Displaying items by tag: Upgrade
FLSmidth to deliver clay calcination plant and grinding plant expansion at CBI Ghana's Tema grinding plant
30 March 2022Ghana: FLSmidth has secured a contract for the supply of a clay calcination plant at CBI Ghana's 0.6Mt/yr Tema grinding plant in Accra. The supplier says that it will also install a complete grinding station to more than double the plant's production capacity. FLSmidth says that the entire project will reduce the Tema facility's CO2 footprint by 20%. When commissioned, the new clay calcination plant will be the largest in the world, according to the supplier.
CBI Ghana chief executive officer Frédéric Albrecht said “Ghana is the perfect location for using clay as an environmentally friendly alternative to clinker. West Africa is traditionally a clinker and cement-importing region due to the lack of suitable limestone reserves. Developing countries with their young populations and a growing need for infrastructure and housing represent the future in cement consumption. Calcined clay cements are the most sustainable alternative to traditional clinker-based cement."
India: Shiva Cement's board of directors has approved the launch of a shareholders' vote over plans to increase its Odisha cement plant's capacity by 2Mt/yr. The plan also involves the expansion of the same plant's clinker capacity by 3Mt/yr and the installation of a 12MW waste heat recovery (WHR) plant. In addition to this, the company is seeking to open two new limestone mines with a combined capacity of 1.9 - 3.1Mt/yr at Khatkurbahal, also in Odisha. The company has received Ministry of Environment, Forest and Climate Change approval for all of the plans.
Austria: Lafarge Zement has announced the successful commissioning of a new raw meal mill at its Mannersdorf cement plant in Lower Austria. CEO Berthold Kren congratulated process engineer Nina Wolf and the Mannersdorf plant team for carrying out the Euro23m project.
From the Nordics to the Mediterranean, European countries lead the field in reduced-clinker cement production using supplementary cementitious materials (SCMs). While consumers, faced with ever-greater choice, continue to opt for sustainability, projects to improve existing SCMs and develop new ones have won government backing and have become a matter of serious investment for other heavy industries beside cement. European cement producers’ decisions are steering the course to a world beyond CEM I. Yet, even in Europe, great untapped potential remains.
Companies generated a good deal of marketing buzz around their latest reduced-CO2 cement ranges in 2021 and the first quarter of 2022: Buzzi Unicem’s CGreen in Germany and Italy, Holcim’s EcoPlanet in six markets from Romania to Spain, Cementir Holding’s Futurecem in Denmark and Benelux, and Cemex’s Vertua in Spain and several other countries. All boast reduced clinker factors through the use of alternative raw materials. This, however, is really a rebranding of a long-established norm in Europe.
Since 2010, cements other than CEM I have constituted over 75% of average annual cement deliveries across Cembureau member countries (all cement-producing EU member states, plus Norway, Serbia, Switzerland, Turkey, the UK and Ukraine). This statistic breaks down differently from country to country. CEM II is the norm in Austria, Finland, Portugal and Switzerland, with deliveries in the region of 90%. Portland limestone cement (PLC) makes up a majority of deliveries in all four. It has been central to Switzerland’s transition to 89% (3.72Mt) of CEM II deliveries out of a total 4.18Mt of cement despatched in 2021. There, the main types of cement were CEM II/B-M (T-LL) Portland composite cement, with 1.38Mt (33%), and two different classifications of PLC: CEM II/A-LL PLC, with 1.28Mt (31%), and CEM II/B-LL PLC, with 888,000t (21%).
A second approach is that of the Netherlands, where CEM III blast furnace slag cement with a clinker factor below 65% predominates, favoured for its sulphate resistance and the protection it offers against chloride-initiated corrosion of steel reinforcement in marine settings. By contrast, the UK has traditionally maintained a higher reliance on CEM I cement. This can be partly explained by the preference of builders there for adding fly ash or ground granulated blast furnace slag (GGBFS) at the mixing stage. Nonetheless, CEM II Portland fly ash cement held a 14% (1.43Mt) market share in the UK’s 10.2Mt of cement consumption in 2021.
The UK Mineral Products Association (MPA) has identified limestone as an underutilised resource in the country’s cement production. Together with HeidelbergCement subsidiary Hanson Cement, it has applied for a change to National Application standards to allow the production of Portland composite cement from fly ash and limestone or GGBFS and limestone. The association has forecast that Portland composite cement could easily rise to 30 – 40% of UK cement consumption, and that this has the potential to eliminate 8% of the sector’s 7.8Mt/yr-worth of CO2 emissions.
