Displaying items by tag: Sustainability

US: Lafarge North America has reported that its Paulding, Ohio, plant achieved 99% alternative fuel (AF) substitution in its cement production, up from 95% in past years. The operator said that the fuel change saved 205,000t of CO₂ emissions in 2021.

Germany/Italy: Italy-based Buzzi Unicem has launched its CGreen reduced-CO₂ cement on the German and Italian cement markets. The product uses alternative raw materials to partially replace clinker and also optimises grinding and mixing conditions through the use of novel specialist additives. In Germany, the available range of CGreen cements will consist of Dyckerhoff Eco Comfort cement and Dyckerhoff Cedur cement.

Italy cemeny chief operating officer Antonio Buzzi said "The ecological transition calls for us to adapt our behaviors and actions in order to neutralise our carbon footprint. This transition implies the partial or total redesign of production processes, distribution systems and consumption patterns, heralding the start of a potential industrial revolution and a change in our habits."

Portugal: Cimpor is participating in a consortium, led by power company Rega Energy, which plans to invest Euro100m in developing scalable green hydrogen production plant technologies. The consortium will deploy infrastructure for its upcoming Vale Hidrogénio Verde Nazaré (NGHV) green hydrogen plant by 2023, including a dedicated 40MW solar-powered electricity grid. It will commission its first green hydrogen plant by 2026, creating 140 new jobs. The consortium aims subsequently to scale up the plant to a renewable power consumption of 600MW. It hopes that, when fully commissioned, the NGHV plant will be a reference project for green hydrogen production.

Australia: Boral plans to install chlorine bypass technology at its Berrima cement plant in New South Wales. The Illawara Mercury newspaper has reported that the installation will help the plant to double its alternative fuel (AF) substitution rate to 100%. This is one of the ways in which the producer aims to reduce its Scope One and Two emissions by 46% between 2020 and 2030.

In mid-February 2022, Boral acquired new land at the site of its Dunmore quarry, also in New South Wales.

UK: A consortium led by Australia-based First Graphene dedicated to developing graphene-enhanced cement has won Euro228,000 in UK government funding. Innovation agency Innovation UK selected the consortium for its work’s potential to contribute towards cement and concrete’s carbon footprint reduction of 25% by 2030. UK-based Breedon Cement represents the cement industry within the consortium.

Argos USA announced this week that its integrated Roberta plant in Alabama is set to produce 100% Portland limestone cement (PLC) by June 2022. As part of the transition three of its terminals in North Carolina will also switch over at the same time. The company also expects that all of its plants will convert to PLC in 2023. Cement sites including Newberry in Florida, Harleyville in South Carolina and Martinsburg in West Virginia are already producing PLC.

The change by Argos marks the latest example in an ongoing trend of US-based cement companies moving entire plants to PLC production. In September 2021 LafargeHolcim US said that its integrated Midlothian plant in Texas was preparing to convert to full PLC production and that it would be the first plant in the US to do so. It later confirmed that the plant had done so by the end of 2021. In October 2021 GCC said that its Trident Plant in Montana would fully move to PLC in early 2022. Then in November 2021 Titan America said that its Pennsuco cement plant in Florida would make the change possibly by 2023. Moving into 2022 brought the news that LafargeHolcim US’ Ste. Genevieve plant in Missouri and its Alpena plant in Michigan had each transitioned to PLC production. Lehigh Hanson then rounded up the bunch earlier this month, at the start of February 2022, when it announced that a PLC was the primary product now coming out of its Mason City plant in Iowa. It even invited a US Member of Congress to celebrate!

The current expansionist phase of PLC usage in the US dates back to late 2020 when the Portland Cement Association (PCA) launched a dedicated website to promote the use of the blended cement by discussing its applications and benefits. It then released a new environmental product declaration in March 2021 and PLC received a mention in the PCA’s Roadmap to Carbon Neutrality when it was released a year later in October 2021. Lots of work went into PLC prior to 2020 though, both by the PCA and others. The first commercial production of PLC in the US started in 2005 and PLC gained its own blended cement specification in 2012. Notably, the PCA has been tracking the state acceptance of PLC by the Department of Transportation and it grew markedly during the 2010s.

