Displaying items by tag: Waste

Dominican Republic: Cemex Dominicana has announced the signing of a new sustainability agreement with food producer Nestlé Dominicana. Under the agreement, Cemex Dominicana will co-process Nestlé Dominicana's non-recyclable high-calorific solid industrial waste as alternative fuel (AF) in its cement plant.

Cemex's Dominican Republic, Puerto Rico and Haiti regional director José Antonio Cabrera said "This agreement with Nestlé allows us to continue promoting our Future in Action strategy by operating our cement plant with AF." He concluded "We are committed to becoming a net-zero CO₂ company."

In Australia and New Zealand, four producers operate a total of six integrated cement plants, with another 13 grinding plants situated in Australia. This relatively small regional cement industry has been on a decades-long trajectory towards ever-greater sustainability – hastened by some notable developments in recent weeks.

Oceania is among the regions most exposed to the impacts of climate change. In Australia, which ranked 16th on the GermanWatch Global Climate Risk Index 2021, destructive changes are already playing out in diverse ways.¹ Boral reported 'significant disruption' to its operations in New South Wales and southeast Queensland due to wet weather earlier in 2022. This time, the operational impact was US$17.1m; in future, such events are expected to come more often and at a higher cost.

Both the Australian cement industry and the sole New Zealand cement producer, Golden Bay Cement, have strategies aimed at restricting climate change to below the 2° scenario. Golden Bay Cement, which reduced its total CO₂ emissions by 12% over the four-year period between its 2018 and 2022 financial years, aims to achieve a 30% reduction by 2030 from the same baseline. The Australian Cement Industry Federation (CIF)'s 2050 net zero cement and concrete production roadmap consists of the following pathways: alternative cements – 7%; green hydrogen and alternative fuels substitution – 6%; carbon capture – 33%; renewable energy, transport and construction innovations – 35% and alternative concretes – 13%, with the remaining 6% accounted for by the recarbonation of set concrete.

Australia produces 5.2Mt/yr of clinker, with specific CO₂ emissions of 791kg/t of clinker, 4% below the global average of 824kg/t.² Calcination generates 55% of cement’s CO₂ emissions in the country, and fuel combustion 26%. Of the remainder, electricity (comprising 21% renewables) accounted for 12%, and distribution 7%. Australian cement production has a clinker factor of 84%, which the industry aims to reduce to 70% by 2030 and 60% by 2050. In New Zealand, Golden Bay Cement's main cement, EverSure general-purpose cement, generates CO₂ at 732kg/t of product.³ It has a clinker factor of 91%, and also contains 4% gypsum and 5% added limestone.

Alternative raw materials

Currently, Australian cement grinding mills process 3.3Mt/yr of fly ash and ground granulated blast furnace slag (GGBFS). In Southern Australia, Hallett Group plans to commission its upcoming US$13.4m Port Augusta slag cement grinding plant in 2023. The plant will use local GGBFS from refineries in nearby Port Pirie and Whyalla, and fly ash from the site of the former Port Augusta power plant, as well as being 100% renewably powered. Upon commissioning, the facility will eliminate regional CO₂ emissions of 300,000t/yr, subsequently rising to 1Mt/yr following planned expansions. Elsewhere, an Australian importer holds an exclusive licencing agreement for UK-based Innovative Ash Solutions' novel air pollution control residue (APCR)-based supplementary cementitious material, an alternative to pulverised fly ash (PFA), while Australian Graphene producer First Graphene is involved in a UK project to develop reduced-CO₂ graphene-enhanced cement.

Golden Bay Cement is investigating the introduction of New Zealand's abundant volcanic ash in its cement production.

Fuels and more

Alternative fuel (AF) substitution in Australian cement production surpassed 18% in 2020, and is set to rise to 30% by 2030 and 50% by 2050, or 60% including 10% green hydrogen. In its recent report on Australian cement industry decarbonisation, the German Cement Works Association (VDZ) noted the difficulty that Australia's cement plants face in competing against landfill sites for waste streams. It described current policy as inadequate to incentivise AF use.

Cement producer Adbri is among eight members of an all-Australian consortium currently building a green hydrogen plant at AGL Energy’s Torrens Island gas-fired power plant in South Australia.

