Displaying items by tag: LafargeHolcim
Ambuja Cement digitises supply chain
13 July 2020India: Ambuja Cement has modernised its logistics operations by digitising its supply chain to “improve visibility, deliver quality customer service and optimise cost.” The Economic Times newspaper has reported that the company has integrated all aspects of raw material, fuel and equipment supply and product deliveries on a single online platform in order to “enhance overall efficiency and productivity.” Company director Martin Kriegner said additionally that the digitisation will aid in, “fuel mix optimisation and strategic sourcing, helping to mitigate rising input costs.”
Ambuja Cement’s 3.0Mt/yr greenfield expansion to its integrated 1.5Mt/yr Marwar Munda, Rajasthan plant is scheduled for commission by 1 January 2021. The company has a master supply agreement with ACC aimed at maximising the consistency of cement supply to the Rajasthan market once the new 4.5Mt/yr plant becomes operational.
Green hydrogen for grey cement
08 July 2020Hydrogen 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.
France: LafargeHolcim France says that it has “responded to the demand for low-carbon concretes” with the launch of a CEM-II Portland limestone cement product with 25% lower carbon dioxide (CO2) emissions than Ordinary Portland Cements (OPC) in its Galaxim Planet range. The new addition to the range, of which LafargeHolcim plans to produce 100,000t by 31 December 2020, contains 35% limestone, up by 23% from 12% in ordinary Portland limestone cement.
LafargeHolcim France south region cement sales director Olivier Mespouilles said, “Our goal is to offer all builders a cement offering properties equivalent to a conventional cement with the advantage of a reduced carbon footprint. This tour de force was successful thanks to the involvement of all our teams, and we are the first player in France to offer this type of limestone cement in such a volume." The cement is due to enter the market in the Languedoc-Roussillon region. From 2021 the company hopes to supply 80% of customers there with the low-carbon cement.
Zimbabwe: LafargeHolcim subsidiary Lafarge Cement Zimbabwe has reported a profit of US$178m in 2019, up by 4.8% year-on-year from US$170m in 2018. Inflation-adjusted sales rose doubled to US$919m from US$449m. Cement volumes remained level at 323,000t. The company said that it, “recorded its best financial performance in over five years. The construction of a US$2m dry mortar mixing plant was completed and installation of the equipment on site is set to be completed in the second half of 2020.”
Sustainable thinking
01 July 2020HeidelbergCement released their sustainability report for 2019 this week. Every large cement producer publishes one but this one is worth checking out because of the company’s ambition to become CO2 neutral. Other companies are heading the same way but few of them have such developed and public plans.
Sustainability reports are often a hodgepodge of non-financial reporting bringing together environment, health and safety, community and other topics. Multinational companies cover a wide range of jurisdictions and combining reporting in these kinds of fields can be beneficial. Typically they are members of various bodies like the Global Reporting Initiative (GRI) or the Global Cement & Concrete Association (GCCA) that give various levels of conformity between reports. Yet, the wider focus of sustainability reports gives companies a chance to promote what they are doing well, away from balance sheets.
One highlight of HeidelbergCement’s report is its progress towards reducing its specific CO2 emissions per tonne of cement and its recognition by the Science Based Targets (SBT) initiative towards this goal. So far it has achieved a reduction of around 22% from 1990 levels to 599kg CO2/t (net) with a target of a 30% reduction or 520kg CO2/t by 2030. There is a lot more going on in the report but it’s led by the vision, ‘to offer CO2-neutral concrete by 2050 at the latest.’ It plans to achieve this by increasing the proportion of alternative CO2-neutral raw materials and fuels, developing lower clinker cement types and capturing and utilising CO2 emissions. A focus on concrete is worth noting given the pivot by building materials manufactures towards concrete in recent years.
Back in the present, HeidelbergCement is roughly in the middle of the pack of major European multinational cement producers with its specific CO2 emissions for cement in 2019. LafargeHolcim reported 561kg CO2/t and Cemex reported 622kg CO2/t. This is a bit of a moving target since corporate acquisitions and divestments can change both the starting point and the apparent current progress. HeidelbergCement’s acquisition of Italcementi in 2017 or CRH’s purchase of Ash Grove did exactly that. The other thing to consider is that these companies manufacture a lot of cement. The actual gross CO2 emissions from a multinational cement producer are immense. LafargeHolcim, one of the world’s largest multinational producers, emitted 113Mt of CO2 in 2019 from process and fuel sources whilst making cement. To put that into context, estimates for total global CO2 emissions range from 33 – 36Gt for 2019. The cement industry’s entire share was estimated by the International Energy Agency (IEA) to be 4.1Gt in 2018.