Metallurgical waste streams have long flowed into European cement production, primarily as GGBFS, but also as bauxite residue. In 2021, alumina production in the EU alone generated 7Mt of bauxite residue, of which the bloc recycled just 100,000t (1.4%) that year. Two projects – the Holcim Innovation Center-led ReActiv project and Titan Cement and others’ REDMUD project – aim to produce new alternative cementitious materials from bauxite residue.
By collaborating with other industries, cement producers’ investments can most effectively reduce the overall cost of using these materials in cement production. In Germany, HeidelbergCement and ThyssenKrupp’s Save CO2 project aims to develop new improved latent hydraulic binders or alternative pozzolan from GGBFS by producing slag from directly reduced iron (DRI). The Save CO2 team believes that GGBFS substitution for clinker has the capacity to eliminite 200Mt/yr of CO2 emissions from global cement production.
Meanwhile in the world of mining, ThyssenKrupp and others’ NEMO project is investigating the recovery of a useable mineral fraction for cement production from the extractive waste of the Luikonlahti and Sotkamo mines in Finland and the Tara mine in Ireland, through bioleaching and cleaned mineral residue upcycling. This may give cement producers full access to Europe’s 28Bnt stockpiles of sulphidic mining waste, of which mines generate an additional 600Mt each year.
Denmark-based CemGreen, which produces the calcined clay supplementary cementitious material CemShale, is developing a shale granule heat-treating technology called CemTower. This consists of three pieces of equipment vertically integrated into cement plants’ preheaters, kilns and coolers, and brings the processing of waste materials – here oil shale – to the cement plant.
Lastly, cement producers are exploring the possible uses of waste made of cement itself. In Wallonia, HeidelbergCement subsidiary CBR’s CosmoCem project is investigating the production of alternative cement additives from large available flows of local demolition, soil remediation and industrial waste. Similarly, the Greece-based C2inCO2 project seeks to mineralise fines from concrete recycling for HeidelbergCement to use in the production of novel cements in its Greek operations.
In Switzerland, ZND Portland composite cement (produced using fine mixed granulate from building demolitions) is the third largest cement type, with 178,000t (4.3%) of total deliveries – narrowly behind CEM I with 239,000t (5.7%).Holcim Schweiz developed its Susteno 4 ZND Portland composite cement with Switzerland’s lack of any ash or slag supply in mind, demonstrating the potential flexibility of a circular economic approach to cement production.
On 21 March 2022, the University of Trier reported that it is in the process of mapping mineral resources, waste deposits and usable residues ‘on a cross-border scale,’ in an effort to produce new materials for use in cement production. Industry participants include France-based Vicat, CBR, Buzzi Unicem subsidiary Cimalux and CRH subsidiary Eqiom. Vicat is preparing a kiln at its 1Mt/yr Xeuilley cement plant in Meurthe-et-Moselle to use in testing new alternative raw materials developed under the project.
For Cembureau and its members, work continues, with the goal of Net Zero by 2050 constantly in sight. This goal includes a reduction in members’ clinker-to-cement ratios to well below 65%. In this, the association and its members are working towards a world not just beyond CEM I, but beyond CEM II, too. What exactly this will mean remains to be seen.
Sources
CemSuisse, ‘Lieferstatistik,’ 11 January 2022, https://www.cemsuisse.ch/app/uploads/2022/01/Lieferstatistik-4.-Quartal-2021.pdf
WSA, ‘December 2021 crude steel production and 2021 global crude steel production totals,’ 25 January 2022, https://worldsteel.org/media-centre/press-releases/2022/december-2021-crude-steel-production-and-2021-global-totals/
MPA, ‘Low carbon multi-component cements for UK concrete applications,’ July 2018, https://prod-drupal-files.storage.googleapis.com/documents/resource/public/Low%20carbon%20multi-component%20cements%20for%20UK%20concrete%20applications%20PDF.pdf
European Commission, ‘European Training Network for Zero-waste Valorisation of Bauxite Residue (Red Mud),’ 16 July 2020, https://cordis.europa.eu/project/id/636876
European Commission, ‘Industrial Residue Activation for sustainable cement production,’ 16 February 2022, https://cordis.europa.eu/project/id/958208
Recycling Portal, Zement der Zukunft – Forschungsprojekt „SAVE CO2“ gestartet, 28 May 2021, https://recyclingportal.eu/Archive/65677
h2020-NEMO, ‘Project,’ https://h2020-nemo.eu/project-2/
European Commission, ‘Green cement of the future: CemShale + CemTower,’ 14 April 2021, https://cordis.europa.eu/project/id/101009382
CosmoCem, ‘Communiqué de Presse,’ https://cosmocem.org/
CO2 Win, ‘C²inCO2: Calcium Carbonation for industrial use of CO2,’ https://co2-utilization.net/en/projects/co2-mineralization/c2inco2/
Les Echos, ‘Rendre le ciment moins gourmand en CO2,’ 21 March 2022, https://www.lesechos.fr/pme-regions/innovateurs/des-substituts-au-clinker-rendent-le-ciment-moins-gourmand-en-co2-1395002
Germany: Australia-based Calix says that its LEILAC-2 carbon capture retrofit of HeidelbergCement's Hanover cement plant has passed its financial investment decision. The company is accordingly proceeding with detailed design and long-lead item purchasing. It will launch construction in 2023. Calix added that, due to a number of project risk flag points given the 'market situation,' it will not buy major components until closer to that time.
