Displaying items by tag: decarbonisation

US: The US Department of Energy has selected Central Plains Cement to receive US$5m-worth of funding to realise its plans for a cryogenic carbon capture (CCC) installation at its Sugar Creek, Missouri, cement plant. Contify Energy News has reported that the system will initially have a capacity of 30t/day of CO₂, with a view to eventually capturing 95% of the plant’s flue gas’ CO₂ content. The Eagle Materials subsidiary will receive US$5m in funding from the US Department of Energy for the project. The sum is part of a raft of a total US$45m-worth of grants to help towards decarbonising heavy industry and natural gas power. Chart Industries will carry out the work.

Chart Industries CEO and President Jill Evanko said that the company’s CCC model increases cement production costs by just 24%, compared to 38% - 130% for other types of system. She added “We are delighted that public and private entities recognise Chart as a leader in carbon capture technologies and products; we view this award as well as our third quarter 2021 commercial activity as meaningful steps and accelerators toward capturing - pun intended - a significant share of our anticipated US$6bn total addressable market for carbon and direct air capture in 2030.”

The St Louis Post newspaper has reported that Holcim US’s Ste-Genevieve, Missouri, cement plant is also among facilities chosen to receive funding for carbon capture and storage (CCS) installations.

Belgium: The low-emissions intensity lime and cement (LEILAC) consortium has published the results of its LEILAC-1 carbon capture and storage (CCS) study at HeidelbergCement’s Lixhe cement plant in Visé. The study found the cost of CCS to be Euro14 – 24/t of CO2 captured. It found that full-chain CO2 mitigation projects incur costs are Euro39 – 80/t, depending on transport and storage selections.

EU Emissions Trading Scheme (ETS) credits currently cost Euro62/t.

Australia: Boral plans to run a pilot scale carbon capture and storage unit at its integrated Berrima Cement plant in New South Wales. The project follows an allocation of a US$1.7m grant from the Australian Government’s carbon capture and utilisation and storage (CCUS) Development Fund in June 2021. The pilot intends to develop and test a re-carbonation strategy for CO₂ storage. Captured CO₂ will be stored in recycled concrete, masonry and steel slag aggregates. In its 2021 sustainability report, the buildings materials company said that, “The relatively low capital and operation costs, abundance of selected waste materials and the financial return potential due to the increased value of processed aggregates are key drivers for adoption of this technology.”

It’s been a good week for carbon capture in cement production with new projects announced in France and Poland.

The first one is a carbon capture and utilisation (CCU) collaboration between Vicat and Hynamics, a subsidiary of energy-provider Groupe EDF. The Hynovi project will see an integrated unit for capturing CO₂ and producing methanol installed at Vicat’s Montalieu-Vercieu cement plant in 2025. It aims to capture 40% of the CO₂ from the kiln exhaust stack at the plant by using an oxy-fuel method and installing a 330MW electrolyser to split water into oxygen and hydrogen for different parts of the process. The CO₂ will then be combined with hydrogen to produce methanol with potential markets in transport, chemicals and construction. The setup is planning to manufacture over 0.2Mt/yr of methanol or about a quarter of France’s national requirement. The project was put forward under a call for proposals by the Important Projects of Common European Interest (IPCEI) program. Pre-notification of its participation in the program has been received from the French government and it is currently being evaluated by the European Commission. Vicat’s decision to choose its Montalieu-Vercieu plant for this project is also interesting since it started using a CO₂ntainer system supplied by UK-based Carbon8 Systems there on an industrial scale in November 2020. This system uses captured CO₂ from the plant’s flue gas emissions to carbonate cement-plant dust and produce aggregate.

