Displaying items by tag: Rohrdorfer Group

Austria: Alpacem Group has appointed Roland Waldenhofer as Head of Development, Quality Assurance and Application Technology of Alpacem Zement Austria. He succeeds Christoph Stotter in the post, who has been working for the group as Quality and Product Innovation Manager since 2024.

Waldenhofer, aged 30 years, trained as a civil engineer at Graz University of Technology. He previously worked for Rohrdorfer as Head of the Sand & Gravel Laboratory and
Head of the Central Laboratory & Technology Projects.

Germany: Rohrdorfer has started operation of a new photovoltaic (PV) unit at its Rohrdorf cement plant near Rosenheim in Upper Bavaria. The rooftop PV installation comprises 1000 modules, covers around 2000m2 and has a peak output of 400kW. The construction time of the solar panels took five weeks. Modules supplied by Hecker Solar were installed by Elektro Ecker.

The cement plant has produced around one third of its electricity requirements via a waste heat recovery unit since 2011. Rohrdorf Group aims to generate 30% of its electricity from renewable sources as a whole by 2033.

Germany: France-based Fives has won a contract to build a 50t/day clay calcination unit at Rohrdorfer’s Rohrdorf cement plant in Bavaria. The unit will integrate into the plant’s clinker line in order to allow it to test the production of limestone calcined clay cement with up to 40% reduced CO₂ emissions. Fives’ clay calcination unit uses a flash calcination process, based on a three-stage preheater, flash calciner and decolourisation system.

Rohrdorfer’s Net Zero Emissions Labs team is responsible for the project to decarbonise the Rohrdorf cement plant by 2038. Its managing director Helmut Leibinger said “After a detailed technical review, we decided that the flash calciner with an integrated clay calcination unit from Fives FCB was the best solution in terms of reliability, efficiency and colour control. We are confident that the unit will be essential in moving forward on our pathway to net zero.”

Austria: Rohrdorfer’s proposed acquisition of a 49% stake in building materials producer Asamer has entered an extended review phase. The parties registered the deal with the Austrian Federal Competition Authority (BWB) on 10 January 2024. Due to competition concerns, the BWB applied to a court for an in-depth investigation on 21 February 2024.

Germany: Rohrdorfer Zement has fired up a pilot clay tempering unit at its Rohrdorf cement plant in Bavaria. The project has received Euro8.65m in funding from the German Federal Ministry for Economic Affairs and Climate Action and the EU. It is one of a number of industrial projects under the EU’s Euro800bn NextGenerationEU post-Covid-19 economic recovery instrument. Sources of heat for the pilot unit at the Rohrdorf cement plant include waste heat from the plant’s clinker line. If the pilot succeeds, the introduction of tempered clay into cement production at the site will follow. This will entail the construction of an on-site full-scale clay tempering plant. Rohrdorfer Zement says that this would reduce the plant’s CO₂ emissions by 16 – 18%, or by 30% if it achieves carbon neutral clay tempering through the use of green hydrogen.

Rohrdorfer’s dedicated Net Zero Emissions Labs team is working to turn the Rohrdorf cement plant carbon neutral by 2038. Other initiatives include the installation of carbon capture systems at the Rohrdorf plant and another in Austria, and participation in the H2-Reallabor Burghausen hydrogen partnership.

Regarding the latest pilot, Rohrdorf Net Zero Emissions Labs project leader Helmut Leibinger said “As a cement component, tempered clays make a significant contribution to CO₂ mitigation. With the pilot project of process-integrated tempered clay, we are taking not just a step in our decarbonisation roadmap, but a leap.”

Austria/Germany: Rohrdorfer Group and gas network company Bayernets have published a feasibility study for a proposed CO₂ transport network in Bavaria in Upper Austria. The first stage of the CO₂peline plan will be to create an ‘island’ network between the Rohrdorfer cement plant in Upper Bavaria and the so-called ‘Bavarian chemical triangle.’ An additional connection to the industrial and chemical region of Linz in Austria would add additional CO₂ sources, places of use and temporary storage sites to the grid. Further expansion plans could see the network expanded to cover the whole of Bavaria. A future connection to a Germany-based national network and international routes could further link the network to other locations where CO₂ is both produced and used, as well as creating routes to sequestration sites.

No dates have been released for the proposed CO₂ pipeline network. However, the project notes that Germany is aiming for carbon neutrality by 2045 and Bavaria and Austria by 2040.

Austria: Rohrdorfer has bought 20 new railcars equipped with ÖBB Rail Cargo’s RockTainer SAND containers. The cars will transport limestone between the producer’s Ebensee quarry and its Gmunden cement plant. Each railcar consists of two RockTainer SAND containers mounted on an InnoWaggon carriage, with a maximum load of 134t. The new cars will increase the volume of despatches from the Ebensee quarry by 28% to 804t of limestone per train from 630t/train, enabling Rohrdorfer to transport 450,000t of limestone per operating season.

Germany: Austria-based Rohrdorfer has started up an amine-based carbon capture system at its Rohrdorf cement plant in Bavaria. The producer plans to ultimately expand the system up to a capture capacity of 1500t/day. The inauguration follows a successful continuous trial of the technology since August 2022, excluding a regular kiln maintenance period over winter. Austria-based Andritz designed the system specifically for the Rohrdorf cement plant. It yields CO₂ that is suitable for numerous applications, including in food and beverages and in intermediate products in pharmaceuticals production. The Rohrdorf cement plant also hosts a formic acid plant which uses captured CO₂.

Rohrdorfer aims to achieve carbon-neutral cement production by 2038. Alongside production-related optimisations, the producer plans to realise its aim through a future expansion to the Rohrdorfer plant’s carbon capture system and the implementation of a further carbon capture upgrade at a second cement plant in Austria.

Austria: Zementwerk Hatschek's Gmunden cement plant eliminated 3800t of CO₂ emissions from its local area during 2022 through its contribution to municipal heating. Zementwerk Hatschek, a subsidiary of Rohrdorfer, heats local households using recovered heat from the Gmunden cement plant's waste heat recover (WHR) system.

A delegation of cement plant representatives and local officials from Baden-Württemberg, Germany, visited the plant to learn about its WHR and heat supply systems on 20 January 2022.

Plant manager Peter Fürhapter said "Municipal heating based on our waste heat contributes to CO₂ reduction in Upper Austria, helping us to achieve our CO₂ reduction goals under the Paris Climate Agreement." He added "We are pleased that with this forward-looking project we are a model for similar projects in Europe."

Germany: Rohrdorfer and Austria-based Andritz Group are in the process of installing a 2t/day CO₂ separation plant on the roof of the former’s Rohrdorf cement plant in Bavaria. The pilot plant will capture CO₂ from the plant’s emissions for use by the regional chemicals industry. The Ingenieur newspaper has reported that it will cost Euro3m and is scheduled for commissioning before June 2022. It is the first installation of its kind at a German cement plant.

Rohrdorfer’s plant and process engineering manager Helmut Leibinger said “We must begin to see CO₂ as a product of value rather than a problem. With CO₂ as a carbon source, Germany can protect the climate and at the same time become less dependent on oil and natural gas. In addition, value creation and jobs will remain in the country.”