Canada: Lafarge Canada, University of Calgary, Queen’s University, and Pembina Institute have started a study on the environmental benefits of introducing lower carbon fuels at the Exshaw Cement Plant in Alberta. Eight lower carbon fuels will be researched, including construction renovation and demolition waste, non-recyclable plastic, carpets and textiles, shingles, treated wood products, wood products, rubber and tyre-derived fuels. These sources of fuel have been successfully used at other LafargeHolcim cement plants in Canada.

“Lab simulations, environmental studies, economics and logistics reviews are already underway. All research will be finalised by December 2019 with regular updates provided to the neighbouring communities via a Public Advisory Committee,” said Jim Bachmann, the plant manager of Exshaw .

Additional research by the partners will measure the environmental components associated with the sourcing, processing and full-scale commercial operation of each lower carbon fuel compared to fossil fuels. The project will also measure the benefits of diverting materials from landfills and determine optimal points in the cement manufacturing process to inject each fuel.

In addition to Lafarge’s support, research funding is being provided by Alberta Innovates, Ontario Centres of Excellence, Emissions Reduction Alberta and the Natural Sciences and Engineering Research Council of Canada. It includes research by Millennium EMS Solutions Ltd., Geocycle, and WSP Global Inc.

As part of its 2030 Sustainability Plan, LafargeHolcim aims to replace 30 - 50% of fossil fuel use at its Canadian cement plants with lower carbon fuels by 2020.

Austria: Rohrdorfer Group has awarded an engineering, procurement and construction (EPC) contract to Humboldt Wedag, a subsidiary of KHD, for the modernisation of the kiln line at its cement plant operations in Gmunden. The upgrade will enable the flexible usage of a wide range of waste fractionally pre-treated derived fuels on a high substitution rate.

The modernisation project comprises the design and supply of KHD’s world´s first ever Pyrorotor Cacliner Technology, as well as the replacement of the existing satellite cooler with a new generation Pyrofloor PFC2 clinker cooler. The existing three station rotary kiln will be fitted with a new kiln drive and a new kiln hood as well as kiln inlet and outlet.

With the installation of the new Pyrorotor Cacliner Technology from KHD the Gmunden plant will be able to burn very coarse waste derived fuels including whole rubber tires, which will lead to drastically reduced requirements in regard to waste pre-treatment. Therefore, the kiln modification will also emphasise on pollutant emission reduction.

The contract includes: three new preheater cyclones; a new preheater ID-fan; a tertiary air duct; a Pyrotop compact calciner mixing chamber; Pyrorotor Calciner burning chamber technology, a Pyroclon Calciner Burning System; a new kiln bypass unit; a multi-fuel Pyro-Jet kiln burner for primary and secondary fuels; a new kiln drive and kiln hood; a Pyrofloor PFC2 clinker cooler equipped with a Pyrocrusher roller type clinker crusher; and Simulex plant simulation software.

KHD services include the dismantling of existing equipment parts as well as the engineering, design, supply and erection of new equipment including commissioning services. Commissioning of the new system is scheduled for April 2019.

Poland: LafargeHolcim has spent Euro36m on upgrades to alternative fuels handling at its Kujawy cement plant. The investment includes preparing the kiln for the use of alternative fuels, building a new terminal, setting up a new automated laboratory and building a hall for storing and processing alternative fuels. The project is intended to adjust the plant’s kiln for processing alternative fuels and securing new alternative fuel sources. The cement producer aims to control the alternative fuels supply chain for its plant from source to kiln.

South Africa: PPC plans to expand its alternative fuel programme as part of a cost saving drive. The producer plans to start using refuse derived fuel (RDF) at its De Hoek cement plant in the Western Cape, according to the Pretoria News newspaper. This will follow the current use of tyres as a fuel at the unit. RDF will be sourced from Cape Town, Drakenstein and Swartland. Savings are expected to be realised from the change in fuel mix by mid-2019.

PPC added that it didn’t expect any disruption to its supply of waste tyres at De Hoek caused from the shutdown of the government’s Recycling and Economic Development Initiative of South Africa (REDISA). Chief executive officer (CEO) Johan Claassen said that the company had anticipated the closure and built up supplies of tyres at the plant and at a site at Vissershok.