BridgeGap Engineering Blog » Lafarge

Lafarge Faces Resistance in Environmental Push in Tulsa

Lehigh Ben — Mon, 01 Aug 2011 19:45:52 +0000

A Lafarge plant near Tulsa, Oklahoma, is facing last minute resistance to the planned installation of a fuel quality waste (FQW) storage system. Tulsa city Councilman Roscoe Turner and environmental group LEAD (Local Environmental Action Demanded) have begun openly opposing the plant’s efforts.

Lafarge desires to install a series of tanks to utilize forty-eight million gallons of FQW per year. The FQW is industrial waste such as paint solvents that the company will gather and burn in its kiln to supplement and eventually eliminate the plant’s dependence on coal for a fuel source. In response to the outcry, plant manager Jim Bachmann said, “These are common household materials that you probably have under your sink or in your garage right now. There are trucks coming through Tulsa with it every day…This is nothing new and nothing dangerous. We know how to handle it.” Lafarge is promoting the move as a win-win for the company and for the environment. It eliminates fossil fuel consumption while offering a viable alternate solution to landfilling for industrial waste. However, LEAD has a serious issue with this new system.

LEAD claims that burning the FQW will increase plant emissions. They predict an increase of particulate matter emissions from 19.3 to 400 tons per year and hazardous air pollutants to increase from 16 to hundreds of tons per year. LEAD’s other main concern centers around how the plant will receive the FQW. They predict that approximately 30 tractor trailers will be traveling to the plant through Tulsa’s highways every day. They are concerned for the potential for accident and exposure to hazardous waste that the area surrounding the plant will incur. Hatley said, “Within a mile or two of this plant, you can find schools, parks, churches. This is not a remote location.”

LEAD’s petition for a hearing to the Oklahoma Department of Environmental Quality could mean the end of the Lafarge project. A hearing could lead to the revoking of Lafarge’s permits which allow them to install the system. If not revoked, Lafarge plans to begin operating the system within months.

Lafarge Sets New CO2 Emission Goals

Lehigh Ben — Thu, 30 Jun 2011 00:56:21 +0000

Cement industry giant Lafarge announced on Thursday a set of new goals in order to continue its agenda of reducing CO₂ emissions. The goals are divided into two main areas: straight emissions reductions and a sustainable construction development.

In developing the first goal category, Lafarge worked within a framework developed in cooperation with the World Wildlife Fund International (WWF). As such, Lafarge has announced its intention of reducing its CO₂ emissions by 33% by 2020 as compared to 1990 values. This comes on the heels of its success in reducing values by 20% by 2010. Not only did Lafarge meet this goal, but it was accomplished a year ahead of schedule and reductions totaled 21.7% at the close of 2010.

The second part of their goals will not help Lafarge comply with any regulations or standards, but is still vitally important to continued environmental improvement which Lafarge recognizes. Lafarge estimates that buildings account for 40% of global energy use. Lafarge hopes to mitigate this problem by launching at least ten new innovative construction products by 2015 along with contributing to five hundred energy-efficient construction projects globally.

Commenting on their recently set goals, Lafarge CEO Bruno Lafant said, “Lafarge has made the reduction of its CO₂ emissions a major objective, and has met its commitments. I am pleased with our partnership with WWF, which helps us to progress even faster. It is no longer a matter of just reducing the CO₂ emitted in the production of our materials, but also of developing construction solutions for buildings that consume less energy.”

Residents in Jordan Oppose Alternative Fuel Proposal

Lehigh Ben — Sat, 11 Jun 2011 14:42:54 +0000

Residents of the Jordanian town of Qadisiyah are actively demonstrating against the Rashadiyeh cement factory, an affiliate of Lafarge, which plans to burn tires and oil shale to supplement its fossil fuel program.

The villagers are concerned over the potential health and environmental concerns that the new fuel will pose. After demonstrating for an hour or so, the residents dispersed; leaving a committee behind to negotiate with the company’s representatives. The demands the committee brought to the company’s attention: reconsider the use of tires as a fuel source and add a health clinic to deal with respiratory illnesses from company work whose medical benefits had been denied.

