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Displaying items by tag: Heidelberg Materials
KIMA Process Control to supply kiln cooling system for Cementa's Slite cement plant
17 November 2022Sweden: Germany-based KIMA Process Control has secured a contract for the supply of a kiln shell cooling system for Cementa's Slite cement plant in Gotland. 88 water jets will deliver centimetre-precision cooling for the 55m-long kiln, while IR pyrometers measure temperatures over areas of 10cm2. According to KIMA Process Control, the equipment can avoid unnecessary cooling of the kiln shell, conserving the heat energy supplied by the main burner.
The new cooling system will eliminate the use of energy intensive electric fans, slashing 1700t/yr in CO2 emissions, according to the supplier. It said that noise emissions will also 'drastically' decline as a result of the upgrade. The system's operating costs are reportedly 98% less than those of the plant's existing fan system.
The supplier said that the new equipment will 'bring the cement plant in Slite an economic benefit in the shortest possible time.' It said "For the cement industry, this project represents a new milestone in terms of best available technology in the operation of rotary kilns."
US: Lehigh Hanson plans to stop cement production at its integrated Permanente plant near Cupertino in California. The subsidiary of Germany-based Heidelberg Materials plans to use the site as a distribution centre and to continue some quarry work, according to the Mercury News newspaper. The cement plant was originally opened in 1939 but it stopped clinker production in 2020.
Catch4Climate to start building oxyfuel pilot unit at Mergelstetten
10 November 2022Germany: 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.
Update on COP27
09 November 2022Readers may have noticed the 2022 United Nations Climate Change Conference (COP27) is currently taking place at Sharm El Sheikh in Egypt. Many of the cement companies, suppliers and related associations are present at the annual jamboree and getting stuck in. For example, Holcim’s chief sustainability officer Magali Anderson was scheduled on 8 November 2022 to discuss solutions to decarbonise the built environment at the event’s Building Pavilion, Cemex’s chief executive officer Fernando A González took part in the First Movers Coalition (FMC) panel, FLSmidth is down for a number of talks and both the Global Cement and Concrete Association (GCCA) and World Cement Association are busy too.
Stone cold progress, if any, from the conference is yet to emerge although there is still time given that the event runs until 18 November 2022. No doubt some sort of ‘big message’ style international commitment or plan will emerge from the haggling. However, on the cement sector side, the biggest story so far has been the FMC plan for some of its members to procure at least 10% near-zero cement and concrete for its projects by 2030. Both Holcim and Cemex were founding members of the collation of companies that intend to use their purchasing power to support sustainable technologies in hard to abate sectors. Commitments for the aviation, shipping, steel and trucking sectors were set at COP26 in Glasgow, aluminium and CO2 removal followed in May 2022 and chemicals and concrete were scheduled for November 2022. The latter has started to happen with the formation of the FMC’s cement and concrete group. Companies involved include ETEX, General Motors, Ørsted, RMZ Corporation and Vattenfall. Of these, Sweden-based energy producer Vattenfall has publicly said it is going for the 10% near-zero cement and concrete target by 2030.
Company | 2021 | 2030 Target | Notes |
Cemex | 591 | 480 | ESTIMATE, 40% less CO2/t of cementitious material compared to 1990 |
China Resources Cement | 847 | UNKNOWN | Emission intensity is for clinker |
CRH | 586 | UNKNOWN | 25% reduction in Scope 1 and Scope 2 CO2 emissions by 2030 (on a 2020 baseline) |
Heidelberg Materials | 565 | 500 | |
Holcim | 553 | 475 | |
UltraTech Cement | 582 | 483 | ESTIMATE, Reduction in CO2 emission intensity by 27% from FY2017 level by FY2032 |
Votorantim | 597 | 520 |
Table 1: Net CO2 emission intensity (kgCO2/t) for cement production at selected large cement producers.
While we wait for more announcements to escape from Sharm El Sheikh it might be worth reflecting upon one of the targets some of the cement companies have set themselves for 2030. Table 1 above compares the net CO2 emission intensity for cement production at some of the large cement producers. It doesn’t tell us much, other than that the CO2 emission intensity for these companies was in the region of 550 - 600kgCO2/t of cementitious material in 2021. This compares to 580kgCO2/t in 2020 for the GCCA’s Getting the Numbers Right (GNR) data for the companies it covers. The companies featured in Table 1 are all aiming – or appear to be aiming – for 475 - 525kgCO2/t by 2030. This may not sound like much but it has and will require hard work, innovation, investment and risk on the part of the cement producers. This is also before carbon capture, utilisation and/or storage (CCUS) units will have been built at most cement plants. Yes, until the CO2 emission intensity goes to down to zero, if cement production volumes keep rising sufficiently then total gross CO2 emissions from the cement industry will also increase. Yet, gross CO2 emissions from cement production are likely to peak sometime between now and 2030 if they haven’t already.
