Displaying items by tag: Tyres

This week we covered Capitol Aggregates’ order of an alternative fuels (AF) system from ATS Walter USA. The story is notable because it is an AF project for a cement plant in the US. Thermal substitution rates (TSR) of AF in the US have typically been lower than in the European Union (EU), but this could be changing.

The order was confirmed publicly at the end of September 2025. The subsidiary of ATS Group will supply a solid AF metering and conveying system to the integrated plant in San Antonio, Texas. The system will include a moving floor receiving station, chain belt conveyors, a screen and a separator, dosing equipment, an air-supported belt conveyor and an injection system. ATS Walter says that, by the end of 2026, it will have supplied four AF projects in North America. As an aside, Capitol Aggregates also mentioned in the press release that it “...views sustainability as essential to long-term success.” This sentiment is backed up by the fact that the plant built an early commercial carbon capture unit in the 2010s!

Data from the American Cement Association (ACA) revealed that the AF TSR in the US reached 16% in 2023 from 14.6% in 2022. This compares to a 58% rate in the EU in 2022. It is also worth noting that, in the US the share of gas in the cement industry energy mix rose from 25% to 31%. The ACA attributed this change to a falling price of gas. It added that the coal and petroleum share of the fuel mix fell to its lowest level since 1974. The point here is that the energy mix used by cement plants changes over time regardless of sustainability trends.

Research by LEK Consulting estimated that 60 of the 87 cement plants in the US had a TSR of below 20% in 2023. 39 of these were believed to have a TSR of under 5%. It summarised that hazardous waste and tyre-derived fuels have tended to predominate in the US compared to refuse-derived fuel (RDF) in the EU and elsewhere. LEK went on to say that its research suggested that a quarter of cement plants in the US were likely to install an AF feeding system in 2024 or 2025. This is likely to be the highest rate of AF uptake in the US cement sector to date.

The ACA reckons in its sustainability roadmap that with the right policies and regulations the country’s AF TSR could reach as high as 50%. Its policy suggestions include: reduce permitting barriers to use of so-called non-hazardous secondary materials (NHSM) fuels in industrial manufacturing; treating waste-to-industrial energy as valid recycling use; building robust recycling infrastructure and markets that incentivise the use of non-recycled material streams as industrial AF; community education and support for use of low carbon AF; and increasing the use of NHSMs to divert these materials from landfills. This can be mostly summarised as supporting the uptake of RDF through better permitting and building up the infrastructure and markets for it. LEK also identified the same issue. It called for the adoption of landfill reduction targets or zero-landfill policies by commercial and industrial waste generators. However, LEK believes that, even if this were done, current sources of high-quality RDF in the US would not be able to increase the TSR to even 20%.

News from Capitol Aggregates and others about AF projects in the US are encouraging. If LEK’s research is indicative then a step change in the TSR in the country’s cement sector is already underway. The beauty of AF usage is that it can both potentially cut fuel costs and reduce CO₂ emissions. It won’t be easy as new supply chains for refuse byproducts are built and utilised. Yet, as the ACA is advocating, it is possible and worthwhile.

The 1st CemFuels Asia Conference will take place in Bangkok in February 2026 and the 19th Global CemFuels Conference will take place in September 2026 in Geneva

Bolivia: The municipal government of Santa Cruz de la Sierra has signed an agreement with Itacamba Cemento to recycle thousands of end-of-life tyres (ENDTs) into alternative fuel for cement production, according to the El Deber newspaper. The initiative was implemented through the Municipal Waste Management Company (Emacruz).

Under the agreement, discarded tyres collected from landfills will be transformed into thermal energy for use in Itacamba’s cement kilns, reducing waste and fossil fuel consumption. The tyres will be incinerated at temperatures exceeding 1400°C, with monitoring and gas-capture systems employed to prevent harmful emissions.

Mayor Jhonny Fernández said “We guarantee the responsible disposal of thousands of tonnes of tyres that would otherwise cause pollution or become breeding grounds for diseases like dengue. This is our tangible contribution to a healthier environment and better quality of life for our citizens.”

Itacamba Cemento general manager Marcelo Morales said “Co-processing is a globally recognised waste management method that complies with the waste hierarchy. Our kiln enables the complete and safe destruction of non-recyclable materials.”

Mexico: Moctezuma inaugurated a US$12m alternative fuels storage system at its Tepetzingo cement plant in Morelos, after two years of engineering, planning and execution. The facility will process over 150,000t/yr of waste, including end-of-life tyres, municipal solid waste and non-recyclable materials, which will replace fossil fuels in cement production, with a goal of 30% substitution by 2030. The company said that the benefits of the project include saving thousands of tonnes of waste from landfill and mitigating methane emissions.

The producer, the Morelos government and the Ministry of Sustainable Development are also developing a circular economy centre in Jiutepec with an additional investment of US$1.6m. The facility will collect, shred and convert up to 3000t/month of tyres into alternative fuels.

Australia: Boral’s Berrima Cement Works celebrated a milestone of using more than 100,000t of alternative fuels in cement manufacturing at its facility during the 2025 financial year, according to a post by the producer on Linkedin. The facility displaced over 80,000t of coal. The fuels included high-biomass waste and tyres, which were diverted from landfill.

