Displaying items by tag: Port

New Zealand: Holcim New Zealand says that it has received a mill for use in its upcoming Auckland cement replacement products import and distribution facility. The company opted for a Christian Pfeiffer ball mill for the project.

Holcim New Zealand says that alternative materials imported via the Auckland facility will eliminate 100,000t/yr of cement from New Zealand's 1.6Mt/yr consumption. The company expects that this will cut 78,000t/yr of CO₂ emissions.

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

India: Adani Group subsidiary Adani Port has sued the government of Kerala for US$9.56m in compensation for on-going delays to the construction of the upcoming Vizhinjam port in the south of the state. A local church-led protest over the rights of fishing communities has stalled construction of the port. The New India Express newspaper has reported that Adani Port had lost over US$12m on 8 October 2022 as a result of the delay. The company rented 12 barges for the work.

The government will hold talks with protestors on 13 October 2022.

Australia: Fremantle Ports has broken ground on its construction of a new US$35.1m cement terminal at Kwinana Bulk Terminal in Western Australia. Business News Western Australia has reported that contractor COVA-Haywards will build a 40,000t-capacity clinker storage dome at the site. The terminal will supply BGC and Cockburn Cement's local grinding operations. Commissioning is scheduled for 2024.

State development minister Roger Cook said"It will significantly improve our capability to move clinker faster, more safely and with very significant environmental benefits, and provide the capacity for the port facility to accommodate future trade growth. It's a great example of planning assets to integrate the state-owned port with adjacent private facilities, with benefits for all."

India: Adani Group has received a letter of intent from the West Bengal government for the establishment of a new deep-sea port in the state for US$3.13bn. Adani Group won an auction to build the port at Tajpur in the district of Purba Medinipur. The project also includes the construction of an 18km-long shipping channel. The facilities will be able to serve vessels with a deadweight tonnage. The port will connect an upcoming industrial and economic corridor between Raghunathpur and Dankuni, with global trade.

Belgium: Holcim Belgium has joined Fluxys open-access CO₂ transport network project. It intends to use the Fluxys network to either transport captured CO2 for sequestration in the North Sea or reuse in other industry after it builds a new 6000t/day production line at its Obourg plant by early 2026. As part of this process Holcim Belgium also plans to build a cryogenic CO₂ capture and treatment unit at Obourg by early 2028.

Pascal De Buck, the chief executive officer of Fluxys, said "Holcim's interest in our CO₂ network project at the Mons industrial cluster confirms the efforts industries are making to find solutions for decarbonising their activities. We're here to meet that need, which is why we offer them an open-access CO₂ network they can use to transport their captured CO₂ to storage or reuse sites. This kind of network helps achieve climate objectives and contributes to the long-term viability of the economy."

The proposed Fluxys CO₂ transport network will see the construction and creation in Belgium of pipelines, intermodal hubs, port terminals and shipping from 2025 onwards. The proposed infrastructure is intended to transport three gases: CO₂, hydrogen and methane.

India: Adani Group subsidiary HDC Bulk Terminal has concluded an agreement with the ports authority of Haldia Dock Complex for the construction of a new terminal at Berth 2 of the Port in West Bengal. The facility will have a handling capacity of 3.74Mt/yr, and will receive bulk solids including raw materials for Adani Group’s cement subsidiaries in the state. The total cost of the terminal’s construction will be US$37.4m. Work will begin before April 2023.

Bangladesh: The high rate of the US Dollar against the Bangladeshi Taka is forcing local cement producers to raise their prices despite an increase in imports of volumes of raw materials. The country imported 5.12Mt of clinker, granulated slag, limestone, gypsum and fly ash in July and August 2022, a rise of 34% year-on-year, according to the Daily Star newspaper. Golam Kibria, the general manager of Premier Cement, said that the negative currency exchange effect was the main cause of local price rises for cement since the cost of raw materials on international markets had remained stable in recent months.

The country imported 36.1Mt/yr of raw materials for cement production in the 2021 – 2022 financial year. These materials mostly came from Thailand, Vietnam and China through ports in Chattogram and Mongla. This compares to imports of 16.8Mt in the 2017 – 2018 financial year.

Sri Lanka: Insee Cement has broken ground on its construction of a 45,000m³-capacity storage facility at Hambantota International Port. When commissioned in early 2023, the facility will store ground granulated blast furnace slag (GGBFS) for use in Insee Cement's cement production. Daily News has reported the cost of the facility's construction as US$3m. At 17,300m², the Hambantota storage facility will be the largest warehouse at any port in Sri Lanka.

Insee Cement chair and CEO Nandana Ekanayake said "Hambantota Port is a vital link in our raw materials supply chain. Insee Cement has been using this port since 2018 and so far we have cleared around 1.7Mt of bulk cargo through the port, of which we did a little over 1Mt in 2021. Today, we laid this foundation as another step to strengthen our partnership with Hambantota International Port Group." Ekanayake concluded "We see great potential in developing channels through Hambantota International Port and we will double our investment in the future."

India: Andhra Pradesh Chief Minister Yeduguri Sandinti Jagan Mohan Reddy has laid the foundation stone for the upcoming Ramayapatnam Port in his state's Nellore district. Phase 1 of the port's construction will cost US$467m and is due to conclude in July 2025. The Hans India newspaper has reported that the new 25Mt/yr-capacity port will ship cement and other goods from four berths. Phase 2 of construction will subsequently increase the number of berths to 15, with a total export capacity of 139Mt/yr.