Across the Tasman Sea, Golden Bay Cement expects to attain a 60% AF substitution rate through on-going developments in its use of waste tyres and construction wood waste at its Portland cement plant in Northland. The producer will launch its new EcoSure reduced-CO₂ (699kg/t) general-purpose cement in November 2022. In developing EcoSure cement, it co-processed 80,000t of waste, including 3m waste tyres. The company says that this has helped in its efforts to manage its costs amid high coal prices.

Carbon capture

As the largest single contributor in Australia's cement decarbonisation pathway, carbon capture is now beginning to realise its potential. Boral and carbon capture specialist Calix are due to complete a feasibility study for a commercial-scale carbon capture pilot at the Berrima, New South Wales, cement plant in June 2023.

At Cement Australia's Gladstone, Queensland, cement plant, carbon capture is set to combine with green hydrocarbon production in a US$150m circular carbon methanol production facility supplied by Mitsubishi Gas Chemical Company. From its commissioning in mid-2028, the installation will use the Gladstone plant's captured CO₂ emissions and locally sourced green hydrogen to produce 100,000t/yr of methanol.

More Australian cement plant carbon capture installations may be in the offing. Heidelberg Materials, joint parent company of Cement Australia, obtained an indefinite global licence to Calix's LEILAC technology on 28 October 2022. The Germany-based group said that the method offers effective capture with minimal operational impact.

Cement Australia said “The Gladstone region is the ideal location for growing a diverse green hydrogen sector, with abundant renewable energy sources, existing infrastructure, including port facilities, and a highly skilled workforce." It added "The green hydrogen economy is a priority for the Queensland government under the Queensland Hydrogen Industry Strategy.”

Logistics

Australian and New Zealand cement facilities' remoteness makes logistics an important area of CO₂ emissions reduction. In Australia, cement production uses a 60:40 mix of Australian and imported clinker, while imported cement accounts for 5 – 10% of local cement sales of 11.7Mt/yr.

Fremantle Ports recently broke ground on construction of its US$35.1m Kwinana, Western Australia, clinker terminal. It will supply clinker to grinding plants in the state from its commissioning in 2024. Besides increasing the speed and safety of cement production, the state government said that the facility presents 'very significant environmental benefits.'

Conclusion

Antipodean cement production is undergoing a sustainability transformation, characterised by international collaboration and alliances across industries. The current structure of industrial and energy policy makes it an uphill journey, but for Australia and New Zealand's innovating cement industries, clear goals are in sight and ever nearer within reach.

References

1. Eckstein, Künzel and Schäfer, 'Global Climate Risk Index 2021,' 25 January 2021, https://www.germanwatch.org/en/19777

2. VDZ, 'Decarbonisation Pathways for the Australian Cement and Concrete Sector,' November 2021, https://cement.org.au/wp-content/uploads/2021/11/Full_Report_Decarbonisation_Pathways_web_single_page.pdf

3. Golden Bay Cement, 'Environmental Product Declaration,' 12 May 2019, https://www.goldenbay.co.nz/assets/Uploads/d310c4f72a/GoldenBayCement_EPD_2019_HighRes.pdf

Japan: Taiheiyo Cement has agreed to buy the cement business of chemicals company Denka for an undisclosed sum. Denka operates an integrated plant in Itoigawa City, Niigata Prefecture where Taiheiyo Cement’s subsidiary Myojo Cement also operates a plant. The three companies have been working on a joint-development plant for local limestone resources since 2018. However, Denka has decided to leave the cement market due to poor local demand and the necessity of upgrades at its plant from 2025 onwards.

From April 2023 cement sold from Denka’s Omi plant will carry the Taiheiyo Cement brand name. Taiheiyo Cement and Myojo Cement have also agreed to continue supplying Denka’s other businesses, such as carbide production, with limestone from 2025. Denka will send by-products and other waste streams to the cement producer. Finally, Taiheiyo Cement, Myojo Cement and Denka will carry on developing the local limestone resources near to Itoigawa City.

Spain: Cementos Portland Valderrivas plans to make Euro6m-worth of investments in its Alcalá de Guadaira cement plant in Seville. The funds will go towards the construction of a refuse-derived fuel (RDF) line to help reduce the plant's petcoke consumption, as well as the renewal of the plant's mining licence for its quarry.

