Displaying items by tag: Refractory
Global: The World Cement Association (WCA) has recently welcomed Refratechnik Asia as an Associate Corporate Member. Refratechnik Asia supplies refractory materials to the cement and lime industries in China, Southeast Asia, and Oceania. The firm produces 120,000t/yr of refractory materials.
Ian Riley, CEO of the World Cement Association, said "We are keen to see Refratechnik Asia promote its value-orientated culture within our organisation and its commitment to driving greener practices in the cement and wider construction industry.”
Boral completes maintenance at Berrima plant
26 February 2024Australia: Boral's Berrima cement plant team has successfully concluded its annual kiln shutdown and maintenance period. The producer invested US$13.1m and 100,000 working hours over a period of three weeks. The project required coordination with 50 different contracting companies to undertake mechanical repairs and replace the kiln refractory, which is crucial for protecting the kiln shell from heat damage and ensuring operational safety. Employing Cement 4.0 technology and advanced diagnostic tools, the team efficiently identified the necessary repairs. About 300 employees and contractors were engaged in the specialist tasks, facilitating a rapid resumption of kiln operations.
Calderys Group reports successful integration of HWI and Calderys
21 February 2024France: Calderys Group says that it has successfully implemented technology sharing between US-based HWI and Calderys, following their integration in February 2023. In the past 12 months, the group has transferred select Calderys products to HWI in the Americas and introduced HWI products in Europe, the Middle East and Africa and Asia-Pacific. The refractories supplier says that the collaboration offers customers an enhanced product range.
Calderys Group president and CEO Michel Cornelissen said "The past 12 months have been exciting, demanding and very productive for our newly-formed group. The combination brought together two dynamic businesses with complimentary product ranges and created the opportunity for technology sharing and cooperation for the benefit of the world's high temperature manufacturing sectors. I am delighted that we are already seeing great results. Throughout 2024, we will continue to add to, and update, our product portfolios.”
HWI details upgrades in 2023
27 December 2023US: Calderys-subsidiary HWI has highlighted upgrades it has undertaken in 2023. This has included upgrading plant production software, increasing capacity at the White Cloud plant in Michigan, the Lowellville plant in Ohio and the Thomasville plant in Georgia, and adding new equipment at sites in Ohio and Missouri. Additional investment projects are planned for 2024.
Ross Wilkin, Calderys Senior Vice President of Americas, said, "In less than a year under new ownership and since combining with Calderys, we've successfully integrated our Americas operations with the former Calderys operations in the US and in Brazil, enhanced our products and services portfolio for customers, and completed massive investments in our manufacturing facilities. We are well-positioned for the future."
Private equity investment company Platinum Equity completed its acquisition of Calderys from Imerys in January 2023. It then purchased HWI in February 2023.
Calderys launches new brand platform
29 November 2023France: Refractories supplier Calderys has announced the launch of its new brand platform following its integration of HWI (formerly HarbisonWalker International) earlier in 2023. The platform is comprised of four values, reflecting the personality of Calderys’ company culture, namely accountability, authenticity, multiculturalism and tenacity.
Chief people officer Melissa Bihary and global vice president communications Aurélie de Chassey-Hayot said “These new values and the overall platform have been developed through an employee-led exercise. Therefore, they truly define the essence of who we are and how we do business. They guide our actions and behaviors and help us make the best decisions for the benefit of our customers.”
RHI Magnesita publishes third-quarter 2023 trading update
01 November 2023Austria: RHI Magnesita says that its sales volumes declined quarter-on-quarter during the third quarter of 2023, with its refractories plants operating at 70% capacity. The company noted ‘under-absorption’ of fixed costs. However it succeeded in maintaining constant earnings before interest, taxation and amortisation (EBITA) levels in line with the second quarter of the year. As such, RHI Magnesita revised its adjusted EBITA guidance for full-year 2023 to Euro380m from Euro360m. It said that its order book visibility is at ‘normal’ levels, with limited signs of a recovery in demand volumes in 2024, as global construction activity continues to be weak.
