Displaying items by tag: Hanson

Hydrogen and its use in cement production has been adding a dash of colour to the industry news in recent weeks. Last week, Lafarge Zementwerke, OMV, Verbund and Borealis signed a memorandum of understanding (MOU) to plan and build a full-scale unit at a cement plant in Austria to capture CO₂ and process it with hydrogen into synthetic fuels, plastics or other chemicals. This week, Air Products and ThyssenKrupp Uhde Chlorine Engineers (TUCE) signed a strategic agreement to work together in ‘key regions’ to develop projects supplying green hydrogen. Both of these developments follow the awarding of UK government funding in February 2020 to support a pilot project into studying a mix of hydrogen and biomass fuels at Hanson Cement’s Ribblesdale integrated plant.

As the title of this column suggests there is an environmental colour code to describe how hydrogen is made for industrial use. This is a bit more codified than when grey cement gets called ‘green’ but it pays to remember what the energy source is. So-called ‘green’ hydrogen is produced by the electrolysis of water using renewable energy sources such as hydroelectric or solar, ‘Grey’ hydrogen is made from steam reforming using fossil fuels and ‘Blue’ hydrogen is similar to grey but has the CO₂ emissions from the fuels captured and stored/utilised. Price is seen as the main obstacle to wider uptake of hydrogen usage as a fuel in industry although this is changing as CO₂ pricing mounts in some jurisdictions and the connected supply chain is developed. A study by BloombergNEF from March 2020 forecasted that green hydrogen prices could become cheaper than natural gas by 2050 in Brazil, China, India, Germany and Scandinavia but it conceded that many barriers would have to be overcome to get there. For example, hydrogen has to be manufactured making it more expensive than fossil fuels without government policy support and its, “lower energy density also makes it more expensive to handle.”

The three recent examples with respect to the cement industry are interesting because they are all exploring different directions. The Lafarge partnership in Austria wants to use hydrogen to aid the utilisation side of its carbon capture at a cement plant. The industrial suppliers, meanwhile, are positioning themselves in the equipment space for the technology required to use hydrogen on industrial plants. Secondly, ThyssenKrupp has alkaline water electrolysis technology that it says it has used at over 600 projects and electrochemical plants worldwide. Air Products works with industrial gas production, storage and handling.

Finally, the Hanson project in the UK will actually look at using hydrogen as a partial replacement for natural gas in the kiln combustion system. A Cembureau position paper in mid-2019 identified that the challenges to explore in using hydrogen in cement production included seeing how its use might affect the physical aspects of the kiln system, the fuel mass flows, temperature profile, heat transfer and the safety considerations for the plant. Later that year a feasibility study by the Mineral Products Association (MPA), Verein Deutscher Zementwerke (VDZ) and Cinar for the UK government department that is funding the Hanson project concluded that a hydrogen flame’s high heat in a burner alone might not make it suitable for clinker formation. However, the study did think that it could be used with biomass to address some of that alternative fuel’s “calorific limitations” at high levels. Hence the demonstration of a mixture of both hydrogen and biomass.

That’s all on hydrogen but, finally, if you didn’t log into yesterday’s Virtual Global CemProducer 2 Conference you missed a treat. One highlight was consultant John Kline’s presentation on using drones to inspect refractory in some hard to reach places. Flying a camera straight into a (cool) pyro-processing line was reminiscent of a science fiction film! Global Cement has encountered the deployment of unmanned aerial vehicles in quarry and stockpile surveys previously but this was a step beyond.

The proceedings pack - including video, presenter slides and delegate list - for the Virtual Global CemProducer 2 Conference 2020 is available to buy now

Germany: Following a comprehensive review of its assets HeidelbergCement has announced a Euro3.4bn impairment to its company value compared to the figure from a precious valuation prior to the second quarter of 2020. The company gave the reasons for the impairment as: the demand impacts of the coronavirus pandemic; economic effects on operations in individual countries; notably in the UK post-Brexit; and an increase in the market risk premium used by the Institut für Wirtschaftsprüfer (German public auditing body) for valuation to 7% from 6%. The largest regional impairment was Euro2.7bn, in Western and Southern Europe. Euro2.3bn of the total impairment, “relates to the Hanson acquisition” by HeidelbergCement in 2007.

UK: Hanson has said that it is supplying 2000m3 of concrete to the Harwell Science Campus, Oxfordshire for use in the construction of the Vaccine Manufacture and Innovation Centre (VMIC), the first facility of its kind in the UK. Due to the on-going coronavirus outbreak, the centre will be finished ahead of schedule in mid-2021. Hanson UK West regional general manager James Moorhouse said, “We are working flat out to manage the accelerated requirements of the construction programme.”