When commissioned, the installation will capture 0.1Mt/yr of CO2 and cost an estimated Euro20 - 25/t of CO2 captured.
China Resources Cement’s profit drops in 2021
21 March 2022China: China Resources Cement’s profit was US$993m in 2021, down by 13% year-on-year from 2020 levels. Its cost of sales grew by 22% to US$3.81bn from US$3.12bn. The group noted that the average cost of coal increased by 54% in 2021. It also pointed out that infrastructure investment growth slowed down in 2021. The company increased its turnover for the year by 9.7% to US$5.62bn. Sales volumes of cement and clinker fell by 7% to 81.3Mt and 7% to 3.3Mt respectively. Concrete sales volumes grew by 11% to 14.8Mm3.
During 2021 the group started construction of a second clinker production line and two cement grinding lines at its plant in Wuxuan, Guangxi. Once the upgrades are completed the plant will have a total cement and clinker capacities of 2.4Mt/yr and 1.4Mt/yr respectively. The group also acquired a 51% stake in Hunan Liangtian Cement in January 2022 to enter into the market in Chenzhou, Hunan. This company has cement and clinker production capacities of 1.6Mt/yr and 2Mt/yr respectively. An ongoing upgrade will increase the cement production capacity of 2.1Mt/yr. In March 2022 it sold its 72% stake in Shanxi China Resources Fulong Cement to Tangshan Jidong Cement to enable it to leave the northern market.
China Resources Cement has also been growing its co-processing capabilities in 2021. At the end of the year it reported 10 co-processing projects with a total capacity of 1.7Mt/yr. The projects, mostly based in Guangxi and Yunnan provinces, process municipal solid waste, urban sludge and industrial waste.
France: Lafarge France has announced a total planned investment of Euro46m in upgrades to its 1.6Mt/yr Saint-Pierre-la-Cour, Mayenne, cement plant and its 1.2Mt/yr La Malle, Bouches-du-Rhone, cement plant. The Holcim subsidiary will invest Euro40m to convert the Saint-Pierre-la-Cour plant to low carbon cement production. Meanwhile, it will invest Euro6m in the La Malle plant’s conversion to ultra-low carbon cement production. The L’Usine Nouvelle newspaper has reported that the transitions will complement the company’s strategy of over 25% EcoPact reduced-CO2 ready-mix concrete sales by 2025.
Update on Pakistan, March 2022
16 March 2022Cement producers in the north of Pakistan have started to increase their use of coal from Afghanistan in response to the ongoing volatility in energy markets. Research from a report by Darson Securities found that companies were already using up to 70% Afghan coal in their fuel mix with a further 20% being considered. Most of the northern producers are reported to have secured the cheaper Afghan coal for about two months of inventory, although Maple Leaf Cement was said to have four to five months of inventory. Meanwhile in the south of the country, producers were reported to be facing a tougher situation as Afghan coal costs more for them due to higher logistics charges and export orders were being reduced due to the low cost of clinker internationally. So they are focusing on the domestic market instead.
Graph 1: Cement despatches in Pakistan, 2015 – 2021. Source: All Pakistan Cement Manufacturers Association.
