Displaying items by tag: Substitution rate

UK: Mexico-based Cemex has inaugurated the Climafuel unit at Rugby cement plant. Climafuel is a waste derived fuel which is made using domestic and commercial waste. The upgrade is intended to allow the cement plant to operate at a 100% alternative fuels (AF) substitution rate. This is the first Cemex plant to be able to do this.

Sergio Menéndez, the President of Cemex Europe, Middle East, Africa & Asia, said, “With the completion of this considerable development, we have set new records in alternative fuel substitution, the highest of any of our plants and eventually expect to phase out completely the usage of fossil fuels at the plant. We expect the Rugby plant to be a model for other Cemex cement plants around the world.”

India: UltraTech Cement’s integrated Reddipalayam plant in Tamil Nadu has reached a 25% alternative fuels substitution rate. The unit sources municipal waste from 11 local municipal corporations including Ariyalur, Erode, Kumbakonam, Thanjavur, Perambalur and Karur. It also sources plastic waste from cities such as Chennai and Kozikhode. In the financial year to 31 March 2020, UltraTech Cement says it replaced 17.2% of its raw material requirement for cement manufacturing and 3.7% of its thermal energy needs with alternative resources across all operations.

Philippines: Holcim Philippines, part of Switzerland-based LafargeHolcim, substituted 100,000t of refuse-derived fuel in its cement plants’ fuel mix in 2020. The Business World newspaper has reported that the figure represents a 41% year-on-year decrease from 170,000t in 2019. That year, the producer recorded 38 days of zero coal use. The company said that the reason for the decline was supply chain disruptions due to the coronavirus pandemic.

Indonesia: The La Tofi School of Corporate Social Responsibility (CSR) has named Semen Indonesia as the winner in three categories at the Nusantara CSR Awards 2020, including Community Involvement in Handling Waste. Indonesia Government News has reported that the award acknowledges the company’s uptake of practices and technologies to increase the alternative fuel (AF) substitution rate. It partnered with Jakarta Province Environment Agency (DLH) and Unilever Indonesia to co-process domestic waste from the Bantargebang waste disposal site as fuel for cement plants.

UK: Helvellyn Group, a manufacturer of high energy, low impact solid fuels, has announced the official launch of its cement industry direct coal replacement product in Europe.

Helvellyn has chosen the Global Cemfuels Conference (Paphos, Cyprus 19 - 20 February 2020) as the location for the launch and will be sponsoring the event as well as attending in person.

Helvellyn solid fuels are designed to meet the needs of hard to adapt large industrial plants that are seeking to reduce, or even eliminate, their reliance on coal. The fuels are manufactured to replicate the physical and combustion properties of coal, while reducing the greenhouse gas emissions associated with mining, transporting and burning fossil fuels.

This latest renewable coal replacement fuel has been developed to address the specific needs of cement producers, many of whom have already introduced alternative fuels but are now struggling to increase the ratio due to physical, chemical and technical constraints.

Helvellyn’s product allows operators to maintain their existing alternative fuel mix while, in most instances, adding Helvellyn fuel as a direct drop-in replacement for coal from the point of delivery through pre-combustion processing and in combustion.

The Helvellyn fuel for cement production is based on four core principals, high energy, low moisture, low chlorine and ease of handling. While exact fuel specification and presentation can be fine-tuned to meet the specific needs of a given plant, fuel is typically presented as 50mm hard, hydrophobic lumps with the following properties: energy >25kJ/kg (10,750btu/lb, 5.97kcal/kg); ash content <6%; moisture <2%; chlorine <0.07%; carbon >60%; sulphur <0.2%; nitrogen <0.4%.

Frank Harris, CEO of Helvellyn Group, said, “We are delighted to be launching this important product at the Global Cemfuels Conference 2020. The cement industry has shown innovation and leadership in utilising alternative fuels and we believe we can help them to meet the challenges of the next decade as they further reduce the environmental impact of their product. We are excited to meet with the industry and let it see our fuel for the very first time - it is like nothing they will have seen before.”

Namibia: Ohorongo Cement’s plant at Walvis Bay has had an alternative fuels substitution rate of 40% for the last six months of 2018. Local recycling company Rent-A-Drum said that it has been supplying waste fuels to the plant, according to the Namibia Economist newspaper. As well as fuels from domestic waste the plant is using wood chips and charcoal dust in its kiln.

Spain: Local environment authorities have approved Cementos Cosmos to increases its alternative fuels substitution rate to up to 45% from its current limit of 30%. The plant has been supplementing its petcoke use with refuse-derived fuel (RDF) and biomass, according to the Córdoba newspaper. The plant, and its owners Brazil’s Votorantim Cement, have faced local opposition to changing its fuels mix.

Slovenia: Salonit Anhovo has won a bronze European Bank for Reconstruction and Development (EBRD) Sustainable Energy Award for progress in the use of non-hazardous solid recovered waste in its energy mix. The cement producer is increasing its alternative fuels substitution rate to over 75% from 60%. This will allow its plant to achieve a carbon emission intensity factor of 0.737kg CO₂/kg clinker, which is below the relevant European Union (EU) benchmark.

The EBRB also said that Salonit Anhovo presently operates at levels expected for the industry for 2025 in terms of specific heat consumption and for 2030 in terms of clinker ratio in cement and specific CO₂ emissions. The bank supported the company with a Euro15m loan in December 2016.

“We are very pleased to recognise Salonit Anhovo’s foray into alternative fuels with this award. This is an excellent example of how an innovative, tailor-made solution can benefit both finances and the environment. This investment will bring significant cost savings, contribute to the operational restructuring and support the resource efficiency of Salonit Anhovo by increasing the use of alternative fuel in the energy mix,” said EBRD director Dariusz Prasek.

France: LafargeHolcim has launched a Euro100m upgrade to build a new clinker production line at its Martres cement plant in Tolosane. Construction work on the new line will start in the third quarter of 2018 and will be completed in mid-2020. A key feature of the upgrade will be a focus on using alternative fuels in the new kiln, particularly tyres. Following the project’s completion the plant will have a substitution rate of 80% from 30% at present.

Nigeria: Lafarge Africa has reported a record alternative fuels substitution rate of up to 46% at its Ewekoro cement plant. The cement producer reported that its energy optimisation strategy achieved strong performance compensating for gas shortages at a relatively low cost. It added that made progress during the first quarter of 2017 towards initial alternative fuels conversion work at its Mfamosing line II at Ashaka Cement.