Displaying items by tag: Pakistan
Update on water conservation
25 July 2018Earlier this year South Africa’s PPC commented on the drought facing Cape Town. It said that cement manufacturing was not water intensive, that its operations were ‘totally’ self-sufficient from its own surface water sources with capacity for several months and that it was working with the local government which viewed construction as an important economic sector. Point made!
Water conservation is an established part of the sustainability toolkit for cement producers. Yet recent weather patterns in the Northern Hemisphere may also test how well companies are doing. Above average temperatures have been recorded this summer, in some places accompanied by unusually dry conditions. A news story this week about Cemex Colombia being fined for using water from a river shows one aspect of the problems that can face industrial users. Another story that we’ve covered previously has been the legal action taken against producers using water from a site near to the Katas Raj Temples in Pakistan.
Wet process cement manufacturing uses more water than dry process but even modern plants use water for cooling equipment and exhaust gases, in emission control systems such as wet scrubbers. In addition, quarrying and aggregate production may require water, and concrete production also needs water. Issues also arise with quarry dewatering and discharging water into rivers and the like. Global Cement Directory 2018 data indicates that, where known, about 10% of integrated cement plants still use a wet production method.
Graph 1: Specific water consumption by selected cement producers in 2017. Source: Corporate sustainability reports.
As Graph 1 shows there is some variation between the major cement producers with regards to how much water they use. They all operate with different types of equipment and production methods in different geographical locations so the difference between the companies is to be expected. A cement plant in northern Europe that normally experiences high levels of rainfall will have a different approach to water conservation than one, say, in a water stressed area like the Middle East. Incidentally, the definition used to define a water-stressed or scarce area is one where there is less than 1000m3/yr per person. One other point to note here is that each of the companies has a higher consumption figure than the 100 – 200L/t that the Cement Manufacturers' Association of the Philippines (CeMAP) reckoned that an average dry-process cement plant used when it was promoting water conservation back in 2013.
Looking at specific recent success stories, India’s UltraTech Cement reported a specific water consumption of 54L/t of clinker at its Star Cement plant in Dubai, UAE in 2016 – 2017 following a dedicated initiative at the site. An another milestone that UltraTech Cement was keen to point out in its last sustainability report was that three of 13 integrated plants had achieved water sufficiency though the use of the company’s 360° Water Management Model with its use of rainwater harvesting and recharging groundwater. These plants are not dependent on any groundwater or fresh water sources. The other larger cement producers all have similar water management schemes with reduction targets in place.
Climate change models generally predict hotter and wetter weather but changing weather patterns and growing populations are likely to impact upon water management and consumption. Given the integral nature of water in the cement production process, many cement producers have realised the importance of it and treat it as an input material like fuel or limestone. Hence the highlighting of water conservation in company sustainability reports over the last decade. The test for the success of these initiatives will be how producers cope in drought situations where they may be seen as being in competition with domestic users. Thankfully in PPC’s case, Cape Town avoided having to ration water to the general public, as the rains returned in the spring.
Lucky Cement awarded environment excellence award
19 July 2018Pakistan: Lucky Cement has won the Environment Excellence Award at the 15th Annual Environment Excellence Awards 2018. It received the award in recognition to its commitment towards sustainable development and contribution towards protecting the overall environment for a ‘greener’ Pakistan, according to the PPI news agency. The award was presented by the National Forum for Environment and Health, a non-government organisation that aims to promote environmental, healthcare and educational awareness.
"Implementation of sustainability into our core business operations has always been one of our main objectives. We follow a comprehensive Environmental Management and Monitoring Plan. The management strongly believes in preserving the ecosystem through the management of gaseous emissions, particulate matter, noise levels, effluents (sewage) and solid waste," said Amin Ganny, Chief Operating Officer, Lucky Cement.
Pakistan: Maple Leaf Cement’s new production line at its Iskanderabad cement plant is expected to start production by mid-2019. It is building a new 7300t/day line at the site to increase its total production capacity to 18,000t/day. The cost is US$206m. Denmark’s FLSmidth is building the line. Approximately 66% of civil work has been completed and 14% of plant erection work was reported complete at the end of June 2018.
Pakistan: The Supreme Court has stopped cement producers near Katas Raj from using drinking water supplies. The order follows a ruling in May 2018 to stop the producers using water linked to a pond near to a Hindu heritage site, according to the Pakistan Today newspaper. However, the ruling was not followed. The senior judge presiding over the hearing said that local plants had been using water without paying for it.
