Displaying items by tag: Emissions

Egypt: Heidelberg Materials subsidiary Suez Cement has invested US$16m in upgrading its operations towards increased alternative fuel (AF) use since 2010. The producer uses AF in the burners and kilns of all three of its cement plants, at Helwan, Kattameya and Suez. Meanwhile, Suez Cement has invested US$60m in dust control measures over the same period. Other on-going investments include US$25m in the construction of a waste heat recovery (WHR) plant at the Helwan cement plant. The company is committed to reaching a 24% reduction in its CO₂ emissions between 2019 and 2030.

Technical director Omar Khorshid said “We are committed to pursue initiatives to broaden our range of innovative and eco-friendly building solutions, advance operational efficiency through digitalisation and strengthen customer engagement for better business results and more positive impact."

Nigeria: Dangote Cement plans to upgrade its Ibese cement plant in order to use biofuels in its cement production. The Nigerian Guardian newspaper has reported that the plant will receive a pneumatic feeding system for the kiln of its Line 2. Dangote Cement plans to use palm kernel shells, rice husks, coconut shells and sugarcane bagasse, along with sawdust. The producer says that this will reduce its CO₂ emissions by 5.2% and help to divert local agricultural waste from incineration.

Project head Sumaila Muhammed said “We carried out alternative fuel resource mapping within our host communities. We decided to collect these wastes and convert them into valuable energy resources as smokeless, renewable biofuel."

Mexico: Cemex Mexico plans to install hydrogen injection systems at four cement plants across Mexico. The producer will use the technology to increase alternative fuel (AF) substitution at the plants by 8 - 10%. A 40% reduction in Scope 3 purchased fuel emissions forms part of Cemex's 2020 -2030 CO₂ emissions reduction strategy. Through the decarbonisation and circular economy pillars of its Future in Action plan, the group aims to become carbon neutral by 2050.

Cemex Mexico president Ricardo Naya said "Hydrogen is a key technology to accelerate the implementation of our climate action roadmap."

The El Financiero newspaper has reported that Cemex set a new group record AF substitution rate of 34% in September 2022. It uses hydrogen at all of its European cement plants and at one plant in the Dominican Republic.

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 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."

US: National Cement Company of Alabama has reported that the new kiln line at its Ragland cement plant will reduce the plant’s CO₂ emissions by 40%. Its energy consumption will also fall by 30% as a result of the upgrade. The new line includes a 78m-high homogenisation silo, vertical crusher, five-stage preheater and automated clay storage system. AF used in the kiln will include waste tyres, woodchip and sawdust. The new kiln will help in the Ragland cement plant’s transition to 100% Portland limestone cement (PLC) production by 2023, further diminishing its carbon footprint.

Vicat CEO Guy Sidos said "Our ambition is to use AF in all our cement plants around the world. In addition to eliminating fossil fuel energy and replacing it with recycled regional waste, our investments contribute directly to local development. We are proud of the modernisation and transformation of our Ragland site, which was our very first acquisition outside France in 1974."

Mexico: Cemex reported 29% alternative fuel (AF) substitution in its global operations in 2021, according to its Integrated Report for the year. The report stated that the group reduced its CO₂ emissions per tonne of cementitious material by 4.7% year-on-year.

Taiwan: Taiwan Cement has commenced the construction of a US$143m waste processing plant and ecopark at its 1.6Mt/yr Hualien cement plant. Japan-based Kawasaki Heavy Industries provided the design for the facility and visitor attraction. When commissioned, the plant will supply the Hualien cement plant with 200t/day of refuse-derived fuel (RDF) produced from municipal solid waste from Hualien. Taiwan Cement estimates that the move will eliminate 40,000t/yr of CO₂ emissions from the plant’s operations.

Russia: Holcim Russia has committed to realising a 15% CO₂ emissions reduction in its cement production between 2019 and 2030 to 475kg/t from 561kg/t. It plans to further reduce its cement’s CO2 emissions to 453kg/t by 2050, and to implement further measures to ensure its net carbon neutrality at that time.

Corporate relations director Vitaly Bogachenko said “The company's goal is to drastically reduce carbon emissions, and there are two working solutions for this. The first is the use of alternative fuels (AF) obtained from different types of waste: residues of municipal solid waste after sorting and extraction of all useful fractions from them, used tyres and others. The presence of biomass in them makes such fuels carbon neutral, so emissions during production are significantly reduced. The second solution is to replace carbon-intensive raw materials. For example, instead of limestone, we use slags. The recipe for the cement is completely different - thanks to the new composition and the lower temperature during the firing process, the carbon footprint in the production of cement is reduced.”

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.”

Hungary: Italy-based Entsorga has completed the installation of an automated alternative fuel (AF) line at a Hungarian cement plant. The plant is believed to be Nostra Cement’s 1.0Mt/yr integrated Kiralyegyháza cement plant, which in early 2020 received an AF fuel store expansion aimed at bringing AF substitution rates to 80% from 60%. The upgrade consists of an Entsorga Spider crane and Pelican power system which will be able to maintain a continuous feed to the plant’s calcination system 24 hours a day.

Entsorga CEO Francesco Galanzino said, “Bringing a commission to a successful conclusion in the middle of the maximum intensity period of the coronavirus crisis has been a great satisfaction. The cement plant will make significant savings in CO₂ emissions.”