Displaying items by tag: Government

Tajikistan: The Tajik parliament has ratified an agreement for the construction of a 1.8Mt/yr integrated cement plant at Qubodiyon in Khatlon Province. ASIPLU News has reported that the government signed an agreement with Orien Invest for the plant's construction on 7 September 2022. Orien Invest said that it hopes to attract US$160m-worth of foreign investment in the project. When commissioned, the Qubodiyon cement plant will be Tajikistan's largest and create 1300 new jobs locally.

During the first nine months of 2022, Tajikistan produced 3.2Mt of cement, down by 0.7% year-on-year from nine-month 2021 volumes. Full-year production was 4.2Mt in 2021, in line with the two previous years.

US: The Alabama Department of Environmental Management (ADEM) has ordered Holcim US to pay a US$100,000 fine for alleged fugitive dust emissions from its Theodore cement plant in Mobile. Between February and August 2022, witnesses reported multiple dust plumes sighted above the plant, which is situated on the Theodore canal. AL.Com News has reported that, while neither admitting or denying the contentions, Holcim US said that it has taken actions affecting its raw materials unloading processes to ensure compliance.

Plant manager Clay Copeland said “We have worked closely with the ADEM to address concerns raised earlier this year."

Vietnam: The Ministry of Construction has appointed Bui Xuan Dung as the chair of the Vietnam Cement Corporation (VICEM).

Bui Xuan Dung trained as a civil engineer and holds a master’s degree in business administration. He worked for the Hanoi Construction Corporation from 1995 to 2021 becoming its General Director in 2015. Since 2021 he has held the post of Director of the Housing and Real Estate Market Management Department at the Ministry of Construction.

VICEM is a state-owned cement producer controlled by the Ministry of Construction. It operates 16 production lines at 10 plants and holds around 35% of the country’s market share in the cement sector.

Philippines: The Department of Trade and Industry (DTI) has backed a recommendation from the Tariff Commission (TC) to repeal import duties on Ordinary Portland Cement and Blended Cement. The so-called safeguard measures were originally introduced in October 2019 for a period of three years, according to the Philippine Star newspaper. The latest investigation by the TC was started due to a request by the Cement Manufacturers Association of the Philippines (CEMAP). However, it found that the domestic cement industry was generally profitable and it said, “There is no existence of an imminent threat of serious injury and significant overall impairment to the position of the domestic cement industry in the near future.” CEMAP said it was saddened by the recommendation of the TC and that it would jeopardise the local sector’s progress.

Canada: The government and the Cement Association of Canada have published the ‘Roadmap to Net-Zero Carbon Concrete by 2050.’ The document details how cement and concrete producers and legislators could achieve net-zero CO₂ emissions from the cement and concrete sector by 2050. The joint government-industry working group next plans to release an action plan explaining how the sector will reduce its CO₂ emissions by up to 40% by 2030 and a plan for research and development required to meet the 2050 target. The country’s cement and concrete industry says it has committed to reducing over 15Mt of greenhouse gases cumulatively by 2030 and achieving net-zero by 2050.

“Decarbonising concrete is a necessity, and Canada’s cement and concrete industry has demonstrated that it is up to the task. This roadmap demonstrates our industry’s leadership in CO₂ emissions reduction and positions us to achieve our goal of net-zero cement by 2050,” said Marie Glenn, chair of the Cement Association of Canada. Association president and chief executive officer Adam Auer added, “While we are steadfast in our commitment to reduce our emissions by 15MT cumulatively by 2030 and reach true net-zero by 2050, we know we can’t do it alone. Together in collaboration with government we will continue to support the innovation and investment needed on our path to delivering net-zero concrete, while at the same time preserving its properties as a durable, resilient, versatile, and cost-effective material.”

Germany: The Catch4Climate project says it is ready to build an oxyfuel pilot unit at Schwenk Zement’s Mergelstetten plant following approval by the Stuttgart Regional Council. The project comprises Dyckerhoff, Heidelberg Materials, Schwenk Zement and Vicat, and It has set up a research company called CI4C to run it. Over Euro120m will be invested towards building a dedicated 450t/day production line to test the oxyfuel process. Jürgen Thormann, the Technical Managing Director of CI4C, said that this is the first time a so-called ‘pure’ oxyfuel process will be used for CO₂ capture. At a later stage in the project the consortium plans to use the captured CO₂ to produce so-called ‘reFuels’, climate-neutral synthetic fuels such as kerosene for aircraft, with the help of renewable electrical energy. Commissioning of the unit is scheduled for mid-2024.

