Displaying items by tag: Plant
Holcim México to install new grinding unit at Macuspana cement plant
14 February 2024Mexico: Holcim México will invest US$55m in the construction of a new cement mill at its Macuspana plant in Tabasco state. The producer says that the mill will increase the plant's cement capacity by 50% to 1.5Mt/yr. This will lead to an increase in the plant’s total workforce to 300 people.
General director Jaime Hill said "This investment in Tabasco reflects our firm conviction in the potential of the Mexican southeast and our commitment to the sustainable development of the region. Through this expansion, we will not only increase our capacity to supply the states of Tabasco, Chiapas, Campeche, Yucatán and Quintana Roo, but also reinforce our role in the decarbonisation of the construction industry, offering low-emission products like our cements from the ECOPlanet range."
Locals protest Ambuja Cements’ Darlaghat cement plant’s water use
14 February 2024India: Protestors from Bilaspur District have opposed the transfer of water from the Ali Khad stream to Ambuja Cements’ Darlaghat cement plant in neighbouring Solan District. A group of local farmers and village officials have successfully suspended water transfer to the plant from the stream at Trivenighat. The Times of India newspaper has reported that the Darlaghat plant will draw an estimated 1Ml/day of water from the Ali Khad stream. Protestors say that this would be enough to dry the stream, turning the area in Himachal Pradesh into a ‘desert.’ The Ali Khad stream currently waters 24 wells and seven irrigation networks, upon which 50,000 people depend.
Ethiopia: The Lemi National Cement Factory is preparing to start production. The 8Mt/yr plant is expected to be completed in March 2024, according to the Xinhua News Agency. China-based Sinoma International Engineering is building the unit. The US$600m project is a joint venture between West International Holding, a subsidiary West China Cement, and the East African Holding Company. The plant is located at the Lemi Building Materials Industrial Park around 150km north of Addis Ababa.
Hetauda Cement Industry resumes production
07 February 2024Nepal: Hetauda Cement Industry has resumed cement production after a three-month cessation since late 2023. The company stopped making cement due to coal shortages, according to the República newspaper. General manager Basant Raj Pandey said that future stoppages were now unlikely, as the company had secured a regular supply of coal. The company is also conducting negotiations with the Ministry of Industry, Commerce and Supplies to install new equipment and provide subsidies for the purchase of raw materials such as coal.
Kenya: Mashujaa Cement plans to build a US$77.4m integrated cement plant at Chasimba, Kilifi South. The Standard newspaper has reported that environmental group Nature Kenya claims that Mashujaa Cement’s environmental and social impact assessment (ESIA) for the upcoming plant ‘lacked comprehensive assessments’ of its possible impacts. These include a possible threat to 31 critically endangered local plant species, including Kenya’s endemic African violets, growing on outcrops of the local Kambe Limestone Belt.
Nature Kenya said “The ESIA indicates scientific unfamiliarity as it contains carelessly worded generic statements such as ‘species will be relocated to Arabuko Sokoke forest’, ‘the site is devoid of any eco-sensitive area’ and ‘impact on biodiversity and wildlife is minimal’.”
Brazil: Secil subsidiary Supremo Secil Cimentos will invest US$20.3m in an upcoming expansion of its Adrianópolis cement plant. Commencing in July 2024, the expansion will raise the plant’s clinker capacity by 10% and enable it to increase its alternative fuel (AF) substitution rate from 25 – 30% to 40%, and eventually to 50% by 2030. To date, AF use at the plant has reduced its cumulative consumption of petcoke by 100,000t.
CEO Paulo Nascentes highlighted the transformative impact of the Adrianópolis plant on its host community, with its initial investment of US$176m and a subsequent US$41.7m in previous upgrades to date. "One of the reasons why the Paraná government allowed the plant was because Adrianópolis was very neglected. The arrival of Supremo transformed the city," he said.
Nuvoco Vistas expands Bhiwani cement plant’s grinding capacity
31 January 2024India: Nuvoco Vistas has commissioned a 1.2Mt/yr cement mill at its Haryana Bhiwani cement plant in Haryana. This expansion will help Nuvoco Vistas to raise its production volumes in Northern India and to diversify its product offering.
Managing director Jayakumar Krishnaswamy said “We are set to seize the opportunities. We continue to emphasise quality and innovation, and secure a larger market share in the North while retaining our leadership position in the East. On the ready-mix concrete end of the value chain, we have also commissioned five new plants in the current fiscal, bringing our total to 56 plants pan-India.”
Kyrgyzstan: The state-owned Bishkek heat and power plant has secured a US$437,000 contract to supply its waste ash and slag to two cement plants in Kemin, Chüy Region. The cement producers party to the contract will be responsible for extraction and transport, commencing in August 2024.
The Bishkek heat and power plant has previously invested US$280,000 in clearing its waste dump. The government says that it has also received interest from a China-based autoclave aerated concrete blocks producer in its waste.
