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Displaying items by tag: European Union
Delegates at the Global CemCCUS Conference last week applauded when Anders Petersen, the Senior Project Manager Brevik CCS, Heidelberg Materials said that the Brevik cement plant will be capturing CO2 and permanently storing it within the year. Rightly so. This moment will mark a historic milestone for the sector when it arrives. Net zero cement production is coming.
Last week’s event in Oslo delivered an overview of the current state of carbon capture in the cement and lime industries. It explored the practical challenges these industries face in capturing CO2 emissions and - crucially – then working out what to do with them afterwards. Incredibly, delegates were able to view the construction site of Heidelberg Materials’ forthcoming full-scale carbon capture unit at its Brevik plant in Norway. On the same day as the tour, Holcim broke ground on the Go4Zero carbon capture project at its Obourg plant in Belgium.
The key takeaway at the conference was that a (dusty) bulk solids sector is starting to work with handling (clean) gases in a way it hasn’t before. This recurred repeatedly throughout the conference. Petersen summarised it well when he described Brevik as a meeting pointing between the cement industry and the petrochemical one. It looks likely at present that there will not be a single predominant carbon capture technology that the majority of cement plants will deploy in the future. Similarly, CO2 storage infrastructure and sequestration sites differ. Utilisation plans are less developed but also offer various options. Yet, if carbon capture becomes common at cement and lime plants, then these companies will need to learn how to filter and handle gases regardless of the capture method and destination for the CO2. So presentations on filtration and compressors were a revelation at CemCCUS.
The key obstacle remains how to pay for it all. By necessity, most of the big early projects have received external funding, mostly from governments. Although, to be fair, the private companies involved are often investing considerable amounts of their own money and taking risks in the process too. In the European Union (EU) CO2 is being priced via the Emissions Trading Scheme and investments are being made via the EU Innovation Fund and other schemes. In the US the approach lies in tax breaks, on-shoring and investment in new sustainable technologies.
However, other countries have different priorities. Or as a South Asian contact told Global Cement Weekly at a different conference, “How can our government think about sustainability when it can’t feed everyone?” The world’s biggest cement producing countries are China and India, and then the EU and the US follow. Brazil, Türkiye and Vietnam are at similar levels or not far behind. The EU and the US represent about 9% of global cement production based on Cembureau figures for 2022. China and India cover 61% of production. Neither of these countries has announced a plan to encourage the widespread construction of carbon capture units. Once China ‘gets’ cement carbon capture though, it seems plausible that it will dominate it as it has in many other sectors such as solar panel production. Exporters such as Türkiye and Vietnam will have to adapt to the rules of their target markets.
The march by the cement and lime sectors towards carbon capture has been long, difficult and expensive. It also has a long, long way to go. Yet, the next decade promises to be exciting as new technologies are developed and tested, full-scale projects are commissioned and CO2 pipelines, sequestration sites and usage hubs come online. The next key milestones to look out for include the first full-scale installations using other capture methods (such as oxy-fuel kilns), the first CO2 pipeline network that hooks up to a cement plant, the first land-based sequestration site, the first industrial hub that uses CO2 at scale to manufacture a product, new government policies in China and India, and the first large unit that is funded entirely from private finance. To end on a positive note, a Cembureau representative at the Global CemCCUS Conference reckoned that Europe will be able to capture 12Mt/yr of CO2 by 2030. If it happens, this will be a major achievement and a serious statement of intent towards net zero for the sector.
The 2nd Global CemCCUS Conference will take place in Hamburg in May 2025
Holcim breaks ground on Go4Zero at Obourg
17 May 2024Belgium: Holcim kicked-off its Go4Zero project at its Obourg plant on 16 May 2024 in an event attended by the Belgian Prime Minister Alexander De Croo and the European Commissioner for Climate Action Wopke Hoekstra. The €500m Go4Zero project, supported with €230m of funding from the European Union, will enable the integrated plant to reduce its CO2 emissions by 30% by 2027 and to produce 2Mt/yr of CO2-free cement by 2029. When fully operational, the Obourg plant will capture 1.2Mt/yr of CO2.
The Go4Zero project incorporates a number of approaches to achieve net-zero CO2 cement. The centrepiece is an oxy-fuel combustion process to generate an easy-to-handle exhaust gas with up to 80% CO2. This will be coupled to a cryogenic purification unit to generate a >99%-pure CO2 stream .The project will also make use of waste heat recovery (WHR), new exhaust filtration equipment and Europe’s largest floating solar panel farm.
