Displaying items by tag: net zero

UK: Heidelberg Materials subsidiary Hanson has awarded a contract to Mitsubishi Heavy Industries subsidiary MHI Engineering for installation of a planned 800,000t/yr carbon capture system at its Padeswood cement plant in Flintshire. The producer plans to store its captured CO₂ in exhausted Irish Sea natural gas fields. MHI Engineering will carry out a pre-front-end engineering design study using its Advanced KM CDR solvent-based process. The supplier developed the process jointly with fellow Japan-based company Kansai Electric Power.

The project will be MHI Engineering's third of its kind at a cement plant, following similar commissions with Lehigh Cement in Canada and Tokuyama Cement in Canada.

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."

US: Mitsubishi Heavy Industries Engineering has launched a new carbon capture alliance with energy company ExxonMobil. Under the partnership, ExxonMobil will deploy Mitsubishi Heavy Industries Engineering's liquid amine carbon capture model for its customers across multiple industries. Kansai Electric Power (KEPCO) will also support the deployment in more CO2-intensive industries, including cement.

Mitsubishi Heavy Industries Engineering president and CEO Kenji Terasawa said “Carbon capture and storage technology and innovation are critical to our path to net zero. As an expert in advanced engineering, Mitsubishi Heavy Industries is committed to leading the way in achieving decarbonisation goals through strategic collaboration and investments in new technologies. We look forward to partnering with ExxonMobil to continue advancing carbon capture technologies, to provide essential carbon neutrality solutions for various industries.”

UK: C-Capture won an IChemE Global Award in the Energy category for its solvent-based carbon capture system. C-Capture's model differs fundamentally from currently commercially available systems, offering a lower energy penalty than technologies including amine-based capture. It is robust in handling impurities in flue gases, including O₂, SO_x and NO_x, while offering competitive cost and safety performance.

CEO Tom White said “Being shortlisted was honour enough, but to win the global Energy award is fantastic recognition for the C-Capture team and our unique carbon capture technology. The IChemE Global Awards represent the pinnacle of excellence in chemical process engineering. This achievement is testament to our exceptional team and their commitment to accelerating the global adoption of carbon capture and storage to achieve net zero by preventing greenhouse gases from entering the atmosphere.”

Singapore: Parliament passed the Carbon Pricing (Amendment) Bill earlier in November 2022. Under the act, Singapore will raise the price of carbon credits to US$18.17/t from 2024, and to US$32.71/t from 2026. CNA News has reported that the government said that the new legislation will provide the basis for the realisation of carbon credit prices of over US$36.31/t by 2030, in line with the country's 2050 net zero CO2 emissions commitment.

Polluters which emit over 25,000t/yr of CO₂ currently pay US$3.65/t for carbon credits.

Saudi Arabia: Yanbu Cement was among successful bidders in Saudi Arabia's largest carbon credit auction to date earlier in November 2022. The Saudi Public Investment Fund (PIF)’s Voluntary Carbon Market Initiative Auction sold 1.4Mt-worth of carbon credits to 15 different entities, of which Yanbu Cement was the only cement sector representative. The PIF said that the sale will support the country's Saudi Vision 2030 development goal, while also advancing its progress towards net zero CO₂ emissions by 2060.

Canada: The government and the Cement Association of Canada have published the ‘Roadmap to Net-Zero Carbon Concrete by 2050.’ The document details how cement and concrete producers and legislators could achieve net-zero CO₂ emissions from the cement and concrete sector by 2050. The joint government-industry working group next plans to release an action plan explaining how the sector will reduce its CO₂ emissions by up to 40% by 2030 and a plan for research and development required to meet the 2050 target. The country’s cement and concrete industry says it has committed to reducing over 15Mt of greenhouse gases cumulatively by 2030 and achieving net-zero by 2050.

“Decarbonising concrete is a necessity, and Canada’s cement and concrete industry has demonstrated that it is up to the task. This roadmap demonstrates our industry’s leadership in CO₂ emissions reduction and positions us to achieve our goal of net-zero cement by 2050,” said Marie Glenn, chair of the Cement Association of Canada. Association president and chief executive officer Adam Auer added, “While we are steadfast in our commitment to reduce our emissions by 15MT cumulatively by 2030 and reach true net-zero by 2050, we know we can’t do it alone. Together in collaboration with government we will continue to support the innovation and investment needed on our path to delivering net-zero concrete, while at the same time preserving its properties as a durable, resilient, versatile, and cost-effective material.”