Boral said that it has achieved over 30% thermal energy substitution in the plant’s kiln, with successful trials reaching 45%. With recent upgrades such as the chlorine bypass and further infrastructure investment, the company targets 60% substitution in coming years.

Georgia: Hunnewell Cement, a subsidiary of HeidelbergCement Georgia, has launched a new project to use tyres as an alternative fuel at its Kaspi cement plant, with support from the Georgian government. The project has a budget of US$2.1m, and is expected to create additional job opportunities. It marks a shift from the use of coal and natural gas at the plant, to ‘significantly’ reduce environmental impact and contribute to sustainable development.

Economy minister Levan Davitashvili said "Our goal is to minimise environmental pollution from ‘waste’ while promoting economic development and creating added value.”

Oman: Oman's solid waste management entity, Be'ah, has reported progress in its strategy to transition solid waste from landfill disposal to refuse derived fuel (RDF), according to Oman Daily Observer.

In 2023, Be'ah launched initiatives focusing on transforming waste into RDF, electrical and electronic waste and green waste. The company has signed an agreement with Oman Cement Company to provide tyre derived fuel for its energy needs, eventually expanding to include RDF. A memorandum of understanding (MoU) was signed with Oman Cement during Oman Sustainability Week to explore the utilisation of RDF as an additional alternative fuel source, according to the company’s 2023 sustainability report.

Chair of Be’ah, Ahmed al Subhi, said "We take pride in our strategic resource management initiatives, having set ambitious targets for transitioning to a circular economy, including achieving 60% waste utilisation by 2025 and 80% by 2030.”

Mexico: The Secretariat of the Environment (Sedema) has reported that over 5600 tyres collected from illegal dumps in the districts of Xochimilco and Gustavo Madero have been transported to a treatment plant to be used as an alternative fuel for cement production. This initiative is part of a strategy to manage tyre waste, supported by a collaboration with Geocycle Mexico. The effort aims to address public environmental issues caused by tyre disposal in public spaces and environmentally sensitive areas, potentially leading to wildfires. Sedema also plans to expand tyre collection through the Reciclatrón Program to promote comprehensive waste management and reduce the reliance on fossil fuels and mineral extraction.

New Zealand: Golden Bay, New Zealand's sole cement producer and a division of Fletcher Building, is advancing its sustainability goals at its Portland plant near Whangārei. The plant has been incorporating old tyres and treated timber in its production process since 2021, with the Ministry for Environment helping fund US$10m of the US$15.5m to upgrade the plant for the project. The plant uses tyres to replace 55-60% of the coal required, and plans to eliminate coal use by 2030. The facility has increased its use of recycled tyres from 15,000t to 30,000t/yr and is aiming for 40,000t/yr. The government’s Tyrewise programme supports tyre recycling, with the plant also investing in an on-site shredder. Upcoming projects include substituting coal with non-recyclable materials like old carpets and plastics, targeting a 30% reduction in emissions. Construction has already started on the project and it is expected to be completed by the end of 2024, according to the New Zealand Herald.

Manufacturing manager Kelly Stevens said, "We’re diverting 100,000t/yr of waste that would’ve gone to landfill.”

Jamaica: Caribbean Cement is allocating US$8m, 20% of its planned US$40m investment in 2024, to increase sustainability efforts at its Rockfort plant. The company is aiming to become net-zero by increasing its use of alternative fuels and repurposing materials like tyres, which will also help to save on operational expenses and fuel costs, according to the company.

The repurposing of tyres, which commenced following a Government of Jamaica partnership, will remove a ‘significant’ portion of the estimated 1.5m tyres at the country’s Riverton dump, along with other materials such as pallets, which Caribbean Cement now uses as alternative fuel sources in the cement manufacturing process. With the help of its XRC3000c shredder obtained from Austria-based company UNTHA, Caribbean Cement said it has shredded more than 9000 tyres to date.

Managing director Jorge Martínez said “At the moment our first goal for the end of 2024 is to at least reach 10% alternative fuels. We will remove some of those fuels that are not renewable, substituting it with ones that are. This is part of our future in action programme. Some of these actions are also related to the reuse of some materials in the plant as we take waste materials from other industries and beach clean-ups for repurposing. We try to reuse them in any way we can.”

US: Holcim US has announced plans for a 25MW solar power plant to serve 75% of the electricity needs of its Alpena cement plant in Michigan. The company says that the installation at the Alpena plant will be the largest in the US Midwest Region. Holcim US chose NorthStar Clean Energy to build the array, which it says will eliminate 25,000t/yr of CO₂ emissions.

Other planned projects at the Alpena cement plant include an upgrade to the plant's dock in order to accommodate larger vessels and reduce the number of trips in its Great Lakes transport operations.

Holcim US' senior vice president, manufacturing, Michael Nixon said “As Holcim is showing in Alpena, the path to net-zero carbon emissions requires a blend of proactive solutions. Whether it’s using alternative fuels or implementing renewable energy from solar power, we are committed to reducing our reliance on fossil fuels — a goal that will benefit the environment as a whole and the Alpena community we have called home for more than 115 years.”