Displaying items by tag: Emissions

Oman: Raysut Cement Company has launched a programme to recycle industrial byproducts for use as alternative fuel in cement production and electricity generation, to align with Oman's goal of net zero emissions by 2050.

Hilal bin Saif Al-Dhamri, Acting CEO of Raysut Cement, said "We use secondary industrial materials resulting from production processes across various industries. These are recycled in cement manufacturing and are categorised into two types: one that can be reused as an alternative fuel in plants, the other is used as a partial replacement to the main raw materials leveraged for cement production.” He added "We implemented a project to reuse exhaust heat and convert it to electrical energy at the Raysut Cement plant in Salalah. This innovative approach permits the plant to generate approximately 30% of its electrical energy, by reducing around 50,000t/yr of CO₂. As a result, the Salalah Raysut Cement plant stands out as environmentally friendly, distinguished by its capability to provide clean energy for cement production."

Al-Dhamri also noted that the company was able to enhance the efficiency of its Salalah plant through this programme, by reducing the clinker content while improving the performance of cement in concrete. This has reportedly contributed to a CO₂ emissions reduction of around 18% compared to ordinary cement.

Romania: CRH has launched a wind farm to supply renewable electricity to its Medgidia cement plant. The wind farm comprises five turbines with a total capacity of 30MW and is expected to generate 80GWh/yr. Now fully operational, the facility can reduce the CO₂ footprint of the cement produced at the plant and contribute to reducing Romania's energy-related CO₂ emissions by 40,000t/yr.

US: Terra CO₂ has received a US$52.6m federal grant from the US Department of Energy to support the construction of a new plant in Magna, Utah, that will produce up to 240,000t/yr of supplementary cementitious materials using mining waste from the nearby Kennecott copper mine. This method reportedly aims to cut CO₂ emissions by 70% per tonne of traditional cement replaced, according to the company’s CEO Bill Yearsley. The project is expected to create 61 jobs.

India: UltraTech Cement has entered a collaboration agreement with the Institute for Carbon Management (ICM) at the University of California (UCLA) to develop new technology that aims to reduce carbon dioxide emissions from cement production. The partnership will see the construction of a demonstration plant at one of UltraTech's integrated cement plants. Further details on the technology are available in Global Cement’s news story from 15 October 2024.

US: Researchers at UCLA's Institute for Carbon Management have developed a new method called ZeroCAL that could eliminate ‘nearly all’ of the carbon dioxide emissions from the process of cement production, according to the UCLA Newsroom. The team created a process using limestone and a water-based solution containing ethylenediaminetetraacetic acid. Through membrane nanofiltration and an electrochemical process, they produced calcium hydroxide.

To meet ZeroCAL’s water demand, the team suggests focusing on cement plants near coasts or rivers. The researchers are reportedly working with Ultratech Cement to build a demonstration plant that will produce ‘several’ tonnes of lime per day using the ZeroCAL process. Currently, the process requires more energy than traditional lime production methods, but ongoing research aims to reduce its energy consumption.

Gaurav Sant, director of the Institute and professor at UCLA Samueli School of Engineering, said “The ZeroCAL approach offers an elegant solution to eliminate carbon dioxide emissions associated with the process of cement production. First, it addresses the carbon emissions resulting from limestone’s decomposition while providing clean hydrogen and oxygen to heat the cement kiln. Second, it enables onsite decarbonisation while making use of existing kilns and limestone feedstocks without having to build separate carbon capture and storage facilities.”

Greece: ThyyssenKrupp Polysius has signed a front-end engineering design contract with Titan Group for the Ifestos carbon capture project at Titan’s Kamari cement plant. The project will equip the plant’s two kilns with oxyfuel systems to reduce CO₂ emissions by 1.9Mt/yr, ‘almost completely’, said ThyssenKrupp. The captured CO₂ is then liquefied and transported to a permanent storage site in the Mediterranean region. Full operation is expected by the end of 2029.

