
Displaying items by tag: Refuse Derived Fuel
Spain: The Cemex plant in Alcanar has been granted €3m from the PERTE project for industrial decarbonisation, facilitated by the Ministry of Industry. This subsidy is part of a broader initiative involving 19 projects with a total aid of €96m under Line 1 of the programme. Cemex aims to contribute to decarbonisation of the clinker production process at its Alcanar facility by centralising compressed air production to enhance energy efficiency, replacing 14 old compressors with two more powerful and efficient units. The plant also plans to increase the use of alternative fuels in clinker production by integrating waste-derived and biomass fuels.
Australia: Veolia ANZ and ResourceCo have secured a contract to supply over 1Mt of refuse derived fuel (RDF) from their Adelaide facility to Adbri Cement's Birkenhead plant, aiming to replace natural gas and reduce greenhouse gas emissions. According to Veolia, around 1.5Mt of waste will be diverted from landfill during the course of the contract.
Brett Brown, chief operating officer at Adbri, said "Adbri has pioneered the use of RDF in Australia. Cement manufacturing is energy intensive, and the use of alternative fuels is one of the levers we are using to reduce our emissions as part of our goal of net zero by 2050."
RDF plant construction begins in Jakarta
22 May 2024Indonesia: The Jakarta administration has commenced the construction of the Rorotan refuse derived fuel (RDF) plant on a 7.8-hectare site in North Jakarta, aiming to process 2,500t/day of waste. The US$75m project is funded from the 2024 regional budget and is expected to be completed by December 2024 and start operations in early 2025. The city of Jakarta produces nearly 8,000t/day of waste, the majority of which goes to the Bantar Gebang landfill in West Java. The facility will convert 35-40% of the waste processed into about 875t/day of alternative fuels.
The Rorotan facility is the second RDF plant initiated by the Jakarta administration, following the Bantar Gebang facility, which began operations in 2023. This new facility marks a shift from the planned waste-to-energy incinerator in Sunter, which was cancelled due to high costs and bureaucratic delays.
Acting Jakarta governor Heru Budi Hartono said "This technology is still a very small part of our larger efforts to address the city's waste problem."
Head of the Jakarta Environment Agency Asep Kuswanto said "The RDF can become another source of revenue for the city, as we can sell the alternative fuel from the facility to industry."
Colombia: Cementos Argos and Sistema Verde have collaborated to transform nearly 27t of waste from the Estéreo Picnic music festival in Bogotá on 21 – 24 March 2024 into alternative fuel for Cementos Argos' Cartagena plant. The initiative, which includes converting materials such as plastics and cardboard into fuel, aligns with Cementos Argos’ aim to reduce fossil fuel use and CO₂ emissions per tonne of cement by 29% by 2030.
Mauricio Giraldo, director of alternative resources at Cementos Argos said "We are very pleased to be part of this alliance with which we join the global need to join efforts to make an adequate use of waste in a safe, controlled and clean manner. Our goal as a company is to dispose of more than 300,000t/yr of waste, and with actions like this, we continue to contribute to achieving this goal.”
India: Kerala has converted approximately 48,000t of non-recyclable waste into refuse-derived fuel (RDF) for use in cement plants, from the period of January - December 2023. The Department of Local Self-Government reported that 29,826t originated from the government sector and 18,205t from the private sector. The material was collected from households and shops, separated at collection facilities and sent to cement plants for co-processing. The local authorities managed the collection and separation of dry waste.
The state has ‘significantly’ invested in infrastructure for dry waste storage, with 167 resource recovery facilities, 1981 collection facilities, 20,904 mini collection facilities, and 57 storage warehouses over 45,522m2. The Haritha Mithram mobile app has led to an increase in door-to-door waste collection and the volume of dry waste processed. The state has added 41 more warehouses so far in 2024 to manage the increased waste collection.
ACC and Ambuja Cements' Geoclean launch new facilities
20 March 2024India: ACC and Ambuja Cements' Geoclean has launched two new facilities for sustainable waste management. The Ambuja Marwar pre-processing and co-processing facility in Rajasthan can convert 220,000t/yr of refuse into alternative fuel, while the ACC Jamul co-processing facility will process an additional 120,000t/yr.
The Ambuja Marwar facility, in collaboration with the Ambuja Marwar Farmer Producer Organisation, aims to source 50,000t/yr of agricultural waste from local farmers. This initiative will also increase the plant's thermal substitution rate to 15%. Similarly, the ACC Jamul facility will enhance its thermal substitution rate to 10%, reducing CO₂ emissions through the co-processing of waste in the cement kiln.
Denmark: Norway-based Geminor has appointed Per Mernelius as Country Manager for Geminor Denmark. He succeeds Kasper Thomsen in the position, who was recently appointed as the Operations Director for Geminor Group. Mernelius is currently the Country Manager for Sweden and he will add the new responsibilities to this role. Initially, he will be in charge of the Danish market for 12 months, pending the appointment of a new country manager in Denmark.
Mernelius commented “Denmark and Sweden are our two biggest downstream markets, with nearly 1Mt of imported refuse-derived fuel/solid recovered fuel in 2023. As such, many similarities open up for synergies in the coming year. An important factor is logistics, and how we can coordinate the two markets for more efficient operations. Our ambition is to grow further and to cater for the existing over-capacity within energy recovery in Scandinavia.”
Mernelius has worked for Geminor since 2016. Before this he worked for Sweden-based energy supplier Jönköping Energi. He is a graduate of the Swedish University of Agricultural Sciences.
