sites for the CO₂ and is working on recycling concrete as aggregates and cementations material via recarbonation. In terms of carbon capture technology, an amine-based industrial scale CCS unit looks likely to be built at Norcem’s Brevik plant in the early 2020s. HeidelbergCement’s other joint-research projects – direct separation and oxyfuel – are further behind, at the pilot and pre-pilot stages respectively. Each technology looks set to offer progressively better and cheaper CO₂ capture as they come on line.

Or put another way, cement companies in Europe could build industrial scale amine-based carbon (CC) capture plants now. Yet the game appears to be to wait until the cost of CCS falls through new technology versus the rising emissions trading scheme (ETS) price of CO₂. CC is expected to become economically feasible in a decade’s time, sometime in the 2030s. At which point there might be an upgrade boom as plants are retrofitted with CC units or new production lines are commissioned. Other ways of reducing the cement industry’s CO₂ emissions, of course, are being explored by other companies such as further reducing the clinker factor through the use of calcined clays (LC3 and others), solar reactor or electric-powered kilns and more.

The usual problem of how the construction industry can cope with a higher cost of cement was acknowledged at IICCC 2020 but it is largely being worked around. Higher priced cement poses competitive issues for specifiers and construction companies but it is widely expected to result in price rises below 5% for most residential end users. In the short-term government policy such as requiring low carbon cement in state building projects could stimulate the market. The start of this process can be seen already with the use of slag cements in various infrastructure projects.

Hans Bergman, Head Unit ETS Policy Development at the Directorate-General for Climate Action (DG Clima) partly addressed the cost issue by talking about the EU Green Deal. The EU wants to meet its new targets but it also wants to let gross domestic product (GDP) rise whilst greenhouse emissions fall. The EU ETS is its principle vehicle for this but the commission is wary of changes, such as making modifications linked to CCS, in case it undermines the system. Discussions are ongoing as the work on the Green Deal continues.

IICCC was a wider forum beyond just what LEILAC is up to. To this extent the CC projects involve multiple partners, including those from other cement companies like Cemex and Tarmac (CRH) in LEILAC and Dyckerhoff (Buzzi Unicem), Schwenk Zement and Vicat in the oxyfuel project. The decarbonisation fair included representatives from Vicat’s FastCarb project and Polimi’s Cleanker. Speakers from the European Climate Foundation, Acatech, INEA, TCM, SINTEF and Lhoist were also present.

During one speaker discussion Calix was described as the 'Tesla' of industrial CC by one speaker, who said that, “…there is a genuine competitive opportunity for those bold enough to grasp it.” Calix’s managing director Phil Hodgson enjoyed the accolade but the point was that leading innovation or setting the agenda offers advantages. In the case of industrial CC for the cement industry, change feels a step closer.

Germany: Research from the Potsdam Institute for Climate Impact Research (PIK) has suggested that wood, including fast-growing bamboo, could supplant 50% of cement and steel used in construction, cutting global CO₂ emissions by up to 880Mt/yr and providing a carbon sink for close to 700Mt/yr of CO2 emissions. Assuming a no-change scenario in cement production practices, PIK fellow Galina Chakina says, ‘the shift to timber would make quite a difference for achieving the climate stabilisation targets of the Paris agreement.’

Germany: Holcim Deutschland has announced the successful development of Holcim EcoPact Zero, a net-zero carbon concrete. It says that it is in talks with customers in Germany and will make the first deliveries of EcoPact Zero in early 2020. Holcim Deutschland CEO Thorsten Hahn said, “The use of clinker-reduced cements and the optimisation of the binder content play a central role. The still unavoidable CO₂-footprint is fully offset at with the support of various certified environmental projects.”

Belgium: Cembureau, the European Cement Association, says it will undertake a review of the targets set out in its 2050 Low Carbon Roadmap (2013/2018) in order to align the industry’s efforts with the carbon neutrality objectives contained in the European Green Deal published in December 2019. Following this reassessment, the association says it publish a revised low-carbon roadmap setting out the key role of cement and concrete in the circular economy and a path to achieving carbon neutrality along its value chain in Europe by 2050. Cembureau expects the revised roadmap to be published in early spring 2020.

“As an industry we are determined to ensure that we play our part in helping Europe to meet its emissions reduction targets. With concrete, our industry has a sustainable building material that is uniquely positioned as an essential enabler of the transition to a carbon neutral society,” said Cembureau’s president Raoul de Parisot.

UK: Mick George Concrete has announced a contract with Highways England for the construction of ancillary features such as kerbs, drains and mass fill usages on the A14 between Huntingdon and Cambridge in early 2020. The project will utilise 500m3 of Cemfree concrete from DB Group (Holdings) ltd., which can be produced releasing just 20% of the CO₂ of ordinary Portland cement (OPC). The value of the project, to which Mick George Concrete has dedicated a 100t silo for Cemfree storage, is Euro1.76bn.

