Displaying items by tag: Plant
India: Wonder Cement says that its Chittorgarh, Rajasthan, cement plant’s electricity consumption fell by 1.8GWh year-on-year in 2021. It attributed the reduction to its use of an ACS880 slip power recovery system (SPRS) supplied by ABB India.
ABB India’s Motion business president Sanjeev Arora said “This project puts forth how we are one of the most trusted partners for customers when it comes to energy efficiency. He said that the company ‘has constantly promoted technologies that help in driving country’s carbon-neutral future,’ concluding “Our solutions are aiding businesses across India to cut energy expenses and decarbonise their operations.”
Benin: The Council of Ministers plans to commission a feasibility study from a third party to look into building a 5000t/day clinker plant with a cement production capacity of 1.6Mt/yr. The government wants to preserve local limestone deposits through the creation of a national integrated cement plant that could supply the market, according to La Nouvelle Tribune newspaper. Cement sales increased by 30% in the country from 2016 to 2021 and this trend is expected to continue. The government hopes to build a new cement plant by 2026.
Menzel to build new motor plant near Berlin
02 March 2022Germany: Menzel Elektromotoren has signed a construction contract to build a larger motor plant at Hennigsdorf near Berlin. The manufacturer says it has experienced substantial growth in recent years and has outgrown its present headquarters in central Berlin. The new site will have an area of around 8500m² and will accommodate a motor plant with production, testing and storage areas as well as offices. The plot will also allow for flexible expansions to meet future growth requirements. Construction is to start in the summer of 2022, with completion scheduled for August 2023.
“Our new location will feature state-of-the-art machinery, efficient logistics, larger hoist capacities for optimised production processes and high energy efficiency,” said chief executive officer Mathis Menzel. “We will also expand our team and create around 100 new jobs in production and administration in the medium term.”
The Germany-based motor manufacturer supplies electric motors to end-users. It is also a supplier and partner of drive manufacturers, distributors and maintenance companies.
Germany/Nigeria: Germany-based Kreisel is sending a RDG 2000 type self cleaning rotary valve for the eventual use by client at a cement plant in Nigeria. The product weighs nearly 25t and has material flow rates of up to 570t/hr. The supplier says it is one of the largest self-cleaning rotary valve products that it provides. Such products are used to discharge typically wet or sticky bulk materials with a constant volume flow rate.
Update on Ukraine, February 2022
23 February 2022International tensions reached a new high this week with Russia’s formal recognition of the breakaway Donetsk and Lugansk regions in eastern Ukraine and its decision to deploy troops accordingly. However, what of the local cement industry in Ukraine going into the current crisis?
Ukrcement, the Ukrainian Cement Association, says that its members reported a record 11Mt of cement production in 2021. Clinker production totalled 8.11Mt during the same period. The cement figure is close to Ukrcement’s forecast in the autumn of 2021 of 11.5Mt, a rise of 17% year-on-year from 9Mt in 2020. At that time association head Pavlo Kachur added that the local cement industry operated at 66% capacity utilisation in the first nine months of 2021.
The big industry story locally was the start of tariffs on cement imports from Turkey that was announced in September 2021. After much complaining by local producers and an investigation the year before in 2020 the Interdepartmental Commission on International Trade (ICIT) introduced anti-dumping duties of 33 - 51% on cement imports from Turkey for five years. Other than this the usual energy preoccupations have been present in Ukraine. In an interview with Interfax in November 2021, Pavlo Kachur expressed alarm that the price of coal had tripled from the start of 2021 to August 2021. At the same time he explained that the biggest driver of cement consumption was infrastructure projects.
CRH, the largest producer locally, rebranded its subsidiary as Cemark in November 2021 with the intention to start shipping cement bags with the new marking from January 2022. It operates three integrated plants at Mykolaiv, Podilsky and Odessa. It reported that its local operating profit grew year-on-year in 2020, despite a “challenging pricing environment” as cost savings initiatives and lower fuel and logistics costs resulted in improved performance. In September 2021 CRH said that sales were up due to growing cement sales volumes resulting from market demand. Although once again it complained about competitive pricing forcing it to lower its prices. Despite this though lower maintenance costs and cost controls had boosted its operating profit.