Spain: Cemex España plans to install a new tertiary mill in its Alicante cement plant’s refuse-derived fuel (RDF) line. The project, called Molentis, is scheduled for completion in early 2025 and will cost €6m. The Molentis upgrade will help the Alicante cement plant to raise its RDF substitution rate by 8%, according to the producer. This in turn will reduce its CO2 emissions by 6700t/yr. The Spanish Ministry of Industry, Energy and Tourism granted €4.4m toward the project to Cemex España under its Innovation and Sustainability Plan.
Cemex España director of operations Benjamín Cabrera said "Molentis will enable us to advance towards climate neutrality and position the Alicante factory at the forefront of new technologies in the decarbonised industry."
Update on synthetic fuels, June 2023
28 June 2023Cemex highlighted its Clyngas project at its Alicante cement plant in Spain this week. The project will produce synthesis gas (syngas) from different types of waste for direct injection into the burner at the plant during the combustion process. It is being run in conjunction with Waste to Energy Advanced Solutions (WTEnergy), a company that Cemex invested in at the end of 2022. It is also receiving Euro4.4m in funding from the European Commission (EC) as part of its innovation fund for small scale projects. The initiative estimates that it will save over 400,000t of equivalent CO2 during the first 10 years of the project's life by replacing petroleum coke with syngas.
Clyngas is another example of Cemex’s innovation with alternative fuels for cement and lime. It follows on from the group’s work with hydrogen injection into cement kilns. As presented at the 15th Global CemFuels Conference 2022 it has been using hydrogen in low volumes as a combustion enhancer in more than 20 plants worldwide. However, it was also looking into using hydrogen more directly as a fuel and as a feedstock for other alternative fuels. WTEnergy’s gasification process could potentially link up to this as it converts waste streams such as wood chips, agricultural waste, refuse derived fuel (RDF), solid recovered fuel (SRF), dry sewage sludge, meat and bone meal, poultry litter and plastics into syngas. WTEnergy then proposes that its gasification process and/or the syngas can be used for power generation and thermal applications. In the case of the Clyngas project it will be the latter, as the gasification process will be used to boost the burnability characteristics of RDF with a high biomass content. One part of this to note is that the syngas can potentially be used to manufacture hydrogen. This would be a useful capability for a cement company, for example, that was already using alternative fuels and was now considering further decarbonisation by switching to using hydrogen.
A few other cement companies have been looking at synthetic fuels too, but this has generally been as a by-product of carbon capture and utilisation. This week Lafarge France, for example, said it had signed a memorandum of understanding with Axens, EDF and IFP Energies Nouvelles for a synthetic fuel production trial. Its plan is to build a unit that will produce synthetic kerosene using captured CO2 from a carbon capture installation at Lafarge France's Saint-Pierre-La-Cour cement plant. The kerosene will then be sold to airlines. Other examples of cement companies looking at using captured CO2 to manufacture synthetic fuels include Finnsementti’s pre-engineering study with Aker Carbon Capture to consider producing methanol as a fuel for transport, Holcim’s and TotalEnergies’ various plans of what to do with the CO2 captured from the-to-be upgraded Obourg cement plant and Cemex Deutschland’s ambitions for its Rüdersdorf plant.
As can be seen above there are different types of synthetic fuels and cement companies are at the research and pilot stages. Although there isn’t a commonly accepted definition of what a synthetic fuel is, the general meaning is that of a fuel made from feedstock using a chemical reaction as opposed to, say, a refining process. The wide variety of potential synthetic fuels puts the confusion over the different types of hydrogen into perspective. However, this may be a problem for a later date if usage by cement companies becomes more serious.
What is a problem, though, has been the EC’s planned legislation to phase out the use of industrial CO2 in synthetic fuels by 2041. Cembureau, the European cement industry association, warned in late 2022 of the issues this would pose for industries trying to find a way to utilise their CO2 emissions where storage was too difficult or expensive. Its view was that while synthetic fuels using industrial CO2 are not fully net-zero, as the captured CO2 is later released into the atmosphere, it is a necessary short to medium term step for sectors trying to make the transition. Companies trying to build industrial-scale chemical plants for synthetic fuels need running periods of 20 to 30 years to achieve payback. As of March 2023 Cembureau was still concerned about the implication of proposed regulations, specifically with regards to the proposed criteria for which synthetic fuels could be used, based on their greenhouse gas emissions savings (at least 70% compared to the regular fuels being replaced). It directly linked this to synthetic fuels projects being launched by the cement sector that might be adversely affected by the new rules. The EC published the legislation in late June 2023 and it is set to become legal in mid-July 2023.
Using synthetic fuels either as a fuel or a by-product from cement production is an area of interest currently with the projects detailed above and others in progress. One vision for their use in Europe, at least, is that they might offer a route for carbon capture for cement plants without access to the logistic networks necessary for sequestration. Whether they find a place in cement manufacture either on a transitional basis or over a longer term should become clearer over the coming decade. Yet the EC’s new rules are likely to slow this process down as at least some of the planned pilots may become unviable in Europe. Other jurisdictions around the world take note.
Indocement Tunggal Prakarsa and Amita Holdings launch feasibility study towards net zero cement production
21 June 2023Indonesia: Indocement Tunggal Prakarsa has engaged Japan-based environmental consultancy Amita Holdings to support a two-year feasibility study to investigate ways to make its cement production carbon neutral. The study will commence with trials of industrial wastes as alternative raw materials and municipal solid waste as refuse-derived fuel. Amita Holdings says that it is in the process of building a recycling-based society in Indonesia, in partnership with Indocement Tunggal Prakarsa.
Amita Holdings supported the establishment of the community-led Meguru waste sorting facility in Central Java. Two of Indocement Tunggal Prakarsa’s cement plants – the 18Mt/yr Citeureup cement plant and 4.1Mt/yr Paliman cement plant – are situated in neighbouring West Java.