India: A violent disturbance brought an end to a public hearing over ACC's plans to establish a new integrated cement plant in Masturi, Chhattisgarh, on 3 November 2022. Police reportedly used 'mild force' to subdue protestors who claimed that ACC has acted illegally. The Free Press Journal has reported that land recorded by ACC as 'barren' in document submissions is allegedly used by residents for cultivation of rice and other crops.

Limestone mining has already commenced at the Masturi site.

India: Dalmia Bharat sold 12Mt of cement during the first half of its 2023 financial year, up by 20% year-on-year from 10Mt in the first half of the 2022 financial year. Its income was US$757m, up by 21% year-on-year from US$624m. Meanwhile, the company's earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 28% to US$116m from US$161m. The company noted the growth effects of 'fuel price corrections' during the second quarter of 2022, which it expects to increase its profitability during the second half of year.

Managing director and CEO Punit Dalmia said “We are pleased with the performance of the first half of this year despite the intense inflationary environment, and are confident that we will be among the best in the industry, leaving the bad times behind. While the geopolitical turmoil continues, we are confident in the resilience of the Indian economy, which is further cementing its position at the centre of global growth and consumption.” Dalmia continued “In view of the government's continued momentum in the infrastructure sector, driven by the revitalisation of the housing sector, we expect the demand for cement to grow rapidly. Looking ahead, we will remain focused on our capacity expansion progress.”

Dalmia Bharat's 14 integrated cement and grinding plants span 10 Indian states and have a capacity of 37Mt/yr, India's fourth largest.

In Australia and New Zealand, four producers operate a total of six integrated cement plants, with another 13 grinding plants situated in Australia. This relatively small regional cement industry has been on a decades-long trajectory towards ever-greater sustainability – hastened by some notable developments in recent weeks.

Oceania is among the regions most exposed to the impacts of climate change. In Australia, which ranked 16th on the GermanWatch Global Climate Risk Index 2021, destructive changes are already playing out in diverse ways.¹ Boral reported 'significant disruption' to its operations in New South Wales and southeast Queensland due to wet weather earlier in 2022. This time, the operational impact was US$17.1m; in future, such events are expected to come more often and at a higher cost.

Both the Australian cement industry and the sole New Zealand cement producer, Golden Bay Cement, have strategies aimed at restricting climate change to below the 2° scenario. Golden Bay Cement, which reduced its total CO₂ emissions by 12% over the four-year period between its 2018 and 2022 financial years, aims to achieve a 30% reduction by 2030 from the same baseline. The Australian Cement Industry Federation (CIF)'s 2050 net zero cement and concrete production roadmap consists of the following pathways: alternative cements – 7%; green hydrogen and alternative fuels substitution – 6%; carbon capture – 33%; renewable energy, transport and construction innovations – 35% and alternative concretes – 13%, with the remaining 6% accounted for by the recarbonation of set concrete.

Australia produces 5.2Mt/yr of clinker, with specific CO₂ emissions of 791kg/t of clinker, 4% below the global average of 824kg/t.² Calcination generates 55% of cement’s CO₂ emissions in the country, and fuel combustion 26%. Of the remainder, electricity (comprising 21% renewables) accounted for 12%, and distribution 7%. Australian cement production has a clinker factor of 84%, which the industry aims to reduce to 70% by 2030 and 60% by 2050. In New Zealand, Golden Bay Cement's main cement, EverSure general-purpose cement, generates CO₂ at 732kg/t of product.³ It has a clinker factor of 91%, and also contains 4% gypsum and 5% added limestone.

Alternative raw materials

Currently, Australian cement grinding mills process 3.3Mt/yr of fly ash and ground granulated blast furnace slag (GGBFS). In Southern Australia, Hallett Group plans to commission its upcoming US$13.4m Port Augusta slag cement grinding plant in 2023. The plant will use local GGBFS from refineries in nearby Port Pirie and Whyalla, and fly ash from the site of the former Port Augusta power plant, as well as being 100% renewably powered. Upon commissioning, the facility will eliminate regional CO₂ emissions of 300,000t/yr, subsequently rising to 1Mt/yr following planned expansions. Elsewhere, an Australian importer holds an exclusive licencing agreement for UK-based Innovative Ash Solutions' novel air pollution control residue (APCR)-based supplementary cementitious material, an alternative to pulverised fly ash (PFA), while Australian Graphene producer First Graphene is involved in a UK project to develop reduced-CO₂ graphene-enhanced cement.

Golden Bay Cement is investigating the introduction of New Zealand's abundant volcanic ash in its cement production.

Fuels and more

Alternative fuel (AF) substitution in Australian cement production surpassed 18% in 2020, and is set to rise to 30% by 2030 and 50% by 2050, or 60% including 10% green hydrogen. In its recent report on Australian cement industry decarbonisation, the German Cement Works Association (VDZ) noted the difficulty that Australia's cement plants face in competing against landfill sites for waste streams. It described current policy as inadequate to incentivise AF use.