Buzzi Unicem runs two integrated cement plants in Ukraine, Volyn and Yugcement, as well as terminals at Kiev and Odessa through its Dyckerhoff Ukraine subsidiary. In 2021 it noted recovery in the construction sector, helped by government stimulus and the introduction of tariffs on imports from Turkey. It said that prices fell in the first half of the year before recovering in the second half. Ready-mixed concrete output showed more growth. Dyckerhoff Ukraine’s net sales rose by 9.4% year-on-year to Euro127m in 2021 even despite negative currency exchange effects.
As for the other producers, NEQSOL Holding Ukraine filed an application to the Antimonopoly Committee of Ukraine (AMCU) in October 2021 to acquire a stake in Ivano-Frankivskcement. Azerbaijan-based NEQSOL Holding also operates the Norm Cement plant near Baku in Azerbaijan. HeidelbergCement used to operate in Ukraine, including the Amvrosiyivka Plant in the contested part of Donetsk region, but it sold up in 2019 to local investors. Its two former integrated plants now operate under the Kryvyi Rig Cement brand. Finally, Russia-based Eurocement runs two plants in Ukraine, at Balakleya in Kharkiv region and Kramatorsk in Donetsk region, under its Balcem subsidiary, which formed in 2019. However the status of the second plant is currently uncertain. Balcem said that the Balakleya plant resumed full cycle production in March 2021 when it restarted kiln two. Kiln one was restarted in June 2021 after a down period since 2008. The plant currently has a production capacity of around 1Mt/yr.
Ukrcement’s Pavlo Kachur said that the cement market in Ukraine was experiencing a positive period in November 2021. Whether this continues is very much in the balance given events in the east of the country. The wider implications for cement producers in the rest of Europe and Russia are the fallout from the economic warfare between both sides. A number of countries have started to react to Russia’s actions with the US, European Union, UK, Japan and Australia announcing economic sanctions and Germany halting approval of the Nord Stream 2 gas pipeline. However, Russia supplies a significant share of Europe’s gas supply. All of this could disrupt energy supplies and force input costs up. This has already been reflected in higher oil prices.
Meanwhile, one aspect of the current situation to watch is how multinational cement producers with a presence in Russia will cope. Moving money in or out of the country is likely to become harder. HeidelbergCement told Reuters this week that it did not expect any major impact on its Russian operations, even if the conflict escalated. Its three cement plants supply local markets and do not export outside of Russia, it added. Other companies straddling the potential sanctions divide include Holcim, Buzzi Unicem and Eurocement.
The crisis continues.
Nanjing Kisen International Engineering to implement Delta CleanTech’s carbon capture and storage technology at two CNBM cement plants
23 February 2022China: Nanjing Kisen International Engineering has secured a collaboration agreement with Canada-based Delta CleanTech for the implementation of the latter’s carbon capture and storage (CCS) systems at two China National Building Material (CNBM) cement plants. SCMP News has reported that there is a one-time licencing fee - which is not paid by Nanjing Kisen International Engineering but is traditionally paid by the CO2 capture plant customer - of 4.5 - 5% of capital costs. Installations cost upward of US$40m, depending on capacity.
There are currently 40 operational or upcoming CCS installations nationally with a total capture capacity of 3Mt/yr, chiefly in the oil, coal chemicals and energy sectors.The Chinese Academy of Environmental Planning has forecast that China’s cement industry CCS demand will reach 200Mt/yr by 2060. Delta CleanTech president Jeff Allison said that current challenges for Chinese cement producers seeking to reduce their CO2 emissions include difficulties disposing of captured CO2 and a lack of rewards and penalties around emissions control beyond the basic national efficiency requirements.
Nanjing Kisen International Engineering previously launched its first 155kg/day pilot CCS study in partnership with the Canada-based International CCS Knowledge Centre in July 2021.
GCC orders upgrade for Samalayuca plant from ThyssenKrupp Polysius
23 February 2022Mexico: GCC has signed an engineering, procurement and construction (EPC) contract with ThyssenKrupp Polysius for an upgrade to its integrated Samalayuca plant to increase clinker production capacity, raise the usage of alternative fuels and reduce emissions. The project includes the engineering, supply and modification of the preheater, including cyclones, and an extension to the calciner, with the installation of a Prepol SC-S type system to increase the utilisation of alternative fuels. The work also includes fitting a Polytrack type clinker cooler and the installation of a bypass system. The project will begin in 2022 with operations scheduled to start in the second quarter of 2023.