The second new project is a pilot carbon capture and storage (CCS) pilot by HeidelbergCement at its Górażdże cement plant in Poland. This project is part of the wider Project ACCSESS, a consortium led by Sintef Energi in Norway that aims to cut carbon capture, utilisation and storage (CCUS) costs and to link CO₂-emitters from mainland Europe to storage fields in the North Sea. The cement plant part in Poland will test an enzyme-based capture method using waste heat at the plant. Another part of the project will look at how the captured CO₂ can then be transported to the Northern Lights storage facility in Norway including the regulatory aspects of cross-border CO₂ transport. ACCSESS started in May 2021 and is scheduled to end in April 2025. It has a budget of around Euro18m with Euro15m contributed by the European Union (EU) Horizon 2020 fund.

HeidelbergCement also says that the second stage of its LEILAC (Low Emissions Intensity Lime And Cement) project at the Hannover cement plant is part of ACCSESS, with both testing of the larger-scale Calix technology to capture CO₂ and the connected transport logistics and bureaucracy to actually get it to below the North Sea. That last point about Calix is timely given that US-based Carbon Direct purchased a 7% stake in Calix in mid-September 2021 for around US$18m. Whilst on the topic of carbon capture and HeidelbergCement don’t forget that the group’s first full-scale carbon capture unit at Norcem’s Brevik cement plant, using Aker Solution’s amine solvent capture technology, is scheduled for commissioning in September 2024. Another carbon capture unit is planned for Cementa’s Slite plant in 2030 but the proposed capture method has not been announced.

Other recent developments in carbon capture at cement plants include Aalborg Portland Cement’s plan to capture and store CO₂ as part of the Project Greensand consortium. The overall plan here is to explore the technical and commercial feasibility of sequestering CO₂ in depleted oil and gas reservoirs in the Danish North Sea, starting with the Nini West Field. The project is still securing funding though, with an Energy Technology Development and Demonstration Program application to the Danish government pending. However, the Danish Parliament decided in December 2021 to set aside a special funding pool to support a CO₂ storage pilot project so this initiative seems to be making progress. If the application is successful, the consortium wants to start work by the end 2021 and then proceed with an offshore injection pilot from late 2022. How and when Aalborg Portland Cement fits in is mostly unknown but a 0.45Mt/yr capture unit at its Rørdal cement plant is tentatively planned for 2027. There’s also no information on the capture method although Aker Carbon Capture is also part of the Project Greensand consortium. Finally, also in September 2021, Chart Industries subsidiary Sustainable Energy Solutions announced that it had selected FLSmidth to help adapt and commercialise its Cryogenic Carbon Capture carbon capture and storage (CCS) system for the global cement industry.

All of this tells the cynics in the audience that a large international climate change meeting is coming up very soon. Most cement companies will likely want some good news to show off when the 2021 United Nations Climate Change Conference (COP26) dominates the media agenda in November 2021. Other observations to point out include that none of the projects above are full-scale industrial carbon capture installations, most of them are consortiums of one sort of another and that they are all subsidised or want to be. While hydrogen and CO₂ networks get built this seems inevitable. Yet, we’re not at the stage where cement companies just order carbon capture units from a supplier, like they might a new clinker cooler or silo, without the need for long lists of partners. When this changes then carbon capture looks set to flourish.

On a final note, the UK is currently experiencing a shortage of commercially-used CO₂. The reasons for this have nothing to do with the cement industry. Yet consider the constant doom-and-gloom about record global CO₂ emissions and the sheer amount of effort going into reducing this by the projects mentioned above and others. Life has a sense of humour at times.

For a view on the CO₂ sequestration permitting process in the US look out for the an article by Ralph E Davis Associates, in the forthcoming October 2021 issue of Global Cement Magazine

Poland: Germany-based HeidelbergCement has partnered with Norway-based Sintef Energi install a pilot carbon capture and storage (CCS) system at its Górazdze cement plant. The company will deploy new enzyme-based CCS technology, which it says allows greater use of the waste heat and simplifies the control of secondary emissions. The project, known as Project ACCSess, has received Euro15m-worth of funding from the EU’s Horizon 2020 industrial emissions reduction programme. 18 industry partners and research organisations will collaborate towards the deployment of the technology at the plant. The consortium will store captured CO₂ in storage fields in the Nordic countries. The project is due to conclude in April 2025. The total cost of the work is Euro18m.