Cetin Nazikkol, chief strategy officer at ThyssenKrupp Decarbon Technologies, said “With the oxyfuel technology we have developed, around 1.9Mt/yr of CO₂ can be captured at the Kamari plant alone. This corresponds to around 12% of greenhouse gas emissions from all Greek industries. We are thus making a significant contribution to one of the largest CO₂ capture projects in Europe.”

Christian Myland, CEO of ThyssenKrupp Polysius, said “For our customer Titan Group, we will be using the latest CO₂ separation technology. We will design and equip the first kiln line with the proven oxyfuel technology. When modernising the second kiln line, the latest generation of this technology will be used with the pure oxyfuel system. Overall, this will enable us to capture almost 100% of CO₂ emissions.”

Ireland: Mannok, Sweden-based minerals company Boliden and the South Eastern Applied Materials (SEAM) research centre at South East Technological University in Carlow, Wexford and Wicklow in Ireland have launched a 30-month project to reduce the embodied CO₂ emissions of cement. The project will investigate possible uses of shale as a supplementary cementitious material (SCM) in cement production and the CO₂ curing of cement paste-based mine backfill. Enterprise Ireland has supplied funding worth €700,000 for the collaboration.

Mannok operations director Kevin Lunney said "We are delighted to be working with SEAM and Boliden on this critical research for the cement sector, which could have many far-reaching benefits for the construction sector more generally. Finding local, viable, low-carbon solutions for the industry can make a major contribution to lowering emissions in Ireland."

Boliden specialist development engineer Adam McElroy and section-mill process head Colum Burns said "This project will greatly enhance our knowledge and understanding of the potential for developing low carbon cement for mine backfill purposes and for utilising backfill systems as a carbon sink. The project will also investigate synergies between the cement manufacturing and mining industries that could enhance the sustainability of both industries."

Sweden: SaltX Technology has secured a new grant from the Swedish Energy Agency for its project ‘Demonstration of new electric kiln technology at industrial scale to enable emission-free cement production.’ This funding follows previous support for testing and optimising electric quicklime production at its test and research facility in Hofors, Sweden. The grant aims to adapt and test SaltX's technology specifically for cement production, awarded under the pilot and demonstration program. It constitutes partial funding for the work that is planned to begin in March 2025 at the company's test and research facility.

Acting CEO of SaltX, Lina Jorheden, said "It is very encouraging that the Swedish Energy Agency supports us in our work to commercialise SaltX's electrification technology for the cement industry. The grant is an important component in the upcoming industrialisation phase."

Canada: Lafarge Canada, a subsidiary of Holcim, has inaugurated a new low-carbon fuel facility at its Exshaw cement plant, in a joint effort with Geocycle Canada. The US$28m facility is supported by a US$7.4m contribution from Emissions Reduction Alberta through the government’s Technology Innovation and Emissions Reduction fund. It will reduce natural gas consumption by up to 50% for one of the plant’s kilns by substituting it with alternative fuels (AF) sourced from construction and demolition materials, primarily wood. Geocycle will process the materials into AF. This initiative is expected to divert up to 120,000t/yr of discarded materials from landfill, reducing CO₂ emissions by approximately 30,000t/yr.

President and CEO of Lafarge Canada (West), Brad Kohl, said "Our commitment to building a sustainable future is at the core of everything we do. The low-carbon fuel project is a prime example of how innovation and collaboration can drive positive change, lowering our environmental footprint through the use of discarded biomass materials while closing the material loop to conserve natural resources.”

Egypt: Cemex Egypt has inaugurated new decarbonisation equipment at the Assiut cement plant, aligning with its ‘Future in Action’ sustainability strategy. The technology repurposes residual material into energy, incorporating high-efficiency separators and improvements to the calciner process, reducing CO₂ emissions by approximately 32kg/t of cement produced, totalling a reduction of 290,000t/yr.

President of Cemex Egypt & UAE, Yago Castro, said “The inauguration of the decarbonisation equipment at the Assiut plant is a testament to our ongoing efforts to create a more sustainable future for our communities and the planet. At Cemex, we are committed to leading climate action in the industry, using the highest alternative fuels substitution rate in the cement industry in Egypt.”