Displaying items by tag: Report

One graph the United Nations’ (UN) Intergovernmental Panel on Climate Change (IPCC) report on Global Warming of 1.5°C didn’t include this week was what happens if the world just doesn’t bother. It’s probably just as well since warming of 1.5°C is likely to happen between 2030 and 2052 at the current rate of climate mitigation efforts. If they had included such as diagram, it likely would have had a ominous red line hurtling skywards like a rollercoaster track just before the screams start.

The giant paper study is really about comparing and contrasting the different impacts and responses to a 1.5°C and a 2°C rise. One taste of what the higher rise threatens is, “limiting global warming to 1.5°C instead of 2°C could result in around 420 million fewer people being frequently exposed to extreme heatwaves, and about 65 million fewer people being exposed to exceptional heatwaves."

The cement industry gets a look-in with an acknowledgment that the sector contributes a ‘small’ amount (5%) of total industrial CO₂ emissions. It then breaks the entire industrial sector’s mitigation strategies down to (a) reductions in the demand, (b) energy efficiency, (c) increased electrification of energy demand, (d) reducing the carbon content of non-electric fuels and (e) deploying innovative processes and application of carbon capture and storage (CCS).

Speaking generally, phasing out coal, electrification and saving energy in mechanisms like waste heat recovery is predicted to get industry only so far. Yet from here even skirting over 1.5°C but below 2°C is ‘difficult to achieve’ without the, “major deployment of new sustainability-oriented low-carbon industrial processes.” Such new process include full oxy-fuelling kilns for clinker production, which have not been tested at the industrial scale yet. Likewise, CCS is seen as a major part of keeping warming below 2°C with a target of 3 Gt CO₂/yr by 2050. Some reality is present though when the report says that the development of such projects has been slow, since only two large-scale industrial CCS projects outside of oil and gas processing are in operation and that cost is high. It even posits a value of up to US$188t/CO₂ (!) for the cost of CO₂ avoided from a Global CCS Institute report.

None of this is new to cement producers. The real debate is how to get there without wiping out the industry. In his address to the recent VDZ conference, Christian Knell, the president of the German Cement Works Association (VDZ), highlighted that meeting climate change goals was leading to ‘considerable’ costs for the cement industry. He then called for policy-related support to on-going research projects into CO₂ mitigation technology.

The bit that the IPCC doesn’t go into is how much those five steps to the industrial sector will cost cement producers and, vitally, who will pay for it. For example, taking a cement plant’s co-processing rate to 70% and building a waste-heat recovery system, might cost around US$30m. The Low Emissions Intensity Lime And Cement (LEILAC) Consortium’s Calix’s direct CO₂ separation process pilot at the Lixhe cement plant in Belgium has funding of about Euro20m. Rolling all three of these measures out to the world’s 2300 cement plants would cost over US$100bn and it would take more than a decade. Beware, the financial figures here are rough estimates and may be way out. The point remains that the implementation costs will not be trivial.

Industry advocates have started in recent years to push back against the climate lobby by highlighting the essential nature of concrete to the modern world. The IPCC barely mentioned this aspect of cement’s contribution to society suggesting recycling, using more renewable materials, like wood, and resorting to the mitigation strategies detailed above. Building new cities out of wood is not inconceivable but CCS seems more likely to solve the climate problem at this stage. Manufacturing the cement that becomes concrete may create CO₂ emissions but it has also built the modern world and raised living standards universally. No cement means no civilisation. There is, at present, no alternative.

Instead of leaving this discussion at an impasse, it is worth reflecting on the last week in the industry’s news. An Indian cement company is importing fly ash, several companies are opening or preparing cement grinding plants, a coal ash extraction pilot project is running, a waste heat recovery unit has opened at a plant in Turkey and a producer is getting ready to co-process tyres as a fuel in Oman. All of these stories are proof that change is happening. The trick for policymakers is to keep prodding the cement sector in this direction without disrupting the good things the industry does for people’s lives through sustainable housing and infrastructure.

The November 2018 issue of Global Cement Magazine will include an exclusive article by Mahendra Singhi, the CEO of Dalmia Cement, about his company’s CO₂ mitigation efforts.

The 2nd FutureCem Conference on CO₂ reduction strategies for the cement industry will take place in May 2019 in London, UK.

Germany: Environmental data from the German Cement Works Association (VDZ) show that average nitrogen dioxide emissions (NO₂) from cement production dropped below 300mg/Nm³ in 2017. The value has more than halved since 2000. Other data from the ‘Environmental Data of the German Cement Industry 2017’ report shows that fossil fuels usage by the cement industry fell to 35% in 2017 compared to 45.6% in 2008.

