Displaying items by tag: hydrogen

UK: The Mineral Products Association (MPA) has announced the successful completion of a trial of cement production using a net-zero fuel mix consisting of hydrogen and refuse-derived fuel (RDF) at Hanson’s Ribblesdale, Lancashire, cement plant. The RDF in the mix consists of meat and bone meal (MBM) from the food industry and glycerol from biodiesel production.

Increased alternative fuel (AF) substitution is one of seven key levers in the MPA’s Roadmap Beyond Net Zero emissions reduction strategy. The association says that the fuel will eliminate 180,000t/yr of CO₂ emissions from the Ribblesdale plant’s operations when fully implemented. The project received Euro3.71m in government funding.

Hanson’s environmental sustainability manager Iain Walpole said “We are delighted to be involved with this world-leading project, which is a further example of our commitment to cutting CO₂ emissions.” He added “It will also contribute to our ambition of supplying net zero carbon concrete by 2050.”

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

Italy: The Italian cement association Federbeton has launched its comprehensive plan for cement industry decarbonisation in line with the EU’s European Green Deal target of a 55% reduction in CO₂ emissions between 1990 and 2030 and carbon neutrality by 2050. The strategy entails Euro4.2bn of total new investments andEuro1.4m/yr of extra operating costs across the industry. This will cover the adoption of transition technologies and the large-scale application of carbon capture and storage (CCS). The association says that while some such actions, such as alternative fuel (AF) substitution,are immediately available, others require further development. The sector’s primary fuel is petcoke, mainly imported from the Gulf of Mexico. As such, Federbeton has identified the 100% replacement of all fossil fuels with ‘low-carbon impact’ alternatives as a means of reducing the industry’s carbon footprint by 12% achievable in the short term. Renewable green hydrogen use can cut a further 3% of CO₂ emissions, an energy transition to renewable sources can cut 5%, clinker factor reduction can cut 10%, alternative raw materials in clinker can cut 6%, CCS can cut 43%, supply chain and logistics changes can cut 16% and the optimisation of construction can cut the remaining 5%.

President Roberto Callieri said “The cement and concrete supply chain wants to be one of the protagonists of the ecological transition.” He added “Only with adequate and immediate support tools will it be possible to prevent the impoverishment of the industrial fabric, preserve the competitiveness of the supply chain and prevent relocation. Last but not least, a new environmental culture must be shared, based on dialogue and no longer on the preconceived opposition to any choice of industry.”

UK: The Mineral Products Association (MPA) has welcomed the government's UK Hydrogen Strategy but warned that the costs of production, transmission and distribution need to be shared by the whole UK economy. The state plan was published in mid-August 2021 and it sets out how progress will be made over the next decade to deliver 5GW of low carbon hydrogen production capacity by 2030, as part of the UK's drive to achieving its net zero targets. A consultation has also been launched to identify how the current cost gap between low carbon hydrogen and fossil fuels can be overcome.

Richard Leese, Director of Industrial Policy, Energy and Climate Change at the MPA said, "it's now critical that energy intensive industries, including the UK cement sector, which are essential for our economy and way of life, are not unduly penalised by additional policy costs for the production, transmission and distribution of hydrogen on top of already high electricity costs and carbon-related environmental taxes. Hydrogen development costs need to be shared by the wider economy to encourage acceleration of the technology and ensure industrial gas users and hydrogen generated power users are not placed at any further international competitive disadvantage.” Leese added that switching fuels away from fossil fuels, including the potential to adopt hydrogen technology, was already one of seven key levers in MPA UK Concrete's Roadmap to Beyond Net Zero.

The MPA is currently undertaking demonstrations of hydrogen as well as plasma technology, which are being partly funded by the Department for Business, Energy and Industrial Strategy (BEIS). The projects follow a BEIS-funded feasibility study in 2019 which found that a combination of 70% biomass, 20% hydrogen and 10% plasma energy could be used to eliminate fossil fuel CO₂ emissions from cement manufacturing.

The association has also welcomed the government's announcement of a Euro47m Red Diesel Replacement competition to help develop diesel alternatives as part of the Net Zero Innovation Portfolio. However, it renewed its call for a delay in the removal of the red diesel rebate, scheduled for April 2022, and estimated to cost the mineral products sector alone nearly Euro120m/yr.