Update on Türkiye, March 2024
13 March 2024TürkÇimento revealed this week that cement production in Türkiye grew by 10.5% year-on-year to 81.5Mt in 2023. In a press release describing the progress of the local cement sector, the cement association reported that domestic sales rose by 19% to 65Mt but that exports fell by 28% to just under 20Mt. Fatih Yücelik, the chair of TürkÇimento, also said that his country was the second largest exporter of cement in the world in 2023 and that its most important target market was the US. He noted that the construction sector grew by 8% during 2023, that reconstruction projects were enacted following earthquakes in early 2023 but that no further growth in domestic sales of cement was anticipated in 2024.
As is standard for these kinds of occasions, Yücelik also raised the association’s sustainability ambitions, describing his sector as one “whose main goal is to provide low-carbon production.” He added that the Turkish cement industry supports the country’s net zero target of 2053. To this end the association has also released its first sustainability report, for 2022, covering 48 of the country’s 52 integrated plants. The Hürriyet Daily News newspaper offered one reason for this enthusiasm for sustainability: the US$30bn in investment required to meet that 2053 net-zero target. It also reported that Yücelik said that the industry needed to spend US$2bn towards meeting the incoming requirements of the European Union Carbon Border Adjustment Mechanism (CBAM).
Graph 1: Domestic and export cement sales in Türkiye, January – October, 2017 – 2023. Source: TürkÇimento.
TürkÇimento’s data for 2023 currently runs up to October 2023 but it supports Yücelik’s assessment. As can be seen in Graph 1, domestic sales of cement rose sharply in the first 10 months of 2023, by 20% year-on-year to 53.1Mt, yet exports fell almost as abruptly, by 18% to 13Mt. This is noteworthy, as exports had been rising steadily each year since 2018. Italy-based Cementir provided some context here in its annual report for 2023 saying that it had decided to focus on the domestic market due to greater profitability. Heidelberg Materials’ joint-venture Akçansa echoes these comments, blaming declining exports on “historically low freight rates increasing competitiveness of southeast Asian suppliers” while emphasising that the shift to the domestic market was made to meet increasing demand.
Graph 2: Revenue of selected large Turkish cement producers, 2022 - 2023. Source: Company reports.
Financial information from the larger Turkish cement producers that have released their results for 2023 follows the same pattern. Three of the four companies included in Graph 2 saw sales revenue grow in 2023. The one that saw its revenue fall, Nuh Çimento, is a major exporter. In 2022 for example it supplied 18% of the country’s total cement exports. All of these companies saw operating profit or earnings increase though.
The other big Türkiye-based news story this week was that Taiwan Cement Corporation (TCC) completed the latest increase to its stakes of Cimpor Global Holdings joint-ventures in Türkiye and Portugal. TCC now owns a 60% stake of the business in Türkiye and a 100% stake in Portugal. With respect to the business in Türkiye this means that TCC now has control of the country’s largest cement producer, OYAK Çimento. Once again the CBAM received a mention, with TCC saying in its valedictory statement that it believed that, “whether it's domestic or imported cement, low-carbon cement will become the main competitive advantage for the cement companies entering the European market.”
The domestic market in Türkiye may have seen a bounce in 2023 but the attention of both TürkÇimento, TCC and others are firmly set on the wider market in the region. TürkÇimento’s Fatih Yücelik said that the country’s cement production capacity was 120Mt/yr and that the population would have to be 150m to eliminate the need for exports. Its population is currently just under 85m. Yücelik set a value of US$2bn for his sector to adjust to CBAM but he also remarked that the income from exports in 2023 was around US$1.3bn. This is not an easy investment ‘pill’ to swallow but one that the country will have to digest if it wants to keep its export levels up.
Greece: Titan has endorsed the Antwerp Declaration, advocating for an European Union (EU) Industrial Deal complementing the EU Green Deal, to bolster the European economy's sustainable growth and competitiveness. Resulting from a summit in Antwerp, Belgium on 20 February 2024, the declaration has gained support from over 630 businesses across 20 sectors. It highlights the necessity of elevating competitiveness, ensuring a level playing field to counter unfair competition, and prioritising infrastructure development in energy, digital technologies, CCUS, and materials recycling.