The Rashadiyeh company heard the requests of the community, but it will remain to see the course of action it will take. The Cement Plant has already installed $20 million filters in order to reduce particulate emissions from the plant.

Mixed Feeling in the UK Over Alternative Fuels

Lehigh Ben — Thu, 14 Apr 2011 00:05:47 +0000

South Ferriby, North Lincolnshire, United Kingdom, was put on the radar of the cement industry as Cemex’s plant achieved production over a three day period using nothing but alternative fuels to fire the kilns. The fuel, known as Climafuel, is gathered locally from residential and commercial waste that would otherwise be sent to a landfill. In addition to the Climafuel, Cemex burns secondary liquid fuels (SLFs) that are made from industrial waste liquids such as paints, inks, and varnishes. The South Ferriby plant is believed to have set a new record in the UK in a country where 35% of all burned fuels are non-fossil fuel based; a notable achievement. Plant manager Philip Baynes-Clarke said, “I am immensely proud that this record has been set using a kiln that was commissioned in 1973. It proves that with the right team, skills and capital investment, plants like ours in South Ferriby can have a long and healthy shelf life…The use of alternative fuels at South Ferriby is key to improving the environmental performance of cement making…Our 100% record was set over a three day period in March, with the kiln remaining stable and producing good-quality cement clinker. The challenge is now to exceed our 90% weekly average record and use 100% over a more sustained period.”

Over the past year, the South Ferriby plant has burned more than thirty-six thousand tonnes of waste that would have ended up in a landfill. The reduction in emissions from this recycled waste is the equivalent of the emissions of eleven thousand automobiles.

However, not all plants in the UK are experiencing such success and acceptance with their local communities. Lafarge’s Aberthaw Works plant located in Southern Wales is finding environmental activists and local residents fighting its proposed plan to burn old tires and plastic in its kilns. Lafarge’s plan to utilize solid recovered fuels (SRFs) would save the plant approximately fifteen thousand five hundred tonnes of coal per year resulting in a reduction of twenty thousand tonnes of carbon dioxide emissions. Plant manage James Kirkpatrick said, “SRF has been used for over 10 years. End-of-life tyres have been used for around 30 years and increasingly so over recent years since landfilling of them became illegal in the UK. We are basing our plans on a safe and proven technology and are aiming to provide cost-effective solutions for local waste.”

Despite these reassuring words, resident Ron Lloyd, who lives adjacent to the plant, has expressed concern over the smell and storage of the tires. Lloyd said “alarm bells [are] ringing” and wants more information for Lafarge before they begin using the SRFs. Environmental activist Keith Stockdale is concerned over possible “chemical and industrial pollution” released by burning this waste. He would want strict government regulation on the plant were the proposal to be adopted. Lafarge has plans to send out four thousand letters to local residents as well as to hold two public exhibitions to inform the public about the ins and outs of the proposed process.

Lafarge Testing Biomass Fuel

Lehigh Ben — Thu, 22 Apr 2010 18:15:20 +0000

As part of its aggressive emissions reduction goals, Lafarge’s plant in Bath, Ontario, Canada, began research and testing of new biomass fuels for its kiln in the middle of 2008. Lafarge partnered with Performance Plants, Inc. to develop a string of seeds that are heat and drought resistant and that can grow on otherwise unproductive farmland. The plants, mainly perennial grasses, were planted on twenty-five acres surrounding the plant and tended by local farmers. That ground, too mineral poor to sustain crops for human consumption, was ideal for Lafarge’s plan.