Brazil: Votorantim Cimentos plans to invest US$1bn in expanding its Brazilian operations in the period up to the end of 2028. US$304m-worth of the investments are already underway at the start of 2024. Reuters has reported that the investments include cement plant projects to raise Votorantim Cimentos’ Brazilian cement production capacity by 8.8% to 37Mt/yr. These include a US$162m investment in a 20% capacity expansion to its Votorantim cement plant and a US$60.8m, 1Mt/yr expansion to its Salto de Pirapora plant. Further aims are to ensure structural competitiveness, raise energy efficiency and digitise operations, including applying artificial intelligence (AI) to freight. The producer expects its earnings before interest, taxation, depreciation, and amortization (EBITDA) to eventually rise by US$263/yr between 2023 and 2028 as a result.
Carbon capture for the US cement sector, January 2024
24 January 2024It has been a busy week for carbon capture in the cement sector with Global Cement covering five stories. However, increasingly, the topic has become a regular feature in the press as the industry bends to the demands of the carbon agenda. This week’s selection is notable because three of the stories cover North America.
Holcim US announced that it is working with Ohio State University and GTI Energy to design, build and test engineering-scale membrane carbon capture technology at the Holly Hill cement plant in South Carolina. The information builds on an earlier release from the US Department of Energy’s (DOE) Office of Fossil Energy and Carbon Management (FECM) in late December 2023 about the project. It has a total budget of US$9m, with US$7m supplied by the DOE. It plans to build a 3t/day CO2 capture unit that uses a method intended to retain 95 - 99% of CO2 from cement kiln gas with a purity exceeding 95%. The new information at this stage is that GTI Energy is involved. Specifically, it will support the development of the pilot skid for site deployment.
The other two stories from North America are worth noting because they both concern commercial equipment or technology suppliers joining up to work together. First, 10 companies - Biomason, Blue Planet Systems, Brimstone, CarbonBuilt, Chement, Fortera, Minus Materials, Queens Carbon, Sublime Systems, and Terra CO2 - announced they were launching the Decarbonized Cement and Concrete Alliance (DC2). The group’s principal aim is to lobby the US government toward using new low-carbon cement and concrete products in public infrastructure. It also intends to look at advocacy and public sector engagement including expanded tax credits, development of standards for novel cements, consistent ecolabeling and accounting, and customer demand support. DC2 was formally launched in January 2024 but it follows previous work by the companies in the area. The other related story was a memorandum of understanding that Aker Carbon Capture and MAN Energy Solutions have also signed this week to jointly pursue opportunities related to carbon capture, utilisation and storage (CCUS) and CO2 compression in the North American market. These two companies have worked on the full-scale CCUS unit at Norcem’s Brevik cement plant, which is due to be commissioned later in 2024. They are likely intending to capitalise on the publicity that is likely to be generated once it officially starts up.
Back in North America the DC2 Alliance noted in its press release the DOE’s release of its Pathways to Commercial Liftoff: Low-Carbon Cement report in September 2023. Although it is similar to many other varied sector roadmaps, including the Portland Cement Association’s Road to Net Zero that was released in 2021, this document is well worth reading due to its details and local market context. The headline figure, for example, is that following a set of pathways to fully decarbonise the US cement industry would cost US$60 - 120bn by 2050. Doing so would involve reducing the clinker factor, improving energy efficiency, increased use of alternative fuels, using CCUS, using alternative feedstocks and adopting alternatives to traditional cement production methods.
Graph 1: US active cement kilns by capacity and age. Source: PCA survey data used in Department of Energy Pathways to Commercial Liftoff: Low-Carbon Cement report.
One other interesting tidbit to consider from the report is an analysis of the age of the US cement sector’s kilns versus their production capacity as shown in Graph 1 above. The largest 10 kilns in the country account for 22% of the country’s total capacity and these were all built after 2000. Then, the next 44% of the national capacity comes from 38 kilns out of a total of 120 kilns at 98 cement plants. The report itself does not make this assertion but the implication is that retrofitting CCUS units at one third of the country’s clinker lines would capture the CO2 being emitted from two-thirds of the sector’s production capacity. This is not to say that this could actually work technically, logistically or economically. Yet seeing the scale of the challenge presented in this way is fascinating and one starts to have thoughts about how a retrofit roll-out of CCUS units might actually be approached.
Whether the cement sector adopts CCUS at scale remains to be seen but demonstration projects are definitely coming in both Europe and North America. The DOE report from September 2023 suggests that decarbonisation will cost a lot of money. No surprises there and, as ever, there is rather less detail on who will actually pay for this. One thing that might help here, that the DOE report mentions frequently, is the 45Q carbon capture tax credit scheme, which was introduced by the Trump administration in 2020. Regardless of the potential bill for consumers of cement though, the suppliers are clearly taking note of the investment potential as evidenced by all the non-cement plant CCUS news stories this week.