"By consistently promoting the development of clinker-efficient cements, German cement manufacturers are noticeably reducing the carbon footprint as compared to traditional Portland cements," said VDZ President Christian Knell.

Knell also warned that the costs of carbon capture technologies should not be allowed to jeopardise the competitiveness of domestic cement manufacturers and give rise to ‘undesirable’ carbon leakage effects. The industry is currently researching methods to further reduce CO₂ emissions such as carbon capture, storage and utilisation techniques, but it is dependent on external financing.

18 German cement manufacturers with a total of 46 cement plants are members of the VDZ. The local industry employs around 8000 people.

Germany: HeidelbergCement has highlighted occupational safety and research into CO₂ reduction as priorities in its sustainability report for 2017. It reduced its accident frequency rate for employees with at least one lost working day per 1,000,000 hours across cement, ready-mixed concrete and aggregates to 1.8 in 2017 from 2.2 in 2016.

“This represents a significant improvement. A large number of locations have now been accident-free for several years, while others have seen drastically reduced accident rates. Nevertheless, serious accidents still occurred in 2017. We will therefore further intensify our efforts to prevent accidents on a permanent basis,” said Bernd Scheifele, the chairman of HeidelbergCement.

The building materials producer has also singled out its commitment to reduce its specific CO₂ emissions by 30% in 2030 compared with 1990. It plans to support this by continually increasing the proportion of alternative raw materials and fuels and, wherever possible, to make its production processes more efficient. In addition, HeidelbergCement has invested in research programmes on carbon capture and its utilisation as a raw material. In 2017, it spent Euro141m on research and technology, an increase of around Euro24m from 2016.

Following HeidelbergCement’s acquisition of Italcementi in 2016 its CO₂ emissions have increased. Its specific net CO₂ emissions (per tonne of cementitious material) rose by 1.9% year-on-year to 609kg Co₂/t in 2017 from 598 kg Co₂/t in 2016. Its overall proportion of alternative fuels has also decreased slightly dropping to 20.8% from 21.4%. However, its specific energy consumption for cement and clinker continued to fall in 2017.

Saudi Arabia: Cement sales revenue is expected to fall quarter-on-quarter in the second quarter of 2018 due to restructuring in the industry and holidays in the period. A report by Al Rajhi Capital found that cement sales volumes fell by 16.7% year-on-year in April and May 2018. 15 cement companies reported falling sales volumes, led by Riyadh Cement and Cement City with 44.1% and 37.5% declines respectively. Only two companies, Tabuk Cement and Hail Cement, reported growth. Total inventory for the industry grew by 1.2% quarter-on-quarter to around 36.2Mt at the end of May 2018. The financial services company forecasts that revenue in the cement sector will fall by 6% year-on-year.

UK: Hanson UK’s sustainability report for 2017 shows that its CO₂ emissions per tonne of product have fallen by 7.2% to reach the lowest level for five years. However, the subsidiary of Germany’s HeidelbergCement may face issues meeting its target of a 10% reduction by 2020 from its 2010 figures as its CO₂ emissions from production have rise by 5.7% since 2010.

Overall, the company described 2017 as a year of ‘solid’ progress. It passed its 2020 targets for reducing both mains water use and waste to landfill. The number of lost time injuries remained static at 21, but the frequency rate was down on the prior year and there was a three-month unbroken spell without a lost time injury. The building materials producer also launched HeidelbergCement’s Sustainability Commitments 2030, including a set of targets for the group to achieve by 2020.

UK: A report by the CDP looking at some of the largest multinational cement producers says that they need to double their emissions reductions in order to meet the 2°C global warming target outlined in the Paris Agreement. The report, entitled ‘Building Pressure,’ analysed 13 large cement companies including LafargeHolcim, HeidelbergCement and Cemex from data in a questionnaire. However, two major Chinese cement producers, Anhui Conch and China National Building Materials, and other producers including Siam Cement and Dangote Cement did not respond.

The report argues that regulation is the key driver to helping the cement industry reduce its emissions, through tightening building regulation and a rise in low carbon cities. However, it concedes that the sector faces a technology barrier, as ‘significant innovation’ is still required. “With potential pressure coming from multiple sources, including down the value chain in the form of building and city regulation, cement companies need to invest and innovate in order to avoid impending risks to their operations and the wider world. This may see m challenging at first, but every year it is delayed, the cost becomes greater, so management teams, regulators and investors need to think long term. There is a solution - cement companies just need to invest properly in finding it,” said Paul Simpson, the chief executive officer of CDP. The CDP report assessed companies across four key areas aligned with the recommendations from the Task Force on Climate-related Financial Disclosures (TCFD). Indian companies toped its league table in part due to better access to alternative materials from other carbon-intensive sectors. They also benefited from

newer cement plants driven by high market growth in the region compared to older plants in Europe. Dalmia Bharat, Ambuja Cement and Cementos Argos were the best performing companies on climate-related metrics and Taiheiyo Cement, Cementir Holding and Asia Cement Corporation ranked lowest.