With the initial trial crops a success, Lafarge launched a multi-year life-cycle assessment despite Performance Plants Inc. being forced to withdraw from the project for financial reasons. The plant set aside 2500 acres for this new experiment in four different locations each with a separate soil compositions. This new trial is being conducted in conjunction with Ontario’s Queen’s University. According to Lafarge environmental and public affairs manager Robert Cumming, the trial’s purpose was “[To] try to confirm that we can get at least a 90 percent savings on CO2 by growing these crops. It would be a 100 percent savings if we could use tractors fired by biomass. We’re looking at carbon sequestration while root structures are being established in the first two years.” The harvest was a success with approximately nine-hundred fifty half ton bales being collected.

The next step in Lafarge’s biomass project is underway now. Machinery is being delivered to the plant in order to grind and shred the bales into a powdered material. This powder will then be pneumatically blown into the plant’s kiln along with the coal and petcoke. Tests scheduled for June will test the emissions of straight fossil fuel firings and of the biomass/fossil fuel mix. Lafarge plans to use between ten and thirty percent biomass in any given firing.

The final step for Lafarge is to help push the biomass concept to the industry. Not only does this process create agricultural jobs, but also reduces the need to transport in fossil fuels therefore further reducing truck emissions. Lafarge’s Ontario plant may have developed a viable option for biomass fuels which has benefits beyond the reduced emissions. Chalk one up for Lafarge’s green strategy.

Construction Waste Recycling

Lehigh Ben — Wed, 07 Apr 2010 10:29:58 +0000

As Lafarge has recently beaten its emission reduction goal, we have time to reflect back on one of the processes the French company used to reach their target. They developed, implemented, and successfully tested a process to re-use waste gypsum and plasterboard products gathered from South Korean construction sites.

The by-products from these sites have become a sore in the side of building contractors. Government legislation makes the cost of transportation and land-fill disposal rise every year. In an effort to alleviate pressure on these companies and to reduce the use of landfills, Lafarge set up a waste collection and treatment service. Once collected, the plasterboard is taken to Lafarge’s Ulsan Transformation Workshop where it is broken down into two components. The first is simply gypsum which can be re-used to create new plasterboard. The second is a paper by-product still rich in gypsum. This product is used as a fuel additive in the cement making process. Not only is the paper product good for burning, but local Korean farmers are able to use it as bedding for their livestock and as an alkaline fertilizer for their fields.

Lafarge’s process started small, but managed to collect 15,000 tons of waste in 2009 with a thirty-two percent recycling rate. Their goal is to be able to handle 30,000 tons/year of the waste. Lafarge saw a growing need for South Korean construction companies, and seized on the opportunity not only to help the builders; but more importantly to positively affect the environment.

Lafarge Beats Its CO2 Goals

Lehigh Ben — Wed, 31 Mar 2010 14:53:27 +0000

French cement company Lafarge set a goal for itself to reduce its carbon footprint by twenty percent by 2010. The company has recently announced that it has beaten its goal by a full year. Lafarge claims to have reduced its footprint by 20.7% as of the end of 2009. Lafarge plans on continuing its green trend in coming years.

Success came for the French company after it spent nearly 800 million Euros over the last five years to reduce its plants’ footprint. This money was partially spent in the development of new products with higher levels of sustainability. Their goal was to help reduce not only their footprint in production, but also of the buildings where their products were being used. An example of one such product is Thermedia 0.6B which is the first in a line of structurally insulating products. In addition to money spent, Lafarge has maintained strong ties with the Cement Sustainability Initiative in order to affect a broader change across the entire cement industry.

Despite the positive steps taken by Lafarge, many European-based heavy carbon emitters have come under criticism regarding their manipulation of the Emissions Trading Scheme (ETS) set up by the European Union. The system works on the principle that companies are granted carbon permits for their emissions which they can buy or sell depending on whether they meet or exceed their quota. However, due to the economic recessions, the heavy CO₂producers (energy, steel, and cement sectors) fell short of their forecasted quotas. These companies now stand to make millions or billions of Euros from the sale of excess permits. Lafarge alone had excess permits valued at 140 million Euros last year. Critics are infuriated that these companies can get away with doing nothing to reduce their environmental impact, yet make millions of free money for it. These critics want the ETS system to be re-evaluated and changed.

