Displaying items by tag: methanol

China: NovaAlgoma Cement Carriers (NACC) has placed another order for a HeatPower 300 waste heat recovery system from Climeon on a second cement carrier, to be built at Zhejiang Xinle Shipbuilding Co. and delivered in 2027.

The 38,000t vessel will run exclusively on green methanol and is expected to cut CO₂ emissions by over 60% compared to conventional vessels, reportedly avoiding around 180,000t of CO₂ emissions over 10 years. The HeatPower 300 will generate up to 300kW of carbon-free electricity from engine cooling water and exhaust gases.

China: NovaAlgoma Cement Carriers has confirmed an order for a 38,000t methanol dual-fuel pneumatic cement carrier by Zhejiang Xinle Shipbuilding, for delivery in 2027.

The vessel will be chartered under a long-term contract by Holcim. Other features include an air lubricating system and a waste heat recovery system, which will recycle exhaust gases to generate electricity.

“By increasing the quantity intake and burning green methanol, the CO₂ emissions on these shipments will be reduced by more than 60% per year in comparison to current freight flows, ie 0.18Mt of CO₂ reduction over a period of 10 years,” NovaAlgoma said.

Finland: Finland-based technology company Wärtsilä will supply a complete propulsion package for the new methanol dual-fuel cement carrier from NovaAlgoma Cement Carriers. The ship is under construction at Zhejiang Xinle Shipbuilding in China and is expected to launch in late 2026. The contract includes two Wärtsilä 32 engines, one Wärtsilä 25 auxiliary engine, two gearboxes, two controllable pitch propellers, one tunnel thruster, three selective catalytic reduction systems, the propulsion control system, two shaft generators and engine accessory items, with deliveries starting in November 2025.

Sweden-based Climeon recently won an order to install its organic rankine cycle waste heat recovery technology, HeatPower 300, on the vessel.

Australia: Calix has been awarded a US$10m grant from the Australian government’s Carbon Capture Technologies Program to build a commercial demonstration electric calciner for ‘near zero emissions’ lime and cement production. The grant covers up to 50% of the expenditure, contingent on meeting project milestones.

The project will utilise the Leilac technology to capture up to 20,000t/yr of CO₂ from the cement and lime manufacturing processes. The project will create two revenue streams via a ‘near zero emissions’ lime product, as well as up to 15,000t/yr of captured CO₂ being sold to the SM1 project for green methanol production.

In the second phase of the project, production will be expanded to include the processing of cement raw meal to a ‘near zero emissions’ clinker product, with captured CO₂ supplied for use.

Italy: NovaAlgoma, a joint venture between the Italian-Swiss Nova Marine Carriers and Canada's Algoma Central Corporation, has announced the construction of the ‘world’s largest and greenest’ cement carrier, weighing 38,000t. This vessel will be built by Xinle Shipbuilding in China and delivered by the end of 2026. It will reportedly be the first to use both traditional fuel and methanol and can connect to electrical grids in ports to eliminate emissions, according to local news reports. Additionally, it will feature a waste heat recovery system that converts exhaust gases into 250kW of electrical energy.

Vincenzo Romeo, CEO of Nova Marine, said "This new construction, which meets the forecasts for the development of our fleet and the growth of cement market demand in the coming years, is intended to consolidate our positioning among the global leaders in cement transportation.”

Spain: Cemex España will install a carbon capture system at its Alicante cement plant in Valencia, as part of its efforts to make the unit a 'benchmark pioneer low-CO₂' cement plant. The producer holds a contract with ET Fuels for the supply of 45,000t/yr of CO₂ captured at the facility for methanol production.

Chief executive officer Fernando González said “Our goal of reaching net-zero CO₂ emissions is achievable and will be driven by collaboration and innovation. Our decarbonisation roadmap includes reducing emissions to the lowest possible level through proven levers such as clinker substitution and alternative fuels. New levers, such as rapidly developing CCUS initiatives, must effectively tackle the remaining CO₂ emissions to hit our ambitious 2050 objectives.”

Finland: Finnsementti and energy provider St1 have selected Norway-based Aker Carbon Capture to carry out a pre-engineering study for a planned carbon capture system at the cement producer's Lappeenranta cement plant in South Karelia. Dow Jones Institutional News has reported that Aker Carbon Capture offers a 40,000t/yr carbon capture system, capable of producing 25,000t/yr of methanol for use as transport fuel. The project is scheduled to deliver commercial synthetic methanol by 2026.

The Lappeenranta cement plant carbon capture project recently received Euro35.4m in additional funding from the Finnish government, subject to European Commission approval.

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

Australia: Cement Australia’s Gladstone cement plant in Queensland will host a study of methanol production from green hydrogen and captured CO₂. Japan-based Mitsubishi Gas Chemical Company will supply its green methanol production technology, while hydrogen and oxygen feedstocks will be sourced locally. Cement Australia and Mitsubishi Gas Chemical Company will collaborate on commercialisation of their green methanol. Cement Australia said that carbon capture and its utilisation in value added products is a strategic pillar of the company’s decarbonisation roadmap.

The cement producer 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. The green hydrogen economy is a priority for the Queensland government under the Queensland Hydrogen Industry Strategy.”

Finland: Energy provider St1 plans to establish a 25,000t/yr renewably powered synthetic methanol plant at Finnsementti's Lappeenranta cement plant in South Karelia. St1 hopes to develop a replicable and scalable synthetic methanol production concept at the site. When commissioned in 2026, the installation will create 20 jobs and produce synthetic methanol for use in maritime and road transport. The Finnish Ministry of Economic Affairs and Employment has granted Euro35.4m-worth of funding to the project.