Located in the west of Spain and close to the border with Portugal, Alconera is the most recently built plant in the country. Inaugurated in 2005, it was incorporated into Votorantim Cimentos’ assets in 2021.
This facility is a driver of economic and social development in the area. With a production capacity of 1.6 million tpy of cement, it employs 130 people directly (company employees plus regular contractors) and 400 indirectly.
Votorantim Cimentos is committed to being part of the solution to reduce global greenhouse gas emissions. This is achieved by supporting the circular economy through the utilisation of waste and by-products from other industrial processes as alternative fuels (AFs) and raw materials for cement production. Additionally, it involves investing in new technologies, innovations and by pursuing a renewable energy matrix.
In December 2022, Votorantim Cimentos announced its revised 2030 decarbonisation target of 475 kg of CO2 per t of cement. This new global target is 8.7% lower than the target previously announced as part of the company’s commitments, of 520 kg of CO2 per t of cement.
In its search for more sustainable solutions, Votorantim Cimentos is a founding member of the Global Cement and Concrete Association (GCCA) and, together with other companies in the sector, works actively to accelerate changes that can enable the production of carbon-neutral concrete by 2050.
In line with this ambition, Votorantim Cimentos developed a decarbonisation strategy that is based on four pillars: co-processing (reduction of fossil fuel usage); utilisation of cementitious materials (partial replacement of clinker, the main cement component); energy efficiency and utilisation of renewable energy sources; and development of carbon capture, utilisation and storage technologies (CCUS).
The Alconera plant plays a key role in the achievement of this strategic goal. Proof of this is that in Alconera, between 2021 and 2023, the emission of 91 000 t of CO2 was prevented by reusing 59 500 t of waste as alternative fuel and raw material. This is equivalent to the volume of CO2 that would be offset by planting 2.1 million trees.
In 2023, Votorantim Cimentos’ global emissions totalled 556 kg of CO2 per t of cement produced, a 4% reduction compared to 2022 (579 kg of CO2 per t of cementitious product).
Co-processing
The first lever in achieving Votorantim Cimentos’ decarbonisation objectives is co-processing. By replacing fossil and non-renewable fuels in its kilns with AFs, the company helps reduce the volume of waste that would otherwise end up in landfills, in turn supporting the circular economy and reducing the company’s environmental footprint.
Globally, in 2023, Votorantim Cimentos replaced 31% of fuels with alternative sources, an increase of 4.4% compared to 2022, when the rate was 26.5%. Votorantim Cimentos’ cement plant in Alconera reached a thermal substitution rate of 40% in just six months in 2023, rising to 53% in June 2024 by using olive pomace and refuse-derived fuel (RDF).
Each type of fuel is carefully selected according to its calorific value, chemical composition, physical properties, and environmental impact, ensuring a balanced and sustainable fuel mix while respecting all permits and environmental emission limits.
Enjoyed what you've read so far? Read the full article and the rest of the September issue of World Cement by registering today for free!