Data from the All Pakistan Cement Manufacturers Association (APCMA) shows that cement despatches have been steadily growing since the mid-2010s with a blip in 2020 caused by the start of the Covid-19 pandemic. The upward trend has been driven by local sales. Exports have generally grown at the same time, with more variance, but they are yet to regain the high of nearly 11Mt reported in 2009. On a rolling annual basis, local sales have remained steady since mid-2021 but exports have been slowly falling. In April 2021 they were 9.17Mt but by February 2022 they were 7.33Mt. For the February 2022 figures APCMA blamed this on the growing cost of production, rising international freight rates, mounting coal prices and a trade ban with India. On that last point for example, Pakistan-based producers exported 1.21Mt of cement to India in the 2017 – 2018 financial year before exports stopped after February 2019. Despite a brief respite in the spring of 2021 talks are still ongoing to resume trade with India.
On the corporate side the country’s largest cement producer by capacity, Lucky Cement, drew the same conclusion as the APCMA with its half-year results to 31 December 2021. Its local sales volumes were down a little but its exports were down a lot. It noted that the reason its local sales were falling but national industry local sales were up slightly was due to some competitor plants being non-operational in the previous year. However, the company managed to keep sales revenue and earnings increasing year-on-year by successfully combating growing input costs with price rises. Bestway Cement, the country’s other large producer, reported a tougher situation in the second half of 2021, with both local sales and export volumes down. This was attributed to a boom in construction activity in the second half of 2020 as Covid-19 lockdowns were eased. Demand for cement since then was said to be ‘sluggish’ due to inflation and high commodity prices. It also pinned its marked fall in exports on political and economic instability in Afghanistan. However, turnover and operating profit were both up due to higher selling prices.
Elsewhere in the sector news since the start of 2021, Pakistan’s exports to South Africa remained stymied in early 2020 due to a review of ongoing tariffs and the government decision to restrict infrastructure projects to only using locally produced cement. On the sustainability front the APCMA started to set out its decarbonisation strategy in November 2021. It may have a long way to go given that a think tank reported earlier in the year that the cement sector was the largest emitter of coal-related CO2 emissions in the country, even more than power generation. Alongside this plenty of capacity additions have been announced. Lucky Cement started commercial cement production at its 1.2Mt/yr integrated Samawah cement plant in March 2021. Various new cement plants and upgrades to existing plants have been proposed by Bestway Cement, Cherat Cement, Fauji Cement, Kohat Cement Company, Lucky Cement and Maple Leaf Cement. Finally of note to a sector troubled by energy prices, in September 2021 the Pakistan International Bulk Terminal said it was going to upgrade its coal handling capacity to around 17Mt/yr by 2024.
Last week’s Global Cement Weekly covered Turkey. The contrasts are interesting because both of these countries have high cement exports and have raised energy concerns recently. This leads to the question of whether other cement exporters may be vulnerable to the current situation. Pakistan isn’t the only country where the cement industry is facing the negative effects of growing energy costs. This week in the sector news, Spain-based Tudela Veguín has shut down the kiln at its La Robla plant down for 10 days due to high electricity prices, Thailand-based Siam Cement Group (SCG) announced it was reviewing its investment plans and the UK-based Mineral Products Association lobbied the government on the issue.
The shift to Afghan coal by Pakistan’s cement producers is rational given the current situation. No doubt fuel buyers all over the world are doing similar things. In January 2022 the International Monetary Fund (IMF) forecast that Pakistan’s gross domestic product would grow by around 4% for 2021, 2022 and 2023 but current geopolitical events may test these estimates. Over the last year domestic cement demand has remained strong but inflation, growing input costs and the impetus to further rise prices may change this. Meanwhile, lots of new production capacity is in the pipeline and, if or when it is built, it may add additional competition pressure. This may present a problem in Pakistan if capacity utilisation levels drop but input costs keep on going up.
ISGEC Heavy Engineering to supply waste heat recovery unit for Shree Cement’s Nawalgarh plant
09 March 2022India: ISGEC Heavy Engineering has received an order from Shree Cement to supply a waste heat recovery (WHR) unit for the integrated 3.8Mt/yr Nawalgarh plant in Rajasthan. The scope of work includes design, manufacture and supply of the system. The supplier says that this will be one of the world’s largest steam-based WHR units by capacity. ISGEC previously supplied two WHR units for Shree Cement’s Raipur plant.
Cemex commissions Line 2 at Tapeaca cement plant
08 March 2022Mexico: Cemex has successfully commissioned its new Line 2 at its Tapeaca, Puebla, cement plant.
Cemex’s Mexico regional vice president operations and technology Ernesto Felix said that the work ‘brought together a great team’ of Cemex colleagues.