US: The Science-Based Targets Initiative (SBTI), a joint initiative of CDP, the United Nations Global Compact (UNGC), the World Resources Institute (WRI) and WWF, has described Switzerland-based LafargeHolcim’s CO₂ reduction targets as ‘adequate’ and ‘consistent with efforts agreed upon at the COP21 World Climate Conference in Paris.’ These are aimed at preventing global temperatures from rising by 2°C.

LafargeHolcim has committed to a 10% reduction in emissions from kiln and pre-heater fuel to 520kg of CO₂ per tonne of cement in 2030 compared to 576kg/t in 2018. Over the same period it will reduce its indirect emissions from electricity consumption by 65%.

It’s the end of the year so it’s time to look at trends in the sector news over the last 12 months. It’s also the end of a decade, so for a wider perspective check out the feature in the December 2019 issue of Global Cement Magazine. The map of shifting production capacity and the table of falling CO₂ emissions per tonne are awesome and inspiring in their own way. They also point towards the successes and dangers facing the industry in the next decade.

Back on 2019 here are some of the main themes of the year in the industry news. This is a selective list but if we missed anything crucial let us know.

European multinationals retreat

LafargeHolcim left the Philippines, Malaysia and Indonesia, HeidelbergCement sold up in Ukraine and reduced its stake in Morocco and CRH is reportedly making plans to leave the Philippines and India, if local media speculation can be believed. To be fair to HeidelbergCement it has also instigated some key acquisitions here and there, but there definitely has been a feel of the multinationals cutting their losses in certain places and retreating that bit closer to their heartlands.

CRH’s chief executive officer Albert Manifold summed it up an earnings meeting when he said, “…you're faced with a capital allocation decision of investing in Europe or North America where you've got stability, certainty, overlap, capability, versus going for something a bit more exotic. The returns you need to generate to justify that higher level of risk are extraordinary and we just don't see it.”

The battle for the European Green Deal

One battle that’s happening right now is the lobbying behind the scenes for so-called energy-intensive industries in Europe as part of the forthcoming European Green Deal. The cement industry is very aware that it is walking a tightrope on this one. The European Union (EU) Emissions Trading Scheme (ETS) CO₂ price started to bite in 2019, hitting a high of Euro28/t in August 2019 and plant closures have been blamed on it. The rhetoric from Ursula von der Leyen, the new president of the European Commission, has been bullish on climate legislation and the agitation of Greta Thunberg internationally and groups like Extinction Rebellion has kept the issue in the press. Cembureau, the European Cement Association, is keen to promote the industry’s sustainability credentials but it is concerned that aspects of the proposed deal will create ‘uncertainty and risks.’ Get it wrong and problems like the incoming ban on refuse-derived fuel (RDF) imports into the Netherlands may proliferate. What the Green Deal ends up as could influence the European cement industry for decades.

The managed march of China

Last’s week article on a price spike in Henan province illustrated the tension in China between markets and government intervention. It looks like this was driven by an increase in infrastructure spending with cement sales starting to rise. Cement production growth has also picked up in most provinces in the first three quarters of 2019. This follows a slow fall in cement sales over the last five years as state measures such as consolidation and peak shifting have been implemented. The government dominates the Chinese market and this extends west, as waste importers have previously found out to their cost.

Meanwhile, the Chinese industry has continued to grow internationally. Rather than buying existing assets it has tended to build its own plants, often in joint ventures with junior local partners. LafargeHolcim may have left Indonesia in 2018 but perhaps the real story was Anhui Conch's becoming the country's third biggest producer by local capacity. Coupled with the Chinese dominance in the supplier market this has meant that most new plant projects around the world are either being built by a Chinese company or supplied by one.

India consolidates but watches dust levels

Consolidation has been the continued theme in the world's second largest cement industry, with the auction for Emami Cement and UltraTech Cement’s acquisition of Century Textiles and Industries. Notably, UltraTech Cement has decided to focus its attention on only India despite the overseas assets it acquired previously. Growth in cement sales in the second half of 2019 has slowed and capacity utilisation rates remain low. Indian press reports that CRH is considering selling up. Together with the country's low per capita cement consumption this suggests a continued trend for consolidation for the time being.

Environmental regulations may also play a part in rationalising the local industry, as has already happened in China. The Indian government considered banning petcoke imports in 2018 in an attempt to decrease air pollution. Later, in mid-2019, a pilot emissions trading scheme (ETS) for particulate matter (PM) was launched in Surat, Gujarat. At the same time the state pollution boards have been getting tough with producers for breaching their limits.

Steady growth in the US

The US market has been a dependable one over the last year, generally propping up the balance sheets of the multinational producers. Cement shipments grew in the first eight months of the year with increases reported in the North-Eastern and Southern regions. Imports also mounted as the US-China trade war benefitted Turkey and Mexico at the expense of China. Alongside this a modest trade in cement plants has been going on with upgrades also underway. Ed Sullivan at the Portland Cement Association forecasts slowing growth in the early 2020s but he doesn’t think a recession is coming anytime soon.