Chief executive officer Stefan Borgas said “I am pleased by the strong execution demonstrated by RHI Magnesita during difficult conditions for our key end markets. We are currently benefitting from the strategic investments we have made in reducing our cost base and rationalising our production network, together with improved planning and careful management of our assets through this period of weaker demand. Pricing discipline has helped to maintain EBITA margins at over 11%, offsetting the impact of lower production on our fixed cost base. We have also been able to progress our mergers and acquisitions strategy, with six acquisitions completed in the first nine months of 2023 and a total of nine in the past 24 months.
RHI Magnesita acquires P-D Refractories
03 October 2023Central Europe: Austria-based RHI Magnesita has acquired P-D Refractories from Germany-based Preiss-Daimler Group for Euro45m. P-D Refractories produces refractories in the Czech Republic and Germany, and operates other sites in the Czech Republic and Slovenia.
RHI-Magnesita’s CEO Stefan Borgas said “The production capabilities and vertical integration of P-D Refractories, combined with RHI Magnesita’s know-how and renowned research and development capabilities, will complement our product portfolio and enlarge our production footprint and sales channels on a global scale. This acquisition is our sixth transaction to close in the year to date and marks a major milestone for both companies in the process industries sector. Together we look forward to expanding our footprint and strengthening our market presence by offering high-grade refractory products and solutions to an enlarged customer base.”
Storing energy at scale at cement plants
27 September 2023Taiwan Cement has just commissioned a 107MWh energy storage project at its Yingde plant in Guangdong province, China. Subsidiary NHOA Energy worked on the installation and has been promoting it this week. The battery storage works in conjunction with a 42MW waste heat recovery (WHR) unit, a 8MWp solar photovoltaic unit and a proprietary energy management system. It is expected to store about 46,000MWh/yr of electricity and save just under US$3m/yr in electricity costs.
NHOA Energy, formerly known as Engie EPS before Taiwan Cement bought a majority stake in it, claims it is one of the largest industrial microgrids in the world. We can’t verify this for sure, but it is definitely large. For comparison, the 750MW Vistra Moss Landing Energy Storage Facility in California often gets cited as the largest such facility in the world. This is run by a power company, as are many other large battery energy storage systems. In its annual report for 2022 Taiwan Cement said it was planning to using NHOA’s technology to build seven other large-scale energy storage projects at sites in Taiwan including its integrated Suao, Ho-Ping and Hualien cement plants.
The aim here appears to be supplying renewable electricity to the national grid in Taiwan. Taiwan Cement is diversifying away from cement production, with an aim to derive over 50% of its revenues from other activities besides cement by 2025. In 2022 cement and concrete represented 68% of its sales, while its electricity and energy division, including power supply and rechargeable lithium-ion batteries, represented 29%. The company is also not using its own batteries at the Yingde plant. Instead it is using lithium iron phosphate batteries supplied by Ningde Times. This is worth noting, as the cement producer’s batteries are used in vehicles.
Global Cement regularly reports news stories on cement plants that are building photovoltaic solar power arrays. However, so far at least, energy storage projects at scale have been rarer. One earlier example of an energy storage system loosely associated with a cement plant includes the now decommissioned Tehachapi Energy Storage Project that was situated next to the Tehachapi cement plant in California. That project tested using lithium ion batteries to improve grid performance and integrate intermittent generation from nearby wind farms. It is also worth noting that Sumitomo Osaka Cement’s sister company Sumitomo Electric is one of the world’s larger manufacturers of flow batteries, although no installation at a cement plant appears to have happened yet. In simple terms, flow batteries are an alternative to lithium ion batteries that don’t store as much energy but last longer.
More recently, Lucky Cement in Pakistan started commercial operation of a 34MW solar power plant with a 5.59MWh energy storage unit at its Pezu plant in Khyber Pakhtunkhwa in late 2022. Reon Energy provided the equipment including a lithium-ion based battery approach to the storage. Then, in March 2023, Holcim US said that it was working with TotalEnergies to build solar power capacity and a battery energy storage unit at the Florence cement plant in Colorado. TotalEnergies will install, maintain and operate a 33MW DC ground-mounted solar array and a 38.5MWh battery energy storage system at the site. Operation of the renewable energy system is expected to start in 2025.