Cement producer Adbri is among eight members of an all-Australian consortium currently building a green hydrogen plant at AGL Energy’s Torrens Island gas-fired power plant in South Australia.

Across the Tasman Sea, Golden Bay Cement expects to attain a 60% AF substitution rate through on-going developments in its use of waste tyres and construction wood waste at its Portland cement plant in Northland. The producer will launch its new EcoSure reduced-CO₂ (699kg/t) general-purpose cement in November 2022. In developing EcoSure cement, it co-processed 80,000t of waste, including 3m waste tyres. The company says that this has helped in its efforts to manage its costs amid high coal prices.

Carbon capture

As the largest single contributor in Australia's cement decarbonisation pathway, carbon capture is now beginning to realise its potential. Boral and carbon capture specialist Calix are due to complete a feasibility study for a commercial-scale carbon capture pilot at the Berrima, New South Wales, cement plant in June 2023.

At Cement Australia's Gladstone, Queensland, cement plant, carbon capture is set to combine with green hydrocarbon production in a US$150m circular carbon methanol production facility supplied by Mitsubishi Gas Chemical Company. From its commissioning in mid-2028, the installation will use the Gladstone plant's captured CO₂ emissions and locally sourced green hydrogen to produce 100,000t/yr of methanol.

More Australian cement plant carbon capture installations may be in the offing. Heidelberg Materials, joint parent company of Cement Australia, obtained an indefinite global licence to Calix's LEILAC technology on 28 October 2022. The Germany-based group said that the method offers effective capture with minimal operational impact.

Cement Australia said “The Gladstone region is the ideal location for growing a diverse green hydrogen sector, with abundant renewable energy sources, existing infrastructure, including port facilities, and a highly skilled workforce." It added "The green hydrogen economy is a priority for the Queensland government under the Queensland Hydrogen Industry Strategy.”

Logistics

Australian and New Zealand cement facilities' remoteness makes logistics an important area of CO₂ emissions reduction. In Australia, cement production uses a 60:40 mix of Australian and imported clinker, while imported cement accounts for 5 – 10% of local cement sales of 11.7Mt/yr.

Fremantle Ports recently broke ground on construction of its US$35.1m Kwinana, Western Australia, clinker terminal. It will supply clinker to grinding plants in the state from its commissioning in 2024. Besides increasing the speed and safety of cement production, the state government said that the facility presents 'very significant environmental benefits.'

Conclusion

Antipodean cement production is undergoing a sustainability transformation, characterised by international collaboration and alliances across industries. The current structure of industrial and energy policy makes it an uphill journey, but for Australia and New Zealand's innovating cement industries, clear goals are in sight and ever nearer within reach.

References

1. Eckstein, Künzel and Schäfer, 'Global Climate Risk Index 2021,' 25 January 2021, https://www.germanwatch.org/en/19777

2. VDZ, 'Decarbonisation Pathways for the Australian Cement and Concrete Sector,' November 2021, https://cement.org.au/wp-content/uploads/2021/11/Full_Report_Decarbonisation_Pathways_web_single_page.pdf

3. Golden Bay Cement, 'Environmental Product Declaration,' 12 May 2019, https://www.goldenbay.co.nz/assets/Uploads/d310c4f72a/GoldenBayCement_EPD_2019_HighRes.pdf

US: Martin Marietta Materials recorded revenues of US$4.68bn throughout the first nine months of 2022, up by 20% year-on-year from US$3.92bn. Cement sales contributed US$455m, 9.7% of total revenues, up by 27% from US$358m. Cost of revenues rose by 4% for the group, to US$3.62bn from US$2.92bn. Nonetheless, Martin Marietta Materials successfully recorded nine-month net earnings growth of 25% year-on-year, to US$638m from US$546m.

Chair and CEO Ward Nye said that double-digit price growth drove the company's record profitability. He said "Importantly, we expect a return to expanding margins in the fourth quarter of 2022, as the compounding effect of multiple pricing actions throughout the year offsets continued inflationary pressure and a slowdown in single-family residential construction. Martin Marietta's strategic coast-to-coast footprint is well positioned for long-term growth, driven by favourable population migration trends, housing shortages in our markets and a long-term federal highway bill complemented by healthy Department of Transportation budgets in the company's key states. Near-term, we expect affordability-driven headwinds in the single-family residential end market will be offset by a significant acceleration in public infrastructure investment and continued strength in large-scale energy, domestic manufacturing and multi-family residential projects."