Where this sustainability report starts to become really interesting is where it talks about CO2 capture and utilisation. Its plans in this department are more mature than many of its competitors with various initiatives at different levels of development, mostly in Europe. Norcem, its Norwegian subsidiary, recently signed an agreement with Aker Solutions to order a CO2 capture, liquification and intermediate storage plant at its integrated Brevik cement plant. The deal is dependent on government support but it’s a serious proposal. As reported previously from the Innovation in Industrial Carbon Capture Conference 2020, HeidelbergCement is actively preparing to hook up with CO2 transport and storage infrastructure. The driver is CO2 pricing from initiatives like the European Union (EU) Emissions Trading Scheme (ETS). With the EU preparing for the next phase of the ETS and talk of the European Green Deal gathering pace, before the coronavirus outbreak at least, CO2 prices in Europe look set to rise. HeidelbergCement is positioning itself to benefit from being the first major cement producer to head into CO2 capture and storage/utilisation with a variety of methods intended for different CO2 prices and regional requirements.
HeidelbergCement doesn’t mention the coronavirus pandemic in its latest sustainability report. The report covers 2019 after all, before all of this happened. These reports do include health and safety information of employees, so this may be something to look out for next year. However, Cemex did mention the coronavirus in relation to its climate action plans this week. Essentially it wants to maintain its plans as a ‘fundamental component’ of its efforts to recover from the health crisis. This chimes with media talk around so-called ‘green-led’ government-backed relief programmes. Governments are the ones who are likely to be handing out the money, probably in the form of infrastructure projects. So it’s the perfect opportunity for them to encourage change from the companies bidding for this funding. Sustainability reports and the information behind them will be a useful tool in accessing this cash.
Czech Republic: LafargeHolcim has appointed Berthold Kren as the manager of its Central Europe region. He succeeds José Antonio Prima Fernandez.
Kren joined LafargeHolcim in 2005, managing alternative fuel projects, and later became a procurement manager in Austria in 2008. He became a sourcing director for fuels in 2010 and managed the company’s energy portfolio for gas, power, solid and liquid fuels in Europe, Middle East and Africa in 2016. In 2017 he took over Geocycle's activities in India and Asia. He is a graduate of the University of Leoben in Austria, where he obtained a master's degree in engineering and environmental management.
France: LafargeHolcim France has said that all bagged cement will now bear a 360Score CO2 emissions reduction rating, “to allow traders, artisans and homebuilders to know the precise carbon impact of their cement.” The rating, between ’A’ and ’D,’ corresponds to the factor of CO2 compared to CEM-I Ordinary Portland Cement (OPC). ’A’ Class cement produces 75% – 100% less CO2, while ’D’ class cement produces 0% – 25% less.
LafargeHolcim France chief executive officer (CEO) François Petry said, “By applying the 360Score rating scale to our bags of cements, we are continuing to implement our Lafarge 360 approach, which consists in supporting all builders to build in a more responsible manner.”
Austria: Lafarge Zementwerke, OMV, Verbund and Borealis have signed a memorandum of understanding (MOU) for the joint planning and construction of a full-scale plant by 2030 to capture CO2 and process it into synthetic fuels, plastics or other chemicals. As part of the ‘Carbon2ProductAustria’ (C2PAT) project the companies intend to build the unit at the integrated Mannersdorf cement plant and capture all of the 0.7Mt/yr of CO2 emitted.
"We are committed to leading the industry in reducing carbon emissions and shifting towards low-carbon construction. We have worked consistently and successfully on the reduction of the CO2 footprint of our cement plants, products and solutions. Ultimately, CO2-neutral cement production can only be possible with the implementation of breakthrough technologies, like carbon capture, which is why we have great expectations for the C2PAT project", said Lafarge’s local chief executive officer (CEO) José Antonio Primo.
The project aims to use hydrogen produced by Verbund to allow OMV to transform the captured CO2 into a range of olefins, fuels and plastics. Borealis would then use some of these products as a feedstock to manufacture plastics. However, the companies say that, “taking the next steps towards a Zero CO2 economy will require the right financial as well as favourable regulatory framework conditions. The success of C2PAT will largely depend on whether the right financial and regulatory framework conditions are created both at the European Union and Austrian national level.”
The joint project is designed in three phases. In phase one, the partners are currently evaluating and developing a joint strategy for project development, business modelling and process engineering. Based on the results of phase one, a cluster of industrial pilot plants in the Eastern part of Austria could be technically developed and built in the mid-2020s in phase two. Phase three entails building a full scale CO2 capture and utilisation unit at a cement plant.
Lafarge Zementwerke is the Austrian subsidiary of building materials manufacturer LafargeHolcim. OMV produces and markets oil and gas, energy and other petrochemical products. Verbund is an Austrian-based electricity generator, with a focus on hydroelectric power. Borealis is a chemical company and a producer of polyolefins, base chemicals and fertilisers.
Digital trends in cement
24 June 2020Many people have been adapting to home working over the last few months due to the coronavirus pandemic and the resulting lockdowns. The digital tools have been present for years but current events were all that was needed to force everyone to try it out en masse, moving much of the back office, supporting and managerial functions to the homes of staff. Some of this communal clerical working may never come back in the views of some commentators. Other functions related to networking, such as sales or knowledge transfer, have moved to different channels like webinars and social networking or have resorted to older methods like using the telephone more. The balance between real world and remote networking may change but a return to some level in favour of the former seems likely.