Mixed picture in Latin America

There have been winners and losers south of the Rio Grande in 2019. Mexico was struggling with lower government infrastructure spending hitting cement sales volumes in the first half of the year although US threats to block exports haven’t come to pass so far. Far to the south Argentina’s economy has been holding the cement industry back leading to a 7% fall in cement sales in the first 11 months of the year. Both of these countries’ travails pale in comparison to Venezuela’s estimated capacity utilisation of just 12.5%. There have been bright spots in the region though with Brazil’s gradual return to growth in 2019. The November 2019 figures suggest sales growth of just under 4% for the year. Peru, meanwhile, continues to shine with continued production and sales growth.

North and south divide in Africa and the Middle East

The divide between the Middle East and North African (MENA) and Sub-Saharan regions has grown starker as more MENA countries have become cement exporters, particularly in North Africa. The economy in Turkey has held back the industry there and the sector has pivoted to exports, Egypt remains beset by overcapacity and Saudi Arabian producers have continued to renew their clinker export licences.

South of the Sahara key countries, including Nigeria, Kenya and South Africa, have suffered from poor sales due to a variety of reasons, including competition and the local economies. Other countries with smaller cement industries have continued to propose and build new plants as the race to reduce the price of cement in the interior drives change.

Changes in shipping regulations

One of the warning signs that flashed up at the CemProspects conference this year was the uncertainty surrounding the new International Maritime Organistaion (IMO) 2020 environmental regulations for shipping. A meeting of commodity traders for fuels for the cement industry would be expected to be wary of this kind of thing. Their job is to minimise the risk of fluctuating fuel prices for their employers after all. Yet, given that the global cement industry produces too much cement, this has implications for the clinker and cement traders too. This could potentially affect the price of fuels, input materials and clinker if shipping patterns change. Ultimately, IMO 2020 comes down to enforcement but already ship operators have to decide whether and when to act.

Do androids dream of working in cement plants?

There’s a been a steady drip of digitisation stories in the sector news this year, from LafargeHolcim’s Industry 4.0 plan to Cemex’s various initiatives and more. At present the question appears to be: how far can Industry 4.0 / internet of things style developments go in a heavy industrial setting like cement? Will it just manage discrete parts of the process such as logistics and mills or could it end up controlling larger parts of the process? Work by companies like Petuum show that autonomous plant operation is happening but it’s still very uncertain whether the machines will replace us all in the 2020s.

On that cheery note - enjoy the winter break if you have one.

Global Cement Weekly will return on 8 January 2020

Belgium: Cembureau, the European Cement Association, has called on the European Union’s (EU) Green Deal to incentivise investment in low-carbon technologies, provide long-term legal certainty and foster the industry’s global competitiveness. It said that the new proposal to tackle climate change showed ‘great promise’ and ‘ambitious vision’ but that this needed to be converted into action to support a successful industrial transformation.

The association is concerned about a new carbon border adjustment mechanism. In its view, “the replacement of the existing carbon leakage measures by an untested mechanism would create considerable uncertainty and risks.” Instead it called on the EU to look at a design that complements the existing carbon leakage measures and is fair for third country importers and EU producers.

Aspects of the European Green Deal that the association praised included the recognition that the cement industry is ‘indispensible’ to the European economy. It also liked the European Commission’s (EC) emphasis on the circular economy that fits with work the sector is doing already from alternative fuels usage to recycling concrete.

"The European Green Deal is our new growth strategy – for a growth that gives back more than it takes away. It shows how to transform our way of living and working, of producing and consuming so that we live healthier and make our businesses innovative. We can all be involved in the transition and we can all benefit from the opportunities,” said EC president Ursula von der Leyen in relation to the new policy proposal.

The EC published its recommendations on how to help energy-intensive industries meet the EU’s 2050 climate target in late November 2019. Its key suggestions were to create markets for climate-neutral and circular products, develop large-scale pilot projects on clean technologies and switch to alternative climate-neutral energy and feedstock sources. It added that the pilot projects should be supported by EU funds and given easier access to private financing. These recommendations will be presented to the EU member states, the EU Competitiveness Council and the European Parliament in early 2020.

India: JSW Cement has revised its planned expansion to its 14Mt/yr total installed capacity to 39Mt/yr before 1 January 2023, an increase of 5Mt/yr compared to its initial target of 34Mt/yr by 2020. The figure includes JSW’s 54% subsidiary Shiva Cement’s new 1Mt/yr integrated and 1Mt/yr grinding plant, valued at a total of US$112m. Parth Jindal, JSW Cement managing director, said that the figure had been revised upward because Shiva Cement had become self-sufficient in clinker production, freeing the group’s east Indian cement production from ‘volatile import costs.’

Economic Times has reported that Shiva Cement is set to bring its limestone reserves to 100Mt with the acquisition of the Khatkurbahal mine. The company sources its granulated blast furnace slag from the Odisha steel industry. Production of JSW Cement’s flagship product, JSW Portland Slag Cement (PSC), releases CO₂ at a rate of 325kg/Mt compared to between 760kg/Mt and 800kg/Mt for typical Ordinary Portland Cement (OPC).