HeidelbergCement chair Dominik von Achten said “The tests of an enzyme-based capture unit at our Górazdze plant in Poland will deliver important insights into how we can further reduce costs in the capture process.” He added “At the same time, it will emphasise our strategy to expand CCS further into our Eastern Europe-based assets.”

France: Vicat’s Montalieu-Vercieu cement plant will host a carbon capture and storage (CCS) installation and methanol plant under a joint project by Vicat and Groupe EDF subsidiary Hynamics known as Hynovi. The project aims to achieve 40% carbon capture at the plant. A 330MW electrolyser will convert captured CO2 to methanol through oxycombustion. Commisioning of the entire system is scheduled for 2025. The partners said that Hynovi may subsequently be taken up by cement plants globally.

Australia: US-based Carbon Direct has bought a 7% stake in Calix. Reuters News has reported the value of the stake as US$17.7m. Reuters News has reported that Calix plans to use the proceeds to scale up its carbon capture and storage (CCS) technology, as demonstrated at the LEILAC and LEILAC 2 installations at Lixhe, Belgium, and Hanover, Germany.

Calix chief executive officer Phil Hodgson said "As the world puts emissions trading schemes in place, CCS does start to look like a multibillion dollar addressable market.”

US/Denmark: Chart Industries subsidiary Sustainable Energy Solutions has chosen FLSmidth to help adapt and commercialise its Cryogenic Carbon Capture carbon capture and storage (CCS) system for the global cement industry. The system captures and stores CO₂ from flue gas as a liquid. FLSmidth says that it will use its global reach and process knowledge to accelerate the commercialisation of Cryogenic Carbon Capture and optimise its design for cement plants. It believes the technology can cut 90% of process CO₂ emissions at half the cost and energy consumption of current CCS processes.

FLSmidth cement president Carsten Riisberg Lund said “The cement industry is pursuing all options to reduce its environmental footprint, and CCS is a necessary technology to achieve this goal. Through this agreement with Chart, we lay the foundation for the scale-up and deployment of Cryogenic Carbon Capture technology with our customers. The technology developed by Chart is expected to become the most competitive at scale.” He added “This agreement is a significant leap forward in our joint efforts to enable our customers to reduce their environmental footprint.”

Denmark: Aalborg Portland Cement will begin construction of a carbon capture and storage (CCS) system at its Rørdal, North Jutland, cement plant. It will collaborate with Project Greensand CCS consortium partners to store the captured CO2 in drained oilfields below the North Sea. The company estimates that the Danish part of the North Sea has 16Gt of CO2 storage capacity, out of 300Gt under all EU waters. The endeavour aims to help Denmark to realise its targeted 70% reduction of CO2 emissions by 2030.

Research and development director Jesper Sand-Damtoft said “The establishment of capture facilities, transformation from carbon to gas and transport to the North Sea all require great investments from a business such as ours, and the realisation of the climate potential thus depends greatly on financial support.”

Denmark: 29 consortium members, including Aalborg Portland Cement, Aker Carbon Capture and INEOS, have signed up to phase two of the Greensand carbon capture and storage pilot project. Proof of concept planning is now underway with a potential start date of around late 2021 subject to securing funding from the government’s Energy Technology Development and Demonstration Program. If successful an offshore injection pilot is scheduled for late 2022.

A majority of the Danish Parliament decided in December 2020 to set aside a special funding pool to support a CO2 storage pilot project, aiming to investigate the reservoir-CO₂ interaction in the Danish North Sea. This pilot project, if designed correctly, could form the basis for a decision, to enable CO₂ storage by 2025.

Mads Weng Gade, Head of Country, Denmark and Commercial Director INEOS Energy said, “We are taking this step by step. We now have the consortium in place, and if we are successful in receiving ongoing support from the Danish Government and advisory board, Greensand will be able to take another important step forward in supporting the Danish Climate Strategy.”