Displaying items by tag: Plant
Turkmenistan: Turkmencement’s Lebap cement plant in Koytendag, Lebap region produced 419,000t of cement over the first seven months of 2020, up by 0.4% from 417,000t over the corresponding period of 2019. Turkmenportal News has reported that the rise is due to the start of addition of porphyritic basalt to the clinker mix.
Vietnam: The government has adopted a cement industry development strategy under which all plants below 0.9Mt/yr capacity must make investments to improve their productivity, product quality, energy saving and environmental protection by 2025. In order to facilitate this, the government says it will improve institutions and policies and improve the efficiency of raw materials exploitation, scientific research and industrial application, promoting domestic consumption, increasing available training and tightening environmental protections, according to Việt Nam News. Plants which fail to increase productivity in the specified ways will face closure.
The government says that strategy aims, “to develop the cement industry to an advanced and modern level, to produce cement of international standard quality with economical and efficient use of energy, giving high competitiveness in the international market, while meeting the needs of the domestic market, completely eliminating out-dated, natural resource-consuming and polluting technology for production.” The measure specifically targets the country’s overcapacity issue in its efforts to develop demand and its emphasis on product quality.
Hindalco secures UltraTech Cement bauxite residue contract
21 August 2020India: Metals producer Hindalco has won a contract to supply fellow Aditya Birla subsidiary UltraTech Cement with 1.2Mt/yr of bauxite residue from its aluminium operations, up by 180% from 250,000t in the 2020 financial year, which ended on 31 March 2020. The Economic Times newspaper has reported that UltraTech Cement will use the bauxite residue – or ‘red mud’ – in cement production at 14 of its plants across seven states. As a result of the deal, Hindalco, the world’s largest producer of rolled aluminium, will have full bauxite residue utilisation across three of its refineries. Managing director Satish Pai said, “We have been working with producers to develop high-grade inputs for the cement industry.”
International Cement Group Salamanga cement plant builders locked down since March 2020
20 August 2020Mozambique: China-based International Cement Group has confined builders working on the construction of its integrated Salamanga cement plant in Maputo Province to the site of the upcoming plant since March 2020. BBC news has reported that 60 Mozambicans have been living in temporary accommodation without being able to leave the site “in order to prevent possible transmission of coronavirus from workers,” according to the company. The group agreed to permit workers to leave from 23 August 2020 following action by a local lawyer.
What is a cement plant for?
19 August 2020In case you missed it, last week we covered a news story about Taiheiyo Cement’s plans to step up its lithium-ion battery recycling business at its integrated Tsuruga plant. It’s the latest step in the Japan-based cement producer’s collaboration with recycling company Matsuda Sangyo. The work is timely given that electric cars accounted for 2.6% of global car sales in 2019 and this share is growing. Many of these electric vehicles use lithium-ion batteries and moving away from fossil fuel powered transport creates new problems such as how to manage old batteries that can no longer be used.
Figure 1: Lithium-ion battery recycling process by Taiheiyo Cement and Matsuda Sangyo. Source: Translated from Taiheiyo Cement CEMS technical magazine.
Taiheiyo Cement and Matsuda Sangyo have been working on their process since 2011. First, they dismantle the batteries to extract base metals and plastics. They then heat the batteries in a dedicated ‘roaster’ using waste heat from the cement production process, before crushing and sorting them to remove cobalt, lithium, aluminium and scrap iron. Hydrogen fluoride produced in this stage is sent to the kiln where it is detoxified by calcium. Remaining elements from the battery that are not reclaimed are then used as an alternative fuel by the cement plant.
Taiheiyo Cement says that its roasting equipment can process up to 10t/day but it’s difficult at this stage to assess what demand for this service they might encounter. If, one estimate of 2m/yr used lithium-ion batteries by 2030 is correct and Taiheiyo Cement’s processing rate doesn’t get much higher, then 500 cement plants could possibly solve this problem. Yet, Taiheiyo Cement and Matsuda Sangyo have made no mention of the economics of their process. Other recycling methods also exist and research into new ones is ongoing. Cement plants recycling batteries might be economic compared to these alternatives or it might not, only time will tell.