France/Switzerland: A technology roadmap by the Cement Sustainability Initiative (CSI) and the International Energy Agency (IEA) sets out a combination of technology and policy solutions that could reduce CO₂ emission from the cement industry by 24% by 2050. The Low-Carbon Transition in the Cement Industry report updates the first global sectoral roadmap produced in 2009. It aims to identify and develop international collaborative efforts and provide evidence for public and private sector decision-makers to move towards a more sustainable cement sector that can contribute to long-term climate goals.

“The first exercise carried out in 2009 had demonstrated its added value to help the sector identify solutions and enablers to reduce its CO₂ emissions and it was essential to adjust this projection with the latest robust emissions data from the CSI’s Getting The Numbers right (GNR) database and the potential of latest technologies developed by the European Cement Research Academy (ECRA),” said Philippe Fonta, managing director, CSI of World Business Council for Sustainable

Development (WBCSD).The report aims to present a way to help the cement industry play its part it meeting the IEA’s 2°C Scenario (2DS) by 2050, which seeks to limit average global temperature increases to 2°C. The report forecasts that global cement production is set to increase between 12 - 23% by 2050 due to rising global population and urbanisation. Despite increasing efficiencies, direct carbon emissions from the cement industry are expected to rise by 4% globally by 2050 under the IEA Reference Technology Scenario (RTS), a base case scenario that takes into account existing energy and climate commitments under the Paris Agreement. The CSI and IEA argue that the low-carbon transition of the cement industry can only be reached with a supportive regulatory framework as well as effective and sustained investments. They say that meeting the RSI requires more investment, with a

potential doubling to meeting the 2DS. Governments, in collaboration with industry, can play a determinant role in developing policy and regulatory mechanisms that unlock the private finance necessary for such a boost in investment.The roadmap uses a bottom-up approach to explore a possible transition pathway based on least-cost technology analysis for the cement industry to reduce its direct CO₂ emissions in line with the IEA’s 2DS. Reaching this goal, the CSI and IEA say, would require a combination of technology solutions, supportive policy, public-private collaboration, financing mechanisms and social acceptance.

Improving energy efficiency and switching to alternative fuels, in combination with reducing the clinker content in cement and deploying emerging and innovative technologies like carbon capture and the use of alternative binding materials are the main carbon-mitigation methods available in cement manufacturing. Further emissions savings can be achieved by taking into account the overall life cycle of cement, concrete and the built environment. The roadmap outlines policy priorities and regulatory recommendations, discusses investment stimulating mechanisms and describes technical challenges with regard to research, development and demonstration.

UK: CO₂ emissions from cement production fell by 2% year-on-year to 696kg/t in 2016 from 709kg/t in 2015. Data from the Mineral Products Association (MPA) Sustainable Development (SD) Summary Data for 2017 report shows that local cement sales rose by 3% to 10.5Mt from 10.2Mt at the same time. Alongside this waste and by-products recovered as raw materials and fuels by the cement industry fell by 6% to 1.5Mt from 1.6Mt.

“The MPA supports the industry's continuing commitment to measuring and reporting data and to transparency on performance. The reporting process is now evolving to reflect the 7 strategic priorities set out in the MPA Charter and as part of this process we will be working to further improve the quality and coverage of our sustainability data,” said Nigel Jackson, the chief executive of the MPA.

Germany: Bernd Scheifele, the chairman of HeidelbergCement, has admitted that his company needs to take action to improve its overall sustainability management following its acquisition of Italcementi. Following the purchase both its specific gross CO₂ emissions per tonne of cementitious material and its alternative fuels mix fell. However, specific emissions of NO_x and SO_x fell, although specific dust emissions rose in the reporting period. The cement producer also improved accident frequency despite increasing its workforce to 15,781 in 2016 from 9560 in 2015.

Indonesia: The Fitch credit rating agency says that cement sales are starting to rise due to increased investment in infrastructure projects but that overcapacity will continue to limit improvements in cement producers' profitability. Indonesian Cement Association's (ASI) data show that domestic cement sales volumes rose by 7% year-on-year in May 2017 to 5.5Mt. Sales volumes for January to May 2017 increased by 4% to 25.3Mt.

Fitch has attributed this growth to a 13% growth in sales of bulk cement, which is used mainly for infrastructure-related developments. By region, the main driver of the increase was in central Java, where toll road projects are underway and where sales rose by 17%. Demand for bagged cement, which is generally used for property developments, rose by 5% in May 2017.