Spain: Acciona and Enagás-led consortium Power to Green Hydrogen Mallorca has begun the construction of one of two planned solar power plants at Cemex España’s Lloseta plant in Majorca. The first, 13,500MWh/yr, plant will consist of 16,600 solar panels. A second, 10,800MWh/yr plant consisting of 12,700 panels will subsequently bring the total power capacity to 24,300MWh/yr. This is enough to produce 300t/yr of green hydrogen for the Lloseta cement plant’s operations.

The project to develop a ‘renewable hydrogen ecosystem’ in Majorca currently has Euro10.0m-worth of funding. The consortium has agreed with local to sheep farmers to allow the latter to use the solar power plant sites for grazing after construction is finished.

Germany: A consortium of Mexico-based Cemex subsidiary Cemex Deutschland, Uckerwerk Energietechnik subsidiary Enertrag and hydrogen specialist Sunfire has announced a cement industry decarbonisation project called Concrete Chemicals. The project will see sequestered CO₂ combined with hydrogen to produce hydrocarbons for use as cement fuel. The consortium has submitted a funding application to the German Ministry for Environment, Nature Conservation and Nuclear Safety for a trial at Cemex’s Rüdersdorf, Brandenburg, cement plant. This would help in the realisation of the plant’s 2030 carbon neutrality target. Alongside a 5000t/yr demonstration plant, the site will have a green hydrogen plant, supplied by Sunfire. When commissioned in 2025, the plant will produce synthetic fuels and other hydrocarbon fractions. The consortium is also investigating a methanol synthesis route using synthetic gas.

Europe, Middle East and Africa regional president Sergio Menendez said “We support the urgency of action to address the climate challenge and have committed to a 55% reduction in CO2 from our 1990 baseline in our European operations by 2030. Together with our industry partners, we can collectively transform ourselves into a CO₂-neutral world. Concrete Chemicals is a promising project.”

Italy: Taiwan-based Taiwan cement has agreed to acquire Engie’s 60% stake in battery and hydrogen power systems supplier Engie EPS. The aggregate value of the deal is Euro132m. The producer expects to close the deal in mid-late 2021, whereupon it will launch an all-cash mandatory tender offer for the company’s remaining shares. Taiwan Cement said that the transaction would provide the cornerstone for its strategic global blueprint in the future.

North America: UK-based Carbon Clean has signed a memorandum of understanding with US-based onsite hydrogen provider BayoTech. Under the agreement, the carbon capture and storage (CCS) specialist will install a CCS system at a BayoTech hydrogen plant in North America, which is expected to be operational by the end of 2022.

The two companies have agreed on a roadmap for the technology integration of a carbon capture process on their hydrogen generating units. The demonstration facility will include a BayoTech H2-1000 generating unit and Carbon Clean’s carbon capture technology. This partnership is intended to enable process optimisation to decrease the cost for small scale hydrogen and CO₂ production.

Carbon Clean was announced in April 2021 as the technology provider for a CO₂ capture demonstration project by Taiheiyo Cement in Japan. It is also working on projects with Cemex USA and LafargeHolcim España.

Spain: Cemex España reopened its Lloseta cement plant in Majorca in mid-April 2021. The unit will start by operating at a low production level until demand levels build, according to the El País newspaper. The plant intends to use alternative fuels such as biomass to reduce its CO₂ emissions. It is also working with the Power to Green Hydrogen Mallorca project to use ‘green’ hydrogen created partly using solar energy. The plant now employs 20 people, compared to 96 before its closure in January 2019.

Germany: Mexico-based Cemex subsidiary Cemex Zement has set up an innovation acceleration partnership called Carbon Neutral Alliance to support its work to achieve net zero CO₂ emissions at its Rüdersdorf cement plant by 2030. The association will work to develop industrial-scale demonstration projects in line with the company’s Future in Action programme. Its scope will include carbon capture and storage (CCS), the transformation of captured CO₂ into building materials, synthetic fuels and green hydrocarbons, hydrogen production and waste heat recovery (WHR). Cemex plans to share the knowledge gained by the alliance across its global cement network.

Managing director and Rüdersdorf plant manager Stefan Schmorleiz said, "It is expected that CO₂ will be further processed to convert to new forms of energy and materials for use locally by industrial, residential, and transport sectors. Together with our partners, we will take feasibility studies through to economic solutions to decarbonising cement production.”