The wider point here is that here is yet another industrial and logistical process that can potentially be linked to cement production. It follows well known ones, such as using alternatives fuels or captive power plants, or more novel ones, such as CO2 or hydrogen networks. In each case the business of making cement changes as new methods are learned, new commodities are sought and new markets are connected. The cement company then has a choice about how involved it wants to become with each new process. The classic example here is the waste processing companies that surround co-processing, with some cement companies having their own dedicated subsidiaries, for example LafargeHolcim and Geocycle.
As it all becomes more complicated the role of a cement plant slowly becomes redefined. If a cement plant disposes of municipal waste and car batteries for its local community, generates electricity from its solar or wind plant for a nearby city and uses its CO2 to either produce biofuels, plastics or baking soda is it still just a cement plant? The pivot by building materials manufacturers in recent years from a focus on cement to concrete suggests that once the societal or economic conditions are right it could change. For the time being cement plants remain cement plants but give it a thought next time you buy a new car.
Les Ciments Du Sahel hires Sinoma International Engineering and Sinoma Construction for Kirene cement plant upgrade
19 August 2020Senegal: Sinoma subsidiaries Sinoma International Engineering and Sinoma Construction have signed a contract with Les Ciments Du Sahel for the upgrade of its 3.0Mt/yr Kirene cement plant in Dakar Region. The Euro245m contract stipulates that a new 6000t/day capacity cement production line will replace the plant’s old third line. Sinoma says that the new line will grind its first batch of cement from clinker in February 2022 and produce its own cement and clinker from October 2022. The group said, “We believe that the contract ought to present no significant challenge for the company.”
Police investigate murder of a Chinese worker at cement plant quarry in Democratic Republic of Congo
19 August 2020Democratic Republic of Congo: Police are investigating the murder of a Chinese worker at the quarry of a cement plant that is being built near Kolwezi, the capital of Lualaba province. The employee of Carrilu was killed in an attack on the site by ‘bandits,’ according to the Agence France Presse. Two other people were also assaulted in the incident. Armed attacks against businesses and residents have been reported regularly in the region.
The Lualaba Carrilu cement and lime plant is a project being managed by China-based Zijin Mining Group. It is expected to start operation in autumn 2020.
Environmental agency orders Lafarge Cement Zimbabwe to shut Harare plant due to dust emissions
19 August 2020Zimbabwe: The Environmental Management Agency (EMA) has ordered Lafarge Cement Zimbabwe to stop operations at its integrated Harare plant due to abnormal dust emissions. As part of the order the plant has been requested to notify local stakeholders and the community of any new developments or incident that may affect them, according to the NewsDay newspaper. It will also be required to report daily dust emissions readings to the EMA every two weeks.
The cement producer said it experienced an unexpected surge in dust emissions during a trial of using saw dust as an alternative fuel at the plant between July 30 and 1 August 2020. It added that immediate action was taken to control and contain the emissions and the incident was reported to EMA in line with regulatory requirements.
India: Aditya Birla subsidiary UltraTech Cement said that it will spend US$200m in capital expenditure (CAPEX) during the 2021 financial year, which ends on 31 March 2021. The plans consist of a capacity expansion to 118Mt/yr from 115Mt/yr, including the completion of the 4.0Mt/yr Bara grinding plant in Uttar Pradesh and 1.2Mt/yr-worth of brownfield projects in Bihar and West Bengal. Solar and wind power capacity will increase to 350MW from 95MW, while waste heat recovery (WHR) capacity will increase to 185MW from 118MW.
Chair Kumar Birla said, “While 2021 will be a challenging year, Birla remains confident that the economy will revert to the 6 - 8% growth trajectory in 2022.”
Russia: Vostokcement subsidiary Teploozorsky Cement has engaged FLSmidth to complete two hot kiln alignments at its integrated Teploozorsky Cement plant in Oblu, Khabarovsk Krai following inspections. Vostokcement said that the plant’s second and third rotary kilns will need to undergo the process of adjustments to their axis and axial balance, in order to eliminate stresses to the kiln body.