Readers may have noticed the 2022 United Nations Climate Change Conference (COP27) is currently taking place at Sharm El Sheikh in Egypt. Many of the cement companies, suppliers and related associations are present at the annual jamboree and getting stuck in. For example, Holcim’s chief sustainability officer Magali Anderson was scheduled on 8 November 2022 to discuss solutions to decarbonise the built environment at the event’s Building Pavilion, Cemex’s chief executive officer Fernando A González took part in the First Movers Coalition (FMC) panel, FLSmidth is down for a number of talks and both the Global Cement and Concrete Association (GCCA) and World Cement Association are busy too.

Stone cold progress, if any, from the conference is yet to emerge although there is still time given that the event runs until 18 November 2022. No doubt some sort of ‘big message’ style international commitment or plan will emerge from the haggling. However, on the cement sector side, the biggest story so far has been the FMC plan for some of its members to procure at least 10% near-zero cement and concrete for its projects by 2030. Both Holcim and Cemex were founding members of the collation of companies that intend to use their purchasing power to support sustainable technologies in hard to abate sectors. Commitments for the aviation, shipping, steel and trucking sectors were set at COP26 in Glasgow, aluminium and CO₂ removal followed in May 2022 and chemicals and concrete were scheduled for November 2022. The latter has started to happen with the formation of the FMC’s cement and concrete group. Companies involved include ETEX, General Motors, Ørsted, RMZ Corporation and Vattenfall. Of these, Sweden-based energy producer Vattenfall has publicly said it is going for the 10% near-zero cement and concrete target by 2030.

Table 1: Net CO₂ emission intensity (kgCO2/t) for cement production at selected large cement producers.

While we wait for more announcements to escape from Sharm El Sheikh it might be worth reflecting upon one of the targets some of the cement companies have set themselves for 2030. Table 1 above compares the net CO₂ emission intensity for cement production at some of the large cement producers. It doesn’t tell us much, other than that the CO₂ emission intensity for these companies was in the region of 550 - 600kgCO₂/t of cementitious material in 2021. This compares to 580kgCO₂/t in 2020 for the GCCA’s Getting the Numbers Right (GNR) data for the companies it covers. The companies featured in Table 1 are all aiming – or appear to be aiming – for 475 - 525kgCO₂/t by 2030. This may not sound like much but it has and will require hard work, innovation, investment and risk on the part of the cement producers. This is also before carbon capture, utilisation and/or storage (CCUS) units will have been built at most cement plants. Yes, until the CO₂ emission intensity goes to down to zero, if cement production volumes keep rising sufficiently then total gross CO₂ emissions from the cement industry will also increase. Yet, gross CO₂ emissions from cement production are likely to peak sometime between now and 2030 if they haven’t already.

One sobering fact to end with is that 1990 is now further in the past than 2050 is in the future. If you can remember George Bush Sr as US president or you saw the film Goodfellas at the cinema then that’s the amount of time we have left to reach net zero. The global economic shocks of the post-coronavirus period and the war in Ukraine are stressing the world’s climate targets more than ever before. Let’s see how COP27 reacts to this. So far though, serious commitments to using low-carbon cement and concrete from big companies are a useful step to entrenching these products in the market.

Egypt: Cemex’s chief executive officer (CEO) Fernando A González was part of the First Movers Coalition panel at the 2022 United Nations Climate Change Conference (COP27) in Sharm El Sheikh on 8 November 2022. He participated alongside the World Economic Forum’s president Borge Brende, Microsoft president Brad Smith, ReNew chair and managing director Sumant Sinha, Volvo Group chief purchasing officer Andrea Fuder and US Special Climate Envoy John Kerry.

Cemex is a founding member of the First Movers Coalition, a partnership between the World Economic Forum and the US Office of the Special Presidential Envoy for Climate, John Kerry. It is the only buyers’ club working to scale new technologies across the heavy industry and heavy-duty transport sectors.

As a First Movers Coalition member, Cemex committed to making 32% of its heavy-duty transport purchases zero emissions by 2030. This commitment aligns with the company’s ambitious goals of reducing transport carbon emissions by 30% by 2030 and becoming net zero by 2050, part of its Future in Action program to achieve sustainable excellence and become a net zero CO₂ company.

This commitment is particularly challenging, as zero-emission heavy-duty transport is presently unavailable at scale. At the panel, Fernando A Gonzalez talked about how collaboration and innovation are at the core of his company’s efforts. Cemex is already piloting fully electric concrete mixer trucks with partners like Volvo. It is also investing in transition technologies such as natural gas, replacing 200 diesel trucks with this lower-emission alternative in 2022.

Cemex will a host a discussion panel called Working Together to Decarbonise the Construction Value Chain, to be moderated by Thomas Guillot, chief executive of the Global Cement and Concrete Association (GCCA), on 10 November 2022. The panelists will include Diane Hoskins (Gensler Co), Aniruddha Sharma (Carbon Clean), Hubertus Meinecke (BCG) and Adair Turner (Energy Transitions Commission), in addition to Cemex’s Fernando A González.

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