One sobering fact to end with is that 1990 is now further in the past than 2050 is in the future. If you can remember George Bush Sr as US president or you saw the film Goodfellas at the cinema then that’s the amount of time we have left to reach net zero. The global economic shocks of the post-coronavirus period and the war in Ukraine are stressing the world’s climate targets more than ever before. Let’s see how COP27 reacts to this. So far though, serious commitments to using low-carbon cement and concrete from big companies are a useful step to entrenching these products in the market.
Heidelberg Materials ‘weathering’ high costs
07 November 2022Germany: Heidelberg Materials has reported that it has increased its revenue by 13% year-on-year to Euro15.8bn during the first nine months of 2022. It said that high energy and raw material costs seen during the third quarter were only partly offset. The group’s net result for the nine-month period showed a 6.1% decline to Euro2.72bn. The decline was also due to significantly higher energy prices and increased raw material costs, which Heidelberg Materials said could only be offset partially by energy savings, cost discipline and price increases.
In the first nine months of 2022, sales volumes in all business lines declined due to consolidation and the economic impact from the Russian-Ukraine war on the European economy. Cement and clinker sales reduced by 6% to 90.0Mt, compared to 95.7Mt in the first nine months of 2021. Heidelberg Materials cited capacity reduction in North America, specifically its Western US operations, and the economic downturn in Europe as factors. Excluding consolidation effects, cement and clinker sales were down by 3.8%.
Heidelberg Materials said that it forecasts increased revenue for 2022, which will be adversely affected by increased outgoings. It expects global demand for building materials to weaken slightly on the back of higher costs and inflationary pressures.
Votorantim Cimentos Spain acquires Heidelberg Materials' Southern Spanish businesses
03 November 2022Spain: Votorantim Cimentos Spain has completed its acquisition of Heidelberg Materials' businesses in the south of Spain. Under the deal, Votorantim Cimentos Spain gains control of FYM's 1.6Mt/yr Málaga cement plant, as well as three aggregates quarries and 11 ready-mix concrete plants in Andalusia.
Brazil-based Votorantim Cimentos' Europe, Asia and Africa CEO Jorge Wagner said “This acquisition is fully aligned with our strategy, reinforces our presence in the Iberian Peninsula to better serve our customers and creates significant synergies with our existing assets. Besides this, it will be key to accelerating our decarbonisation journey to achieve our 2030 Sustainability Commitments."
Votorantim Cimentos Spain operates six Spanish cement plants with 6Mt/yr in integrated capacity across Andalusia, the Canary Islands, Castile and León, Extremadura and Galicia.
Slashing cement's CO2 emissions Down Under
02 November 2022In 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
Suez Cement to undertake US$14.4m solar project at Suez cement plant
02 November 2022Egypt: Suez Cement has partnered with Intro Power and Utilities for the construction of a 20MW solar power plant at its Suez cement plant. From its commissioning in early-mid-2023, the installation will provide the plant with 45GWh of energy annually, 20% of its annual consumption. Suez Cement says that this will eliminate 22,000t/yr-worth of CO2 emissions. Construction is expected to cost US$350m and commence in 2023.
Suez cement aims to achieve specific CO2 emissions of 400kg/t of cementitious product by 2030, down by 47% from 1990 levels.
Managing director Mohamed Hegazy said “Through transitioning to renewable solar energy, we are looking at long-term economic benefits, laying the foundation for a low-carbon business and energy security, without jeopardising the health of our environment. We are proud about this new milestone and to be one of the few cement players in Egypt taking this step towards using a more affordable and cleaner energy."
KHD hosts ACCSESS consortium meeting in Cologne
26 October 2022Germany: KHD hosted a meeting of the research and development consortium of the ACCSESS project in Cologne on 18 and 19 October 2022. The consortium is intended to develop replicable carbon capture utilisation and storage pathways to support a net zero strategy in Europe by 2050. KHD’s involvement with the project concerns running engineering feasibility studies for the retrofit of CCUS projects at two cement plants in Europe. It is also working on the concept development for a new clinker production technology, which is optimised as a new plant for operation with downstream carbon capture technology.
Other project partners working on ACCSESS of note to the cement sector include Heidelberg Materials and the German Cement Works Association (VDZ). Project completion is scheduled for mid-2025 with KHD’s contributions to be delivered by mid-2024.
HeidelbergCement India's second-quarter sales drop
18 October 2022India: HeidelbergCement India recorded consolidated sales of US$61.5m during the second quarter of its 2023 financial year, down by 11% year-on-year from US$69.2m in the second quarter of the 2022 financial year. The Heidelberg Materials subsidiary's net profit in the quarter fell by 88% over the year, to US$852,000 from US$7.24m in the 2022 financial year's second quarter. The second quarter of the 2023 financial year brought a 0.3% year-on-year drop in the producer's operating expenses, to US$55.7m from US$55.9m.