Displaying items by tag: CO2

Canada: The Cement Association of Canada (CAC), with its members and partners in the concrete sector, has released Concrete Zero, an action plan to help the local cement and concrete sector reach net-zero CO₂ emissions by 2050. The five priority areas it is focusing on include: eliminating the use of coal and petroleum coke as fuel sources for clinker production; reducing the volume of clinker used to produce cement; increasing the use of supplementary cementitious materials; working towards building carbon capture, utilisation and storage capacity; and advocating for performance-based codes, standards and specifications, procurement policies and increased material efficiency in construction. Targets include reaching a 100% fuel mix from non-fossil-based sources by 2050. The latest plant follows the goal of achieving a 40% emissions reduction by 2030 as part of its Roadmap to Net-Zero Carbon Concrete by 2050.

Adam Auer, the president and chief executive officer of CAC, said “Our net-zero action plan is ambitious and cannot be achieved by industry action alone. Working with government, industry, and partners in the design, architecture, and construction industry will be essential for success. Canada’s cement and concrete industry are committed to doing our part to help Canada build a better, cleaner future. Working together, we can deliver Concrete Zero.”

US: Holcim US has joined the Department of Energy's (DOE) 'Better Climate Challenge' to reduce CO₂ emissions and save energy. It is the first cement producer to commit to the DOE program. The subsidiary of Switzerland-based Holcim plans to power the electrical operations at 13 cement plants in the country with 100% renewable energy by 2030 and to reach net zero CO₂ emissions by 2050. As part of the 'Better Climate Challenge' it has committed to reduce CO₂ emissions in the US by at least 25% by 2033.

Examples of current renewable power usage at Holcim US cement plants include the installation of three onsite wind turbines at the Paulding plant in Ohio that generate 11,500MWh while a forthcoming solar unit at the Hagerstown plant in Maryland will generate up to 18,440MWh. All 13 Holcim cement plants will conduct reviews to identify projects that could contribute to meeting goals of the challenge.

With grant support from the DOE, Holcim is also investigating the feasibility of using carbon capture utilisation and storage (CCUS) at its cement plants in Portland, Colorado, and Ste. Genevieve, Missouri. In addition to involvement in the Better Climate Challenge, Holcim US is a continuing partner of the DOE's 'Better Plants Challenge', sharing facility-level energy data and solutions to help guide other industrial companies with implementing energy solutions in their facilities.

Italy: Buzzi Unicem reduced its specific gross scope 1 CO₂ emissions by 4% year-on-year to 664kg/t cementitious product in 2022 from 689kg/t in 2021. As part of its Sustainability Report for 2022 it revealed that specific CO₂ emissions varied from a low of 500kg/t in Luxembourg to a high of 812kg/t in Ukraine. Its specific thermal consumption fell slightly to 4084MJ/t clinker and its thermal substitution rate was 29.9%.

The company’s Lost Time Injury Frequency Rate (LITFR) was 4.9 and two fatalities were reported. It also noted that six employees – five Ukrainian and one Russian – died as a result of the war between Ukraine and Russia that started in February 2022. In addition, six staff were wounded, one taken prisoner and two were reported missing from its Ukrainian workforce.

The building materials producer noted that it had met some of its five-year sustainability targets set in 2017, including a 5% reduction in specific CO2 emissions, the implementation of structural engagement projects at all of its production sites with a high economic, environmental and social impact and the achievement of increasingly safe working conditions.

France: Ciments Calcia has announced an investment of Euro86m to further decarbonise cement production at its integrated Beaucaire plant. The subsidiary of Germany-based Heidelberg Materials has allocated a total of Euro600m towards reducing CO₂ emissions from all of its operations in the country in response to a government initiative, according to The Tribune newspaper.

The current funding follows a spend of just under Euro7m on upgrades at the site, including installing a new clinker cooler that will allow for greater recovery of waste heat, and the addition of a new computer control system. Following this work, the single production line plant was restarted in early April 2023.

The next stage of investment has started with a feasibility study. If successful, a tendering process could start in the second half of 2023 with work planned to start in 2025. The company intends to renovate the plant’s electricity network, modernise the production line with a preheater and a pre-crusher and make further changes to target an alternative fuels thermal substitution rate of 75%. A third stage, involving carbon capture and utilisation and/or storage, is tentatively planned to start in 2030.

Philippines: Cemex Philippines (CHP) says it has reduced the CO₂ emissions from its subsidiaries, Solid Cement Corporation and APO Cement Corporation, by 50% between 1990 and 2022. From 2020 to 2022 CHP reduced its net CO₂ emissions by 18%. The company claims this is the highest CO₂ emissions reduction in the sector based on publicly released information.

Luis Franco, the president and chief executive officer of CHP, said "This milestone CO₂ reduction was possible because of our team's high commitment to achieve net zero. We are on track to meet our ambition of less than 430kg of net CO₂ per tonne of cement by 2030 and deliver net-zero CO₂ concrete by 2050." He added that the company is confident it can reach a 67% reduction by 2030 through the continued used of alternative fuels and decarbonated raw materials.

Ireland/UK: A six-month feasibility study conducted by Mannok at its Derrylin plant, in conjunction with Catagen, has found a number of ways that the cement producer can reduce its CO₂ emissions. Using Catagen’s HGEN renewable hydrogen generator with waste heat recovery could potentially decrease the cement plant’s annual CO₂ emissions by 7%. In addition the study found that using biohydrogen generation from waste biomass could generate larger volumes of hydrogen with less renewable energy required, compared to electrolytic hydrogen generation. Using Catagen’s BIOHGEN process in this way could minimise carbon intensity by a further 18%. A combined group of engineers from Mannok and Catagen worked on the project.