New cement plant planned for West Kazakhstan Province
23 February 2022Kazakhstan: A new 0.58Mt/yr cement plant is being considered in West Kazakhstan Province. The project has an estimated investment value of US$170m, according to local government and Kazakhstan Newsline. Negotiations are underway with foreign investors. The plant has been included in plans to develop the region. It is expected to create 60 jobs.
Ambuja Cement to support Bhatapara cement plant upgrade with 7Mt/yr grinding capacity expansion
18 February 2022India: Ambuja Cement plans to invest US$469m in a 7Mt/yr expansion to its total grinding capacity. BusinessLine Online News has reported that the new capacity will consist of a new grinding plant at Barh, Bihar, and expansions to the company’s Farakka and Sankrail grinding plants in West Bengal. The company says that the new grinding capacity will become crucial after it completes its planned 3.2Mt/yr clinker capacity expansion to its Bhatapara cement plant in Chhattisgarh.
Growing Portland limestone cement production in the US
16 February 2022Argos USA announced this week that its integrated Roberta plant in Alabama is set to produce 100% Portland limestone cement (PLC) by June 2022. As part of the transition three of its terminals in North Carolina will also switch over at the same time. The company also expects that all of its plants will convert to PLC in 2023. Cement sites including Newberry in Florida, Harleyville in South Carolina and Martinsburg in West Virginia are already producing PLC.
The change by Argos marks the latest example in an ongoing trend of US-based cement companies moving entire plants to PLC production. In September 2021 LafargeHolcim US said that its integrated Midlothian plant in Texas was preparing to convert to full PLC production and that it would be the first plant in the US to do so. It later confirmed that the plant had done so by the end of 2021. In October 2021 GCC said that its Trident Plant in Montana would fully move to PLC in early 2022. Then in November 2021 Titan America said that its Pennsuco cement plant in Florida would make the change possibly by 2023. Moving into 2022 brought the news that LafargeHolcim US’ Ste. Genevieve plant in Missouri and its Alpena plant in Michigan had each transitioned to PLC production. Lehigh Hanson then rounded up the bunch earlier this month, at the start of February 2022, when it announced that a PLC was the primary product now coming out of its Mason City plant in Iowa. It even invited a US Member of Congress to celebrate!
The current expansionist phase of PLC usage in the US dates back to late 2020 when the Portland Cement Association (PCA) launched a dedicated website to promote the use of the blended cement by discussing its applications and benefits. It then released a new environmental product declaration in March 2021 and PLC received a mention in the PCA’s Roadmap to Carbon Neutrality when it was released a year later in October 2021. Lots of work went into PLC prior to 2020 though, both by the PCA and others. The first commercial production of PLC in the US started in 2005 and PLC gained its own blended cement specification in 2012. Notably, the PCA has been tracking the state acceptance of PLC by the Department of Transportation and it grew markedly during the 2010s.
The US is playing catch-up with PLC. In Europe its usage dates back to the 1960s. Cembureau, the European Cement Association, reported usage of around 30% in 2004. More recently in 2020, the VDZ, the German Cement Association, reported a similar figure domestically with the proportion of blended cement shipments including limestone, shale and multiple additives at 31.6%. In the US it is hard to gauge the scale of the current move towards PLC by producers, due to limited publicly available data. A PCA survey reported PLC production of 0.89Mt in 2016. If all the plants mentioned above convert fully to PLC and maintain their rated production capacity that would be something like 14Mt/yr of PLC in 2023 or 11% of the US’s total cement capacity. For comparison, the United States Geological Survey (USGS) reported total shipments of all blended cements at 3.3Mt in 2020 and a total of 5.4Mt for the first 11 months of 2021. Plus, remember that PLC is just one blended cement among others, like those that use slag or fly ash.
Recent developments show that a large change is coming towards the US cement market in the update of blended cements. It’s been a long time coming but the last six months have seen brisk increases in PLC production at scale. The exact data is not available but one might expect something around triple the current number of production plants making PLC if the US market heads towards European levels. This rough estimate doesn’t take into account existing partial PLC production levels. At the same time the US cement sector should see a fall in its emissions due to PLC’s 10% reduction in CO2 emissions compared to ordinary Portland cement