The US is playing catch-up with PLC. In Europe its usage dates back to the 1960s. Cembureau, the European Cement Association, reported usage of around 30% in 2004. More recently in 2020, the VDZ, the German Cement Association, reported a similar figure domestically with the proportion of blended cement shipments including limestone, shale and multiple additives at 31.6%. In the US it is hard to gauge the scale of the current move towards PLC by producers, due to limited publicly available data. A PCA survey reported PLC production of 0.89Mt in 2016. If all the plants mentioned above convert fully to PLC and maintain their rated production capacity that would be something like 14Mt/yr of PLC in 2023 or 11% of the US’s total cement capacity. For comparison, the United States Geological Survey (USGS) reported total shipments of all blended cements at 3.3Mt in 2020 and a total of 5.4Mt for the first 11 months of 2021. Plus, remember that PLC is just one blended cement among others, like those that use slag or fly ash.

Recent developments show that a large change is coming towards the US cement market in the update of blended cements. It’s been a long time coming but the last six months have seen brisk increases in PLC production at scale. The exact data is not available but one might expect something around triple the current number of production plants making PLC if the US market heads towards European levels. This rough estimate doesn’t take into account existing partial PLC production levels. At the same time the US cement sector should see a fall in its emissions due to PLC’s 10% reduction in CO₂ emissions compared to ordinary Portland cement

Spain: Cementos Molins has committed to a 20% reduction in its CO₂ emissions between 2020 and 2030. The company has set out its strategy in its 2030 Sustainability Roadmap. The roadmap covers five areas: health and safety, energy and climate change, the circular economy, nature and the environment, and corporate social responsibility. Thus, Cementos Molins aims to achieve an accident-free workplace, to source 55% of its electricity consumption renewably, to increase its alternative fuel (AF) substitution rate to 40% and reduce its cement’s clinker factor to 68%, to halve particulate matter emissions and cut nitrous oxides (NO_x) and sulphur oxides (SO_x) emissions by 40% and 10% respectively and to have signed official agreements with all host communities and employ women in over 23% of management positions.

Chief executive officer Julio Rodríguez said “Sustainability is the cornerstone of our strategy here at Cementos Molins, and today we are delighted to announce the specific targets that we have set out in our 2030 Sustainability Roadmap. The targets and their corresponding action plans - the result of the hard work and dedication of the Cementos Molins team, together with our stakeholders – will help drive our company forward in actively tackling climate change.” He added “We are deeply committed to achieving zero emissions and building a better world for everyone.”

US: Eco Material Technologies has successfully completed its acquisition of near-zero carbon cement alternatives producer Green Cement. Eco Material Technologies previously agreed to acquire Boral’s US fly ash business in December 2021, a transaction which it expects to conclude in 2022.

US: Argos USA has announced the upcoming transition of its Roberta, Alabama, cement plant to Portland limestone cement (PLC) Type IL production. By mid-2022, the company plans to produce 100% PLC at the 1.7Mt/yr plant. Its Durham, Statesville and Wilmington cement terminals in North Carolina will also transition to the exclusive distribution of PLC. The Roberta plant will directly serve customers in Alabama, Florida, Georgia and Mississippi.

Argos USA has also launched PLC production at its Harleyville, South Carolina, Newberry, Florida, and Martinsburg, West Virginia, cement plants. It aims to begin producing PLC at all of its cement plants nationally by 2024.

CEO Bill Wagner said "We are excited to announce the transition of the Roberta plant to 100% (PLC) Type IL. With this transition, we continue to support our customers and the industry on its road to lower greenhouse gas emissions. With PLC, we are supplying a more environmentally friendly building solution for our customers, engineered to deliver an outstanding quality and performance while lowering our carbon footprint.”

US: Eco Materials Technologies has finalised its US$1.05bn acquisition of Boral’s US fly ash business and launched an oversubscribed US$525m green bond issue. The issue will help it to become a global green cement production leader, according to the group. The Australian Financial Review newspaper has reported that subscriptions were four times the available bonds.