Kevin Lunney, operations director at Mannok, said “We are very excited to be working with the Catagen team, who have demonstrated a deep level of technical ability and competency during the feasibility work. I have no doubt that Mannok will derive significant value from the work already completed, with many new opportunities for collaboration now presenting that we would not have considered before. Achieving Net Zero is now the primary goal for our business and I expect Catagen will play a significant role in our achieving that goal, which we expect will have major benefits for the sector overall.”

In early April 2023 Mannok revealed that it had secured funding from the UK Government Green Energy Scheme to support its energy transformation programme. The first phase of the initiative, which the funding will support, is the generation of onsite green hydrogen to replace the use of diesel in over 70% of the company’s 150 heavy-goods truck fleet.

Belfast-based Catagen started as a testing company providing emissions data to the automotive sector. It has started working in other industrial sectors - such as cement, glass and steel in Europe and the US – as part of its ClimaHtech product range.

Germany: Heidelberg Materials has appointed industrial gases and engineering company Linde to install a carbon capture and liquefaction plant at its 1Mt/yr Lengfurt, Bavaria, cement plant. The project is scheduled for delivery in 2025. When commissioned, the system will capture and liquefy 70,000t/yr of CO₂. Heidelberg Materials plans to use a small part of the liquefied CO₂ in its development of recarbonation technologies for cement and concrete, with the remainder to be marketed by Linde to industries, including chemicals and food. The German government granted Euro15m in funding for the project under its Decarbonisation of Industry programme.

Heidelberg Materials’ chief executive officer Dominik von Achten said "We are pleased to be able to implement the world's first carbon capture and utilisation (CCU) project in the cement industry on an industrial scale.”

Linde’s executive vice president Jürgen Nowicki said “With this joint venture, two companies that are world leaders in their field are combining their skills with the aim of finding a solution that is as sustainable as it is economical. After successful pilot applications, this large-scale plant paves the way for sustainable cement production.”

Image credit: Cement plant Lengfurt, Germany. Copyright: Heidelberg Materials. Photographer: Steffen Fuchs.

US: A team from the Massachusetts Institute of Technology (MIT) has developed a new method to sequester CO₂ in concrete before curing it. The method is based on the addition of bicarbonate of soda, which reacts with cement to produce a calcium carbonate-calcium silicone hydrate composite. The Journal of Engineering has reported that the method adds the benefits of CO₂ mineralisation during production and casting, doubling the mechanical performance of early-stage concrete. It also eliminates the effects of carbonation reactions in cured concrete, which weaken the concrete by lowering its alkalinity, which accelerates the corrosion of rebar. The method has the potential to sequester 15% of CO₂ emissions from cement production.

The team said “The pre-curing capacity of concrete to sequester CO₂ has been largely underestimated and underutilised. Our new discovery could further be combined with other recent innovations in the development of lower carbon footprint concrete admixtures to provide much greener, and even carbon-negative, construction materials.”

India: UltraTech Cement says that it has made a second deployment of GreenLine liquefied natural gas (LNG)-powered cement trucks in its cement operations. Indo-Asian News Service has reported that the new trucks will operate from UltraTech Cement’s Pune cement terminal in Maharashtra. GreenLine says that its LNG trucks have 28% lower CO₂ emissions than ordinary cement trucks, equating to reductions of 24t/yr per truck for UltraTech Cement.

The cement producer’s associate vice president Tanmay Pradhan said “We are dedicated to creating a sustainable future, and we are fully committed to collaborating with our partners and stakeholders to achieve our goal of a cleaner environment. Our association with GreenLine is a step forward in our ongoing efforts to decrease emissions, enhance energy efficiency, and promote sustainability."

Switzerland: Holcim has published its Climate Report 2023, detailing the company’s progress towards meeting its sustainability commitments up to the end of 2022. The cement producer recorded net specific CO₂ emissions per tonne of product of 562kg/t, down by 1.7% year-on-year from 572kg/t in 2021. In line with its 1.5°C climate change-aligned targets, Holcim is committed to 420kg/t specific CO₂ emissions by 2030 and net zero by 2050.

Overall, the group’s Scope 1 CO₂ emissions from cement production fell by 2.5% to 77Mt from 79Mt, while its Scope 2 emissions remained at 5Mt and its Scope 3 emissions fell by 11% to 47Mt from 53Mt. Its cement had an average clinker factor of 73%, down from 73.6% in 2021. Holcim processed 6.8Mt of construction and demolition waste, up by 3% from 6.6Mt. Meanwhile, its thermal substitution rate of alternative fuel (AF) rose to 28% from 26%.

CEO Jan Jenisch and chief sustainability officer Magali Anderson said “With our successful transformation, we reduced our CO₂ per net sales by 21% in 2022, and commit to reducing it by over 10% in 2023. Accelerating the shift to net-zero cities requires deep partnerships across our value chain. In 2022 we engaged with public authorities to evolve building standards, with cities to scale up green demand in their projects, and with architects and engineers to specify sustainable solutions in their designs. We did this as a key partner for our customers, bringing solutions that help them achieve their sustainability goals.”