The core processes of cement manufacture are resistant to this trend as workers need to be on site to mine limestone and maintain production lines. Although, that said, Global Cement Magazine has covered examples of remote commissioning and maintenance of equipment at plants in recent issues. Prior to this there has been steady work on remote monitoring of equipment and plants by both suppliers and producers and moves by cement companies to focus on digital operation such as LafargeHolcim’s ‘Plants of Tomorrow’ Industry 4.0 from 2019 or Cemex’s work on autonomous cement plant operations with Petuum.
Some ways in which cement companies have coped with social distancing recently have been revealed as they have published their best practice guides. Last week, for example, Holcim Philippines was promoting its various online customer interaction tools including its existing sales platform and a new online customer engagement program to ‘provide updates on the company’s directions, share knowledge and best practices on Health and Safety and to bond with business partners while quarantines are in place.’ Other companies have done similar things like the Cemex Go platform. On the supplier side there have been various announcements as companies have pushed their digital offerings. Meanwhile, the companies offering automation or remote operation products have been handed a unique stage to promote their wares.
Another example of cement companies trying something new in digital is the pilot that was announced this week by Siam Cement Group with the Bank of Thailand to test out payment systems using a central bank digital currency (CBDC). This likely has very little to do with the cement industry and much more to do with the sheer size of that conglomerate in Thailand. As the second largest company in the country, it’s an obvious target to try out something new like this at scale. The project will run from July 2020 until the end of the year. It will build on work that the central bank has carried out on Project Inthanon, a project between the bank and the eight financial institutions to study and develop a method for domestic wholesale funds transfer using wholesale CBDC. Any benefits using a CBDC eventually bring to Siam Cement Group and other producers in the country are likely to be limited to finance departments but savings are always welcome wherever they arise.
One cautionary note to consider though is that introducing changes to national currency systems can have impacts upon cement companies through general effects to the economy as a whole. The classic example of this in recent years is that of banknote demonetisation in India in late 2016. Cement production growth declined for about half a year at the time due to the disruption it caused.
The downside of this increased reliance on digital products and platforms is increased exposure to cybercrime. There was a rare good-news story in this area recently when Schmersal Group revealed that it had intercepted a network attack in progress in May 2020. It promptly took its IT network offline and disconnected its various systems, from the telephones, to its business software, to its production processes and automated storage systems, at all of its locations. Systems were then gradually cleansed and restored over the next two weeks. Schmersal’s response is commendable but chillingly it ended its press release by saying that, “the attack demonstrated that standard protection from antivirus programs and a firewall is powerless in the event of a targeted attack with previously unknown malware.” Companies had the same vulnerabilities before the pandemic but the increased reliance on digital platforms has heightened the potential risk. As we mentioned last time we covered this topic companies that admit to large scale malware attacks are hard to find most likely because it looks bad. Although since that article was published, Buzzi Unicem admitted that a ransonware attack on its information systems originating from its Ukrainian operations were delaying its financial disclosures in mid-2017.
In the longer term it will be interesting to see how much of the altered working patterns or methods created by the coronavirus lockdowns remain afterwards. The current situation isn’t quite like the ‘disruptive innovation’ business theory pedalled by Clayton M Christensen that has led in-part to established companies setting up start-up incubators to try and spot the next big new thing. Yet, existing trends are being sped up and this may lead to some surprises that were coming down the road anyway. For example, buying someone shares in video networking tool Zoom would have made a nice Christmas present this year! Hindsight is a wonderful thing.
Philippines: Holcim Philippines has appointed Edwin Villas as Senior Vice President Logistics, Bobby Garza as plant manager at its integrated Norzagaray cement plant and Arnold Pepino as Vice President of Operations of its integrated Lugait plant.
Villas was appointed as the Senior Vice President Logistics after serving as officer-in-charge of the department since 2019 concurrent to his role as Vice President for Sales for Greater Manila Region and South Luzon. He previously held senior sales leadership roles and served in procurement and internal audit. Villas is a certified professional for supply management, a certified information system auditor and holds a degree in computer science. He also completed a leadership program at the International Institute of Management Development (IMD) Switzerland.
Garza, Vice President for Operations of the Holcim’s Lugait, Misamis Oriental plant, will lead the Norzagaray, Bulacan plant. Garza is a licensed mining engineer and has attended leadership programs in IMD Switzerland.
Pepino, who was previously the Production Manager at Lugait, succeeds Garza as Vice President of Operations at the site. He started his career in Holcim Philippines as a cadet engineer in 1996. Over the years, he moved to different roles and projects in production, process and manufacturing excellence. In 2017, he was sent by LafargeHolcim Group to plants in Romania and Austria to learn best practices under its ‘Learning Across Borders’ program. Pepino holds a master’s degree in business administration and a computer engineering degree.