Whether Lafarge’s CO₂reduction stems from actions taken by the company or simply from decreased demand is yet to be seen. However, you cannot ignore the fact that less CO₂is being released into the atmosphere from Lafarge plants. No matter what the cause, the environment has come out ahead.

Current Woes, Future Hopes

Lehigh Ben — Thu, 04 Mar 2010 22:37:27 +0000

Despite predictions that the global recession is beginning to slowly right itself, many cement companies are still experiencing tough financial situations. Many large producers have posted losses in the 2009 fourth quarter, but are holding high hopes for increased business throughout 2010.

French-based company Lafarge posted a loss of $51.76 million dollars (38 million Euros) after earning $54.5 million dollars (40 million Euros) last year. Their sales declined 22% in the fourth quarter alone. Following in the wake of this news, Lafarge announced that it would be selling three Beijing cement and concrete making facilities for $74.3 million dollars to Chinese BBMG Corporation. These new assets along with predicted increased demand in developing areas leave Lafarge expecting a stronger 2010.

Cemex, the world’s third largest producer and the US’s biggest producer, is still struggling with reducing the debt accumulated in its 2007 acquisition of Australia’s Rinker. The company is working to sell assets around the globe to reduce their $15 billion dollar tab. At the end of February, Cemex announced the sale of 12 ‘non-strategic’ quarries throughout the US through its joint venture Ready Mix USA LLC, of which is will see $100 million. A company statement said, “Cemex, which does not consolidate the results of Ready Mix USA LLC, expects to use its cash proceeds from this divestment to reduce outstanding debt and to enhance its liquidity position.” These sales and expected sales in Austria, Hungary and Britain started in 2008 will help solidify Cemex’s position in 2010.

Danish-based cement and mineral equipment supplier FLSmidth, Inc. also posted a profit drop in the fourth quarter; but was less harsh than predicted. Reuters predicted a profit of 539 million crowns ($98.7 million), but the company ended with an unexpected 764 million crowns ($138 million). Despite the extra profit, FLS stocks fell 1.2% over 2009. Chief Executive Jorgen Huno Rasmussen said, “We have bottomed out in both our markets, and that means that things will look slightly better in 2010.” Order intakes are expected to rise this year over 2009 values, though the total volume will be less than before the financial crisis.

Despite problems with debt and lack of business due to the recession, cement producers around the globe are taking positive steps to securing their future. They are taking advantage of the opportunities presented through this crisis to emerge stronger and more well-founded than ever before.

Lafarge talking about expansion in India

Demosthenes — Fri, 08 Jan 2010 23:31:47 +0000

Lafarge says they will double their commitment in India over the next five years. Bruno Lafont, Chairman and Global CEO says that Lafarge primarily intends to expand organically through greenfield plant construction, but that they will not rule out acquisitions if the opportunities present themselves. Lafarge expects a consolidation in the Indian cement market in the “mid term” over the next five years. “And, if you are well prepared, you can seize the opportunity. We are open to both the possibilities. Our strategy is to invest in cement, select regions for it and to create excellent positions there,” He went on to add that Lafarge is still focused on preserving capital, and “Our strategy is to give priority to cement sector in emerging markets.” We commented on this emerging market focus by the big producers, and the opportunities it may present in the developed markets, in an earlier post.

Holcim moves. Lafarge, Cemex stay in the game.

admin — Tue, 16 Jun 2009 23:40:12 +0000

Yesterday, while Lafarge was announcing a 750 million Euro bond issue to solidify its short term dept, Holcim was suprrising many in the industry by announcing an acquisition of Cemex assets in Austrialia for a significant 1.6 billion dollars. Analysts characterized the deal as “too good to pass up” for Holcim. Still, in the current business environment, this is a bold move and one that demonstrates a financial position of strength for Holcim.

As Cemex and other players look to liquidate non core assets, will others be able to capitalize?