EU: The European Commission has introduced a Draft Guidance document regarding the Free Allocation Regulation (FAR), now expanded to include ‘alternative hydraulic binders’ within the cement clinker benchmark. To qualify for allocation under this benchmark, these binders must meet three specific criteria: they must be used in cement production, not be included in any other benchmark under the European Union's Emissions Trading Scheme (ETS), and must not be by-products of waste or other production processes.
The European Cement Association (CEMBUREAU) has expressed concerns regarding these criteria. Namely, that the proposed changes suggest a shift from a clinker to a cement-based benchmark approach, making current methodologies and regulations inconsistent and impractical, especially as cement production often occurs outside ETS-covered sites. CEMBUREAU also states that some materials like pozzolana and calcined clay, requiring activation by lime or grey cement clinker, do not fit the hydraulic binder definition. Lastly, the association suggests that only materials covered by the standard EN 197-1 should be considered as alternative hydraulic binders, implying that the current definition in the FAR is overly broad and potentially problematic.
Türkiye: The Turkish cement industry needs to invest approximately US$30bn to achieve its net-zero carbon goal by 2053, according to sector representatives. Additionally, around US$2bn is required to adhere to the European Union’s Carbon Border Adjustment Mechanism (CBAM), according to Fatih Yücelik, chair of the Turkish Cement Manufacturers’ Association (TÜRKÇİMENTO).
Yücelik said “The most important issue for us this year is carbon emissions. The amount of investments to be made swiftly in transformation and efficiency work to overcome the barriers created by the CBAM is around US$2bn. However, under the current situation, it is difficult for us to find this financing.”
There are 77 factories producing cement in Türkiye, according to Yücelik. “They all use kilns which heavily consume energy. We are establishing waste heat recovery facilities. The amount of electricity generated by those units can power 618,000 homes,” he said. The industry also faces rising operational costs, with energy comprising about 80% of these expenses.
Czech Republic: The Czech Cement Association (SVC ČR) says that it is “firmly” committed to decarbonise the cement industry and has agreed a clear roadmap explaining how to reach net zero by 2050. It added that it was also backing the strategy outlined in the European Commission’s (EC) industrial deal. In a statement the association said, “The position of SVC ČR regarding the proposal of the decarbonising targets by 2040 is that the Czech government has to prepare in cooperation with the individual industries a deep analysis of the opportunities and the risks arising from the new proposal and prepare a long-term strategy to support the competitiveness of Czech energy-intensive industries.”
SVC ČR distanced itself from comments published in ČTK Business News reporting that a group of energy-intensive industry associations in the country had challenged the EC's proposal to aim to reduce CO2 emissions by 90% by 2040. The associations argue that the target will harm the competitiveness of Czech industries. They say that it is based on unrealistic assumptions and overlooks the absence of necessary conditions for major investment in the EU’s green industry transformation.
This story was updated on 29 February 2024 with comments from SVC ČR
Cemex welcomes European Commission's Carbon Management Strategy
07 February 2024EU: Cemex has welcomed the European Commission's Carbon Management Strategy, its new policy approach to industrial CO2 emissions reduction. The approach highlights the storage of biogenic CO2 and the development of CO2 transport infrastructure as major strategic paths. Cemex said that it will assist in the design and implementation of actions under the Carbon Management Strategy. In its European cement operations, Cemex reduced its CO2 intensity by 45% in 2023 compared to 1990 levels, and aims to achieve a 55% reduction by 2030. The producer called for ‘the completion of the policy landscape’ in complement to the industry’s on-going efforts towards full decarbonisation.
Cemex Europe, Middle East and Africa director communications, public affairs and social impact Martin Casey said “The strategy is comprehensive and outlines relevant fields of action, but what is essential now is a timely implementation. For companies to move forward, the regulatory framework regarding carbon capture and utilisation or storage, along with carbon accounting and removals, must be completed as a matter of the utmost urgency. The cement plant of 2030 is planned and designed today.”
Spain: Cementos La Cruz plans to build a new unit to produce reduced-CO2 cement at its 1.5Mt/yr Abanilla grinding plant in Murcia. In a video posted on YouTube, the producer said that the new unit will produce cement using supplementary cementitious materials (SCMs) derived from industrial waste streams. Additionally, it will source 100% of its electricity consumption from biofuel-fired generators. Cementos La Cruz has secured Euro4.5m in European Union funding for the project.