Away from electrical batteries, the other approach to energy storage at cement plants that has received attention recently from several quite different companies has been thermal batteries. The two prominent groups using them at different scales are Rondo Energy and Synhelion. The former company has developed its Heat Battery technology, which uses refractory bricks to absorb intermittent renewable energy and then supply the energy back as a steady stream of hot gas for use in a cement plant mill, dryer, calciner or kiln. Both Siam Cement Group (SCG) and Titan Cement have invested in Rondo Energy. In July 2023 SCG and Rondo Energy said that they were planning to expand the production capacity of a heat battery storage unit at a SCG plant to 90GWh/yr. Synhelion, meanwhile, has been working with Cemex on using concentrated solar power to manufacture clinker. It achieved this on an ‘industrially viable scale’ in August 2023. It has since been reported that the companies are working on building a small scale industrial plant at Móstoles near Madrid by 2026. Crucially for this discussion though, the process also uses a thermal energy storage unit filled with ceramic refractory material to allow thermal energy to be released at night, and thus ensure continuous operation.
The examples above demonstrate that some cement companies are actively testing out storing energy at scale. Whilst this will not solve the cement sector’s process emissions, it does potentially start to make using renewable energy sources more reliable and reduce the variable costs of renewable power. Whether it catches on remains to be seen. Most of these kinds of projects have been run by power companies and that is where it may stay. It is instructive to note that Reon Energy was the only company to state that its battery-based energy storage system has a life-span of 8 - 12 years. Our current vision of a net-zero future points to high electrical usage but it may be shaped by how good the batteries are… from our phones to our cars to our cement plants.
For more information on Rondo Energy read the January 2023 issue of Global Cement Magazine
Thailand: US-based Rondo Energy and Siam Cement Group (SCG) plan to expand the production capacity of a heat battery storage unit at a SCG plant to 90GWh/yr. Once complete the site will reportedly have a production capacity larger than any current heat battery-supported manufacturing facility worldwide and will save up to 12Mt/yr of CO2. The SCG site already has a capacity of 2.4GWh/yr.
SCG’s executive vice president Thammasak Sethaudom said “Rondo offers an innovative solution to reduce the carbon emissions from industrial process heat used in factories worldwide. SCG can use Rondo’s technology to lower our own carbon emissions and SCG Cleanergy can partner with Rondo to help our customers cut emissions.” He added “We also realised that we can leverage our 70 years of technical expertise in the refractory business and supply chain.”
Rondo heat batteries consist of refractory bricks capable of storing renewable energy as heat. The heat energy can then be returned to an industrial process as hot air or steam. SCG invested in Rondo Energy in 2022.
This story was amended on 4 July 2023, after a previous version erroneously stated the location of the plant as Ukraine. Global Cement apologises for this error.
Austria: RHI Magnesita says that its earnings before interest, taxation and amortisation (EBITA) continued to grow year-on-year during the first quarter of 2023. This was despite an 8% year-on-year drop in refractory sales during the period under review. The refractory supplier attributed its declining sales to reduced construction activity outside of China and India. It said that this slowed demand both for cement and steel. RHI Magnesita noted higher energy costs, while raw materials costs 'remained low.' During the first quarter of 2023, the company acquired India-based refractory producers Dalmia OCL and Hi-Tech. These give it a 20 - 30% market share in India. This advanced its goal of strategic growth in markets in which it is under-represented, including China, India and Türkiye.
Chief executive officer Stefan Borgas said “RHI Magnesita benefited from resilient pricing in the first quarter, as we fulfilled orders placed in the fourth quarter of 2022 during the peak inflationary period. Our improved refractory margin performance benefits from the investments we have made to rationalise our network, and leaves us well placed to meet expectations for the year. We have continued to make steady progress in mergers and acquisitions as we identify value-adding opportunities to grow our business through consolidation in key target geographies and product areas, whilst carefully managing our balance sheet."