Displaying items by tag: Project

Saudi Arabia: Yamama Cement has announced the signing of a contract to transfer its seventh cement line from its old factory to its new plant location. The project, which follows similar moves for other lines, will start in the first quarter of 2023 and cost an estimated US$220m. The company expects the project to be completed during the second half of 2025.

The project, to be overseen by China-based Sinoma Overseas Development, will include dismantling, transporting and reinstalling the equipment, in line with Saudi Arabia’s 2030 vision to keep pace with its many development projects. After the trial run period is completed, it is expected to have a positive impact on the company's financial results.

India: JK Cement subsidiary Jaykaycem has commissioned the 2Mt/yr grinding unit of its upcoming Panna cement plant in Madhya Pradesh. The producer expects to commission the plant's clinkerisation unit later in the 2023 financial year.

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

Mexico: GCC has made new appointments to the roles of project director, chief financial and planning officer and general counsel, effective immediately. Luis Carlos Arias will now serve as project director to the company's Odessa, US, cement plant expansion. Arias previously served as the group's chief financial officer. Maik Strecker steps into the role of chief financial and planning officer. Strecker joined GCC as chief planning officer in 2020. He has two decades' previous experience in roles spanning mergers and acquisitions, business development, product line management, operations and sales and marketing. Lastly, Cesar Conde will serve as GCC's general counsel. Conde has worked for the group since 2006.

GCC's CEO Enrique Escalante said "I am confident these executives bring proved strategic and execution leadership to the Company, and I look forward to the challenges and opportunities ahead."

Uzbekistan: Turkey-based engineering company Deha Tech says that it is 95% of the way to completion of its construction of a new grinding plant in Tashkent. The supplier says that it expects to commission the new facility in late January 2023. It thanked employees and partners for all of their efforts towards helping it realise the project. Deha Tech secured an engineering, procurement and construction (EPC) contract for the work in 2020.

Pakistan: Askari Cement has ignited the newly installed 6500t/day kiln at its Nizampur cement plant in Khyber Pakhtunkhwa province. The kiln increases the plant's capacity by 73% to 4.85Mt/yr. The project, along with parent company Fauji Cement's construction of a new 2.05Mt/yr integrated cement plant in Dera Ghazi Khan, cost US$339m. Fauji Cement took a US$212m loan to support the works in January 2022. The group expects both projects to raise its capacity by 56% to 10.5Mt/yr and to increase its market share to 13%.

Fauji Cement's upcoming Dera Ghazi Khan cement plant is scheduled for commissioning in mid-late 2024.

Spain: Brazil-based Votorantim Cimentos' Córdoba, Niebla and La Araña cement plants in Andalusia are at the centre of a planned Euro1bn decarbonisation project by the company. Votorantim Cimentos will publish details of its plans, which include renewably powered green hydrogen and biofuels production, in early 2023.

Votorantim Cimentos Europe, Asia and Africa CEO Jorge Wagner said "We need agility with the administration, because the investments are stratospheric and long-term. We want to obtain subsidies, taking advantage of European funds." He concluded "We have the opportunity to carry out a very beautiful project in Andalusia and beat the Americans."

Peru: Grupo Gloria subsidiary Yura says that it is contemplating a cement production capacity expansion. The producer says that process optimisation across its Arequipa and Southern Peruvian cement footprint might go some way towards achieving the envisioned growth. It added that any such projects would go hand in hand with a reform of its customer service practices. Yura is also evaluating possible new limestone mining projects at Pampas del Pongo and Zafranal, and an expansion of its lime production.

DF Sud News has reported that Yura expects to increase its Peruvian cement deliveries by 8 – 10% year-on-year in 2022. Its cement, concrete and lime director for Peru, Chile and Bolivia, Julio Cáceres, forecasts that Peru’s construction demand will continue to grow at twice the rate of gross domestic product. He acknowledged that the company’s 2023 results will likely reflect the country’s expected muted growth compared to 2022. Cáceres said that US$700m-worth of private investment across 30 residential projects in Arequipa is currently suspended, pending the publication of the city’s revised metropolitan development plan.

Europe: The European Commission has approved the IPCEI Hy2Use plan for the construction of an international hydrogen electrolysis, transport and storage network. IPCEI Hy2Use consists of multiple projects planned for completion by 2026, with the commissioning of all infrastructure scheduled for 2036. 13 EU member states and Norway will contribute Euro5.2bn in funding, with a view to attracting private investments worth Euro7bn.

Pakistan: Cherat Cement expects cement consumption in Pakistan to fall by 3 – 4% year-on-year in the 2023 financial year, which will end on 30 June 2023. Amid the general decline, the company foresees a slight rise in areas devastated by recent flooding with the onset of repair and rebuilding works during the second half of the financial year. Exports are expected to fall by 20%, with prices remaining level while costs increase due to the high price of imported coal.

Pakistan Business News has reported that Cherat Cement is reappraising the investment cost and planned commercial operation date of its upcoming 8000 – 9000t/day new cement plant. It previously valued the project at US$158 – 173m.