Pakistan: Cement despatches rose by 15% year-on-year to 23.7Mt in the first half of 2018 from 20.5Mt in the same period in 2017. All Pakistan Cement Manufacturers' Association (APCMA) data showed that despatches in the north of the country rose by 13% to 17.5Mt and in the south they grew by 7% to 3.8Mt. However, despatches in the south fell by 13% year-on-year to 4.2Mt in June 2018.
Arif Hameed Dar appointed as head of Pioneer Cement
26 June 2018Pakistan: Pioneer Cement has appointed Arif Hameed Dar as its chief executive officer (CEO). He replaces Syed Mazher with effect from 1 July 2018. Abdul Wahab has also been appointed as the company secretary in place of Waqar Naeem.
Pakistan: Power Cement plans to take out a Euro30m loan from Germany’s Deutsche Investitions to finance building a 7700t/day new clinker production line. In mid-2017 the cement producer ordered a production line from Denmark’s FLSmidth for a third line at its plant at Nooriabad.
Pakistan: Germany’s Aumund Fördertechnik is supplying equipment for a new 8000t/day production line that Flying Cement is building at its Mangowal plant in Punjab Province. Aumund is providing bucket elevators, pan conveyors and silo discharge gates for the project.
One belt bucket elevator will feed raw meal to the silo. It is designed with a centre distance of 87.6m and will reach a capacity of around 650t/hr. The other belt bucket elevator will also have a capacity of 650t/hr. Its centre distance is 115m and it will take raw meal to the heat exchanger. Flying Cement will use an Aumund KZB 1200/400 pan conveyor to transport clinker to the main silo. This conveyor will be approximately 115m long, with a lift of 43.5m, and a capacity of up to 580t/hr. The off-spec silo will be served by an Aumund KZB 1200/400 pan conveyor which is 42m long and has a capacity of 580t/hr. The order also includes 13 silo discharge gates.
The bucket elevators will be dispatched to Pakistan at the beginning of August 2018 and the pan conveyors will be supplied in a second consignment at the end the year.
Germany/Pakistan: Germany’s Loesche says it has sold over 400 vertical roller mills for cement and ground granulated blast furnace slag, following a sale to Kohat Cement. Two LM 53.3+3 CS type mills has been sold to the Pakistani cement producer. The plant will produce 210t/hr of Ordinary Portland Cement at a fineness of 9% R 45 μm. No value for the deal has been disclosed.
The first Loesche LM type mill was put into operation at Fos sur Mer in France in 1994. Sales of the mill type for cement and slag markets have accelerated since 2006. The engineering company sold 50 LM mills in the 10 years to 2004. It then sold another 50 mills to 2006. However, from 2006 to 2014 it sold 200 mills. It then sold a further 100 mills after 2014.
Pakistan: Business activity slowed during the month of Ramadan in Pakistan, with cement demand also affected. In May 2018, domestic cement sales were the slowest seen in the current fiscal year, which runs until the end of June 2018, yet they still rose by 2.4%. When exports, which rose by 41.8%, are also included, the year-on-year change rises to 5.7%.
The All Pakistan Cement Manufacturers’ Association (APCMA) reported that 3.92Mt of cement was sold in May 2018 compared to 3.71Mt in May 2017. Sales in the country's northern region stood at 2.81Mt, compared to 2.8Mt in May 2017. In the south, sales came to 0.67Mt in May 2017, as opposed to 0.59Mt in May 2017. Exports from the northern region were 0.224Mt in May 2018 compared to 0.219Mt in May 2017. From the southern region, exports totalled 0.215Mt compared to just 0.09Mt in May 2017.
Total cement sales in the first 11 months of the 2018 Fiscal Year hit a record high, with 42.92Mt sold, a 14.2% rise year-on-year compared to 37.6Mt in the first 11 months of the 2017 Fiscal Year. The APCMA reported that the national capacity utilisation rate over the 11 months period was 94.7%, beating the previous 93.6% record from 1992-1993.
An APCMA spokesperson said the association anticipated that domestic cement consumption would once again rise after Ramadan, while a continued increase in exports was a welcome sign for the industry. However, he said the major factor behind the rise in exports had been the decline in the value of the Pakistani Rupee against the US Dollar, which greatly improved the competitiveness of cement manufacturers in global markets.