New Zealand: Fletcher Building subsidiary Golden Bay Cement has co-processed 80,000t of waste in production of its EcoSure reduced-CO₂ general-purpose cement at its Golden Bay, Whangarei, cement plant. The plant has achieved a coal substitution rate of 50%. It has processed various waste streams, including 3 million used tyres. EcoSure cement generates CO₂ emissions of 699kg/t of product, 20% less than its imported alternatives, according to Golden Bay Cement. Fletcher building CEO Nick Traber said that this figure is 'simply our starting point.' The company's next target is to achieve a 30% CO₂ reduction by 2030.

Traber said "We needed to think outside the box, or rather the cement bag to be more precise. The challenge was around what enhancements we could make to our manufacturing processes at our Golden Bay cement works in order to improve the plant's sustainability. We quickly realised that consuming used tyres and wood waste as alternative fuels was a win-win. When we started with the idea in 2015, we were aiming to replace 15% of coal with end-of-life tyres. Fast forward to 2022, and our rate of coal substitution is now at 50%, which has obviously delivered further reductions in carbon emissions, as well as helping to offset increased coal costs."

Philippines: Republic Cement is supporting efforts to remove plastic pollution from the sea by co-processing the waste in its cement production. The Business Mirror newspaper has reported that the cement producer has partnered with plastic waste collector Pure Oceans to take delivery of shipments cleaned up from off the coasts of Batangas and Davao.

Republic Cement chief executive officer Roman Menz said "Republic Cement is proud to partner with organisations such as Pure Oceans. Their deep commitment towards safeguarding the environment, while making significant contributions to the Philippine plastic waste crisis, is an inspiration for us to continue doing what we do in order to make a tangible impact on our communities, towards building a greener and stronger republic."

Through its partnerships with local fishing communities, Pure Oceans diverted 1.93m bags of plastic waste over the three years prior to the start of October 2022.

UK: Innovative Ash Solutions, a joint venture of Levenseat and Organic Innovative Solutions, has launched a new air pollution control residue (APCR)-based supplementary cementitious material (SCM). The supplier produces the material at its Lanarkshire treatment facility using APCR local from municipal solid waste (MSW) and wood biomass incinerators. Innovative Ash Solutions has received planning permission for a 54,000t/yr industrial-scale APCR-based SCM plant, and plans to establish a total of three plants in the UK, one of which will reach a capacity of 500,000t/yr. It has also signed an exclusive licensing agreement with an Australia-based importer for the material.

The SCM is designed to replace pulverised fly ash (PFA), of which the UK imported 325,000t in 2019, more than four times its 2012 import volumes of 76,000t.

Innovative Ash Solutions director Robert Gren said “We are excited to bring this new product to market. Innovative Ash Solutions is the first and, so far, the only company in the UK to have achieved ‘End of Waste’ accreditation for a PFA replacement for this type of use. Our research shows there is potential to produce more than 500,000t/yr of PFA replacement from UK APCRs every year, which would reduce the need for importing materials and support the decarbonisation of cement and concrete products.”

Europe: RHI Magnesita is heading a European Union Horizon project called ReSoURCE. The project seeks to develop a sensor-based refractory waste sorting and powder handling system. It involves academic partners in Austria, Germany, Ireland, Norway and the UK. The European Health and Digital Executive Agency (HADEA) supplied Euro6m in funding for the study, while the UK government supplied Euro1m. Global refractory waste generation is currently 28Mt/yr.

RHI Magnesita chief executive officer Stefan Borgas said “On average, 60% of all spent refractories generated by refractory-consuming industries go to landfill, while only 30% are recycled. With the ReSoURCE project, we aim to increase it up to 75%. This means we can achieve significant savings of CO₂ emissions per annum. With this research project, we have the chance to make a difference in the world.”

Pakistan: The Pakistan National Forum of Environment and Health (NFEH) has recognised Lucky Cement’s sustainability successes with a prize at the 19th Annual Environment Excellence Awards 2022. The company’s comprehensive environmental management and monitoring plan covers its solid waste, noise pollution and emissions, including particulates. It says that this is essential to preserving the ecosystem in which it operates.

Chief operating officer Amin Ganny said “We believe in environment-friendly practices and are committed to conserving the environment. Implementation of sustainability into our core business operations has always been one of our main objectives.”

Philippines: Holcim Philippines has launched its ECOPlanet 30% reduced-CO₂ cement range in the city of Davao on Mindanao. The producer also introduced its Balik-Plastic waste cement bag recycling programme, offering a collection service to customers in order to reuse waste bags as alternative fuels and raw materials in cement production at its Davao plant.