General director Juan Luis Porrúa said that cement from the upcoming unit will have a specific carbon footprint below 200kg/t, and will eliminate over 400,000t of CO2 emissions from Spanish construction in its first 10 years of operation.
Who will build the cement plants of tomorrow?
13 December 2023Sinoma International Engineering revealed this week that it has signed a Euro218m contract to supply a new clinker production line for Holcim Belgium. The scope of the deal covers building the new line from limestone unloading via train to clinker transportation and storage. Provisional acceptance and first clinker are stipulated to occur within about four years, by late 2027. Holcim Belgium operates the Obourg Plant, its only integrated unit in the country, and the unit has been preparing to build a new line as part of its Go4Zero project.
Two main points compete for one’s attention with the project at the Obourg Plant. Firstly, this may be the first time a large Europe-based cement producer has publicly contracted a China-based supplier to build a new production line. Secondly, the new line is part of a process to first replace two wet kilns at the site with a dry kiln. This is part of a grand plan at the site to add oxyfuel technology to the plant and then start capturing most of the CO2 emitted for sequestration in the North Sea.
On the first point, China-based Sinoma International Engineering reported to the Shanghai Stock Exchange in early December 2023 that it had signed a contract for the project. Holcim Belgium has not said that it has appointed the subsidiary of CNBM but this is not unusual. Buyers are at liberty to name suppliers, or not as may be the case. Holcim has been talking about the Go4Zero project for several years though, so appointing a lead contractor is not surprising.
Yet, some cement companies in Europe have previously been circumspect about revealing the use of China-based suppliers. Lafarge France, for example, did not appear to publicly name the involvement of Sinoma International Engineering and its subsidiaries on the construction of a new line at its Martres-Tolosane cement plant between 2019 and 2022, although Lafarge Poland did say in 2020 that it had contracted China Triumph International Engineering for an upgrade to its Małogoszcz cement plant. No doubt there have been other plant projects in Europe from China-based suppliers that Global Cement Weekly is unaware of. It is also worth considering that just because a lead contractor on a plant project is from a particular country it doesn’t mean that the equipment and other sub-contractors necessarily are. And, of course, to add to the confusion, some Europe-based equipment suppliers are owned by companies based in China.
This leads to the second point. Holcim Belgium’s eventual goal is to set up a full-scale carbon capture, transportation and sequestration (CCUS) operation at Obourg using oxyfuel technology by the end of the 2020s. Spending over Euro200m on building a new (but conventional) production line is not trivial but it is being presented as one step towards creating a cement plant for the net zero age. To this end Holcim Belgium has been less shy in naming its partners for the second phase of the project: Air Liquide; Fluxys; and TotalEnergies. This may be due to the collaborative nature of this phase though and the need to apply for European Union (EU) funding to support it. In July 2023 Holcim disclosed that the EU Innovation Fund had allocated grants for three of its projects including the one at Obourg.
For reference, a number of other full-scale oxyfuel projects have been announced in Europe including in Germany at Heidelberg Materials' Geseke cement plant, Holcim Deutschland's Lägerdorf plant in Germany and Schwenk Zement’s Mergelstetten plant. Another one is planned for Heidelberg Materials’ CBR's Antoing cement plant in Belgium. Most of these are planned for the late 2020s or with pilots sooner. The key bit of information to consider here is that adding oxyfuel technology to a cement kiln (or building one with it to start with) makes it easier to capture CO2 from the flue gas as it is more concentrated. However, the technology is newer and less-tested than many post-combustion carbon capture methods. Hence, the world’s first full-scale CCUS unit at a cement plant, at Brevik in Norway, will use a post combustion method.
All of this begs the question about where the value will lie in building cement plants for the age of net zero? The planned work at Holcim Belgium’s Obourg Plant pretty much summarises this quandary. Building a cement production line is expensive but the cost of disposing of CO2 may become the single-biggest driver of whether a plant is profitable or not if governments are serious about reaching net zero. To that end today’s announcement from the 2023 United Nations Climate Change Conference (COP28) calling on the parties to “transition away from fossil fuels to reach net zero” is another sign of the increasing effects of the so-called ‘carbon agenda’ upon the cement sector. In which case the companies that can supply equipment to take care of the CO2 emissions start becoming more important and discussions over who supplies the rest of the kit less so. Naturally, some cement equipment suppliers are already pivoting towards this approach. Others may find different solutions. Whether this works or not is a question for the future. In the mean-time, building new plants is looking increasingly collaborative.