Displaying items by tag: US

US: Holcim US has inaugurated a waste tyre processing plant at its Alpena cement plant in Michigan. The facility will process 22,000t/yr of tyres into refuse-derived fuel (RDF) for use at the cement plant. Holcim US partner Geocycle will collect, pre-process and deliver the tyres to the new facility.

Holcim US’ North regional senior vice president of manufacturing Michael Nixon said "Holcim has invested more than US$100m in eco-friendly technologies at the Alpena plant in the past 15 years. The tyre-derived fuel facility is another strong demonstration of our commitment to reducing emissions."

US: Continental Cement has ordered a Fuelflex Pyrolyzer alternative fuels combustion system from Denmark-based FLSmidth for installation at its Davenport plant in Buffalo, Iowa. The supplier says that its product offers a lower capital expenditure compared to competing systems, can control NOx emissions without the need for ammonia water and can be installed without a long shutdown period. This is the first commercial installation of the Fuelflex Pyrolyzer system following a pre-commercial installation at the Mannok cement plant in Northern Ireland, UK, in 2022.

David Loomes, the president of Continental Cement, said “We’re very excited about what the Fuelflex Pyrolyzer will do for our process.” He added, “We’re planning to achieve 55% fossil fuel replacement across the plant, utilising non-hazardous waste that would otherwise go to landfill or incinerators. The economic and environmental benefits of this technology are very significant and a key element of executing our carbon reduction commitment.” Continental Cement, a subsidiary of Summit Materials, has been incorporating waste materials as fuels for more than 30 years.

Jens Jonas Skov Larsen, Head of Capital Sales at FLSmidth, said “Mannok has called the Fuelflex Pyrolyzer a game-changer for the cement industry.” He continued, “This system effectively rearranges the order of the combustion process to make use of hot preheater meal, which is the heat source for the waste fuel pyrolysis. It’s a more efficient way of burning alternative fuels and it comes with a host of benefits, including reduced emissions and a more stable process.”

The installation at Davenport cement plant is expected to start operation in 2024. The full commercial launch for the system is scheduled by 2025. No value for the order has been disclosed.

US: Heidelberg Materials subsidiary Mason City Cement plans to invest US$4 - 5m in upgrades to its kiln line by 2026. Upon completion, the work will enable the plant to achieve an alternative fuel (AF) substitution rate of 50%.

Heidelberg Materials' North America regional vice president of government affairs and communications David Perkins said "We want to be proactive as a company and really try to lower our carbon footprint and energy intensity, while recognising we have to be competitive." He added "We're a long-term industry on the cement side because of the investment that's required to produce it."

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."

US: Vicat subsidiary National Cement Company of Alabama inaugurated its new US$300m production line at its Ragland cement plant on 21 July 2022. Local press has reported that the line includes a new rotary kiln, equipped for alternative fuel (AF) use.

President Spencer Weitman said “This puts us into the next 40 or 50 years. And it’s prolonged the life of the plant to move us forward into the next entry hopefully.”

US: Cemex USA plans to increase its rate of alternative fuel (AF) substitution at its 2.2Mt/yr Brooksville, Florida, cement plant to 30%. It will also increase its AF use at its 1Mt/yr Demopolis, Alabama, cement plant. At both plants, the new fuel mix will include biomass. The producer says that it will complete the plants’ transitions before 2023.

US: The Department of Environmental Conservation (DEC) of New York state has turned down Lafarge Cement’s application for a licence to burn tyres as an alternative fuel (AF) at its Ravena cement plant. The Times Union newspaper has reported the DEC found that the plant in Albany county was inadequately equipped to burn tyres under the permit for which the company had applied.

Spokesperson Jocelyn Gerst said “We received the DEC’s correspondence and are reviewing it. We will be weighing all available options.”

US: Veolia North America (VNA) has signed a contract for the supply of used blades from onshore wind turbines from GE Renewables. The waste management company will process the blades to produce shredded composite materials for use in cement production, both as replacement for war materials such as sand and clay and as an alternative fuel. As a part of the agreement, blades that have been removed from turbines will be shredded at VNA’s processing facility in Missouri and then used in cement plants across the US. On average, nearly 90% of the blade material, by weight, will be reused as a repurposed engineered material for cement production.

Environmental solutions and services chief operating officer (COO) Bob Cappadona said, "By adding wind turbine blades — which are primarily made of fibreglass — to replace raw materials for cement manufacturing, we are reducing the amount of coal, sand and minerals that are needed to produce the cement.” GE Renewables and sustainability consultant Quantis said that the use of turbine blades in cement production would reduce net CO₂ emissions by up to 27% and water consumption by up to 13%.

US: Geocycle has planted its first crop of perennial native grasses at its Dorchester, South Carolina site. The supplier says that it is trialling the crop as an alternative fuel and future biofuel for the US Southeast region. It sowed giant reed, miscane, miscanthus and switchgrass, which it praised for their ‘low establishment and upkeep costs’ and demonstrated yields of between 12t/acre and 20t/acre.

The company said, “The team is committed to actively participating in the communities’ and state’s bioenergy projects, which aim at developing the circular economy and help achieve net zero future.”

US: The Portland Cement Association (PCA) has named Beumer Group winner of its Chairman’s Manufacturing Performance Award 2020. The award is for economical and sustainable operations. It acknowledges Beumer Group’s alternative fuels and raw materials (AFR) systems business unit’s achievements in supporting cement producers with complete systems to supply calciners and main burners with alternative fuels and raw materials, the main component of which is the pipe conveyor. "I am very honoured to receive this recognition on behalf of Beumer Group,” said Brian Giese, Beumer Corporation Director of Business Development, Conveying & Loading. "It demonstrates our commitment to support cement manufacturers in their efforts to make production greener and more sustainable."

Business development, conveying and loading director Brian Giese said, "I am very honoured to receive this recognition on behalf of Beumer Group. It demonstrates our commitment to support cement manufacturers in their efforts to make production greener and more sustainable."