Lafarge Canada Low Carbon Fuel Technology Expansion

Lead Proponent

Lafarge Canada Inc.

Project Objectives

Cement manufacturing is an energy intensive industry, consuming significant amounts of fossil fuels and with it, generating greenhouse gases (GHG). Therefore, it is important to advance the re-tooling of the Canadian cement industry towards the use of cleaner, lower carbon fuels (LCF) and away from coal and petroleum coke, the most common fuels in current use.

This project will demonstrate and optimize low carbon fuel (LCF) use in cement manufacturing, through two distinct technologies and in two cement plant technology vintages; pre-heater, pre-calciner injection technology, and a mid-kiln injection technology.  Both of these demonstrations have the objective to raise fuel substitution rates to 50% and beyond.

The project will substitute fossil fuels with waste derived biomass, wood waste, scrap tires or other low carbon fuel packet prototypes and low carbon material waste streams.

The project includes validation and certification work, including before and after emission data evaluation. Furthermore, it is intended to demonstrate a dual dosing and firing point system which, if successful, the combustion efficiency in the calciners will increase and may also lead to a decrease in emission rates.

Expected Results

The project directly supports energy technology innovation to use energy in a more clean and efficient way. It is intended to achieve verified, full scale emission, real world industrial emission reductions while maintaining Canada’s economic advantage and preserving and creating jobs for Canadians. This is a long term project which will reduce air pollutants from energy use with elements of clean energy research, development, and demonstration.  Collaboration with Dalhousie University will create more value and lead to the training and development of Lafarge staff and students.

Project Outcomes

The project enabled Lafarge to increase the low carbon fuel injection rate, thereby replacing fossil fuel use in its cement kilns. It is expected that the Lafarge Richmond plant will be able to replace up to 50 per cent or more of the fossil fuel use with non-recyclable waste by-products to make the site one of the most carbon efficient cement plants in Canada. At Lafarge Brookfield, the plant used repurposed scrap tires as an alternate fuel to displace up to 15% of traditional fuels, and indicated greenhouse gas emissions reductions of between 20 - 30% for every tonne of coal replaced.