UK: A team of Hanson employees has produced a sign from recycled materials from around the company’s 1.0Mt/yr Purfleet slag cement grinding plant. The 6m-long luminous sign, which reads ‘NHS Thank You,’ has been installed at the plant on the mill three tower overlooking the QE2 Dartford Crossing. Hanson Purfleet plant manager Warren Scott said, “The team wanted to show their appreciation for the NHS and key workers and came up with and executed this idea in their own time.”

Hanson has kept ‘a number of key sites’ open through the coronavirus outbreak in order ‘to supply key national infrastructure projects or to provide maintenance materials to critical sectors.’ Hanson has furloughed part of its staff under the government’s Coronavirus Job Retention Scheme.

UK: Hanson Cement has appointed Andy Murphy as national commercial director. He reports directly to chief executive officer (CEO) Simon Willis and assumes commercial responsibility for the cement division as well as Hanson’s major projects and commercial excellence teams. Murphy holds experience in sales and marketing roles in the construction sector, including at Lafarge Tarmac, Jewson and building materials supplier SIG Distribution.

UK: Hanson has appointed Andrew Simpson as its packed products director, adding operational responsibility to his commercial remit. He is responsible for sales of all of its packed products, including cement, ready-to-use concrete and aggregates, and will now also look after manufacturing at the company’s ready-to-use production site in Nuneaton, as well as its construction aggregates packing plants across the country.

Simpson started his career with Hanson in 1997 when he was appointed area sales manager for Castle Cement, part of the HeidelbergCement Group, which bought Hanson in 2007. Since then he has held a number of different sales roles and attained a degree in Business Studies from De Montfort University in Leicester. In 2017 he was honoured with the freedom of the City of London and installed as a Liveryman of The Worshipful Company of Builders Merchants in recognition of his work within the builders’ merchants’ industry.

UK: Hanson’s ship Arco Avon has uncovered a mammoth tooth whilst dredging the seabed for aggregates for use in cement production off the east coast of Norfolk. Natural History Museum palaeontologists have identified the specimen has having belonged to a 35-year-old animal that died between 10,000 and 0.35m years ago. The dredging lane, 10km offshore from Great Yarmouth, has previously turned out mammoth vertebrae and a tusk fragment.

UK: Hanson has appointed Rick Green as the managing director of its Leicestershire-based asphalt and quarrying business MQP (Midland Quarry Products). He moves from his role as managing director of Hanson Contracting to replace Dave Bagshaw, who has retired after 39 years in the industry. Green has also been chair of the Asphalt Industry Alliance (AIA) since 2017. The AIA was established in 2000 and is a partnership between the Mineral Products Association (MPA) and Eurobitume UK.

MQP consists of three quarries and 10 asphalt plants located across the Midlands. It was operated as a joint venture with Tarmac until 2013, when Hanson wholly acquired the company.

UK: Hanson has opened a new ready-mixed concrete (RMX) plant in Rochester, Kent, to supply growing demand for construction projects in the South East. The new unit replaces the subsidiary of HeidelbergCement’s former concrete plant in the town. The group says it provides increased capacity, improved productivity, lower power consumption and reduced ongoing maintenance costs.

UK: Hanson has been part of a new continuous concrete pour record in the UK as part of its work at the EDF Energy’s Hinkley Point C (HPC) new nuclear power station in Somerset. It supplied raw materials for the concrete to main civil engineering contractor BYLOR, which operates the on-site concrete production plant. The 9000m³, five-day, pour was to construct the last of five reinforced concrete segments that make up the cross-shaped foundations on which all of the first nuclear reactor’s buildings will sit. The record-breaking pour beats the previous UK record set by the Shard skyscraper in London.

The completion of the foundation platform, which is up to 4m thick, represents a significant milestone for the project, described by EDF Energy as J-zero. It marks the transition from below ground activity to the construction of permanent reactor buildings above ground.

Hanson says that mix design for HPC took three years of development and testing to ensure that the concrete was of the required quality mandated by the Office for Nuclear Regulation. The subsidiary of Germany’s HeidelbergCement has 65 employees directly involved in the HPC project team. To date Hanson has supplied 51,000m³ of concrete, 2.5Mt of aggregates, 210,000t of marine sand, 65,000t of cement; 105,000t of ground granulated blast furnace slag (GGBS) and 125,000t of asphalt.