Displaying items by tag: Upgrade
Philcement takes US$1.73m loan for Mariveles cement terminal expansion
21 September 2022Philippines: Phinma Corporation subsidiary Philcement has taken a US$1.73m loan for an expansion and upgrades to its Mariveles cement terminal in Bataan. The Manila Times newspaper has reported that the company secured the loan using the proceeds from its bond issuance earlier in September 2022.
Angola: Portugal-based IPIAC has won a contract to upgrade the Cimangola plant in Luanda region to use Limestone Calcined Clay (LC3). The project will be the first in the world to convert an existing clinker production line into a clay calciner. Switzerland-based Ecosolutions conducted a study of raw materials and sustainability issues prior to the signing of the contract. The project will be coordinated and supervised by Portugal-based Techbelt. Once completed the plant will produce 0.3Mt/yr of calcined clay, which can be used to manufacture up to 1Mt/yr of LC3 cement.
Holcim Belgium joins Fluxys CO2 transport network
21 September 2022Belgium: Holcim Belgium has joined Fluxys open-access CO2 transport network project. It intends to use the Fluxys network to either transport captured CO2 for sequestration in the North Sea or reuse in other industry after it builds a new 6000t/day production line at its Obourg plant by early 2026. As part of this process Holcim Belgium also plans to build a cryogenic CO2 capture and treatment unit at Obourg by early 2028.
Pascal De Buck, the chief executive officer of Fluxys, said "Holcim's interest in our CO2 network project at the Mons industrial cluster confirms the efforts industries are making to find solutions for decarbonising their activities. We're here to meet that need, which is why we offer them an open-access CO2 network they can use to transport their captured CO2 to storage or reuse sites. This kind of network helps achieve climate objectives and contributes to the long-term viability of the economy."
The proposed Fluxys CO2 transport network will see the construction and creation in Belgium of pipelines, intermodal hubs, port terminals and shipping from 2025 onwards. The proposed infrastructure is intended to transport three gases: CO2, hydrogen and methane.
Eurocement to upgrade mill at Lipetskcement
21 September 2022Russia: Eurocement is investing over Euro3m towards upgrading a mill at its integrated Lipetskcement plant. The main work will add a separator to the mill. The addition will allow the unit to produce finer grades of cement and increase output by 20%. Work on the project started in September 2022 and is expected to be completed in early 2023.
Nuh Çimento to expand waste heat recovery unit at Hereke cement plant
16 September 2022Turkey: Nuh Çimento has applied for environmental clearance for the expansion of a waste heat recovery (WHR) unit at its Hereke cement plant in Marmara. En Kocaeli News has reported that the company seeks to expand the plant’s power capacity by 66% to 29.6MW from 17.7MW. The company estimates that the project will cost US$4.38m. Its construction will employ 50 people.
Update on hydrogen injection in cement plants
14 September 2022Argos Honduras revealed this week that it has been testing the injection of hydrogen into the kiln of its integrated Piedras Azules cement plant. It has completed a pilot with Portugal-based company UTIS. As part of the process it has been trialling, it has split water by electrolysis and then injected the hydrogen and oxygen directly into the kiln via the main burner. The pilot has reportedly increased clinker production and reduced petcoke consumption at the plant.
Argos is far from alone in using hydrogen in this way. At the end of August 2022 Cemex said that it was also starting to use hydrogen at its San Pedro de Macorís cement plant in the Dominican Republic. CRH UK-subsidiary Tarmac completed a trial in July 2022 using hydrogen as an alternative to natural gas at its Tunstead lime plant. HeidelbergCement UK-subsidiary Hanson also ran a successful trial using hydrogen as part of the fuel mix at its Ribblesdale cement plant in 2021. The government-funded trial used a combination of hydrogen (39%), meat and bone meal (12%) and glycerine (49%) to reach a 100% alternative fuels substitution rate. In 2021 Hanson reported that fuel switching to hydrogen could help it reduce its 2050 CO2 emissions by about 3%, or by -35kg CO2/t of cement product.
Cemex appears to be a leader in using hydrogen in this way. The Mexico-based company started injecting hydrogen in 2019 and retrofitted all of its European cement plants with the technology to do so in 2020. It then said it wanted to roll this out to the rest of its operations. The project in the Dominican Republic is an example of this. In February 2022 it announced an investment in HiiROC, a UK-based company that has developed a method using thermal plasma electrolysis to convert biomethane, flare gas, or natural gas into hydrogen. The stated aim of this investment was to increase Cemex's hydrogen injection capacity in its cement kilns and to increase its alternative fuel substitution rate. Back in 2020 Cemex said that it planned to use hydrogen injection to contribute 5% of its progress towards its 2030 CO2 emissions reduction target along with other measures such as increasing its thermal substitution rate and reducing its clinker factor.
As can be seen above there are a number of examples of hydrogen injection being used in cement plants in Europe and the Americas. However, there is very little actual data available publicly at this stage on how much hydrogen that the plants are actually using. For example, Cemex may have hydrogen injection equipment installed at all of its plants in Europe but it is unclear how many plants are actually using it. This is understandable though, given how commercially sensitive the fuel mix of a cement plant is and in Cemex’s case if it wishes to maintain a leader’s advantage in using a new technology.
It is interesting to see, in what has been released so far, the focus on doing deals with companies that supply electrolysis technology such as HiiROC and UTIS. A feasibility study ahead of the Hanson trial at Ribblesdale by the MPA, Cinar and the VDZ suggested that upgrading a kiln burner and adding all the necessary hydrogen storage and pipework could cost at least Euro400,000. However, this study also pointed out that the cost of hydrogen made a big difference to the cost of the CO2 saving from using it as an alternative fuel. Hence the focus on the technology partners. It will be interesting to see how many more hydrogen injection projects are announced in the coming months and years and, crucially, who is providing the technology to supply the hydrogen.
Capital controls delay handover of new cement mill to Lafarge Zimbabwe
14 September 2022Zimbabwe: Government capital controls are delaying the handover of a new vertical cement mill ordered from China-based CBMI to Lafarge Zimbabwe. The cement producer still owes the supplier US$5.2m but has been unable to make the payment due to economic measures the government has taken to avoid depreciation of the local currency, according to the The Insider newspaper. The subsidiary of Switzerland-based Holcim is unable to obtain a certificate of completion from the supplier until the transaction has been completed. CBMI handled the order and Germany-based Gebr. Pfeiffer supplied the mill. The outstanding debt to CBMI may also delay Holcim’s deal to sell Lafarge Zimbabwe to Fossil Mining, which was announced in June 2022.
Lafarge Zimbabwe to increase cement capacity
13 September 2022Zimbabwe: Part of Lafarge Zimbabwe’s approved US$25m capital expenditure investments will go towards further expanding the company’s cement capacity in order to meet local demand. The company also plans to establish a new dry mortars plant. Lafarge Zimbabwe is on track to commission a new vertical roller mill at its Manresa grinding plant in early 2023. Lafarge Zimbabwe’s chief executive officer Geoffrey Ndugwa said, “The overall market demand continues to grow, driven by the segment of individual home builders as well as the ongoing major government infrastructure development projects. The company is confident that volumes will recover and grow as the availability of cement stabilises.”
Cemex inaugurates restarted kiln at cement plant in Dominican Republic
08 September 2022Dominican Republic: The President of the Dominican Republic, Luis Abinader, has inaugurated the kiln of a restarted production line at the San Pedro de Macorís cement plant. The US$34m upgrade project was started in 2021. The line has a clinker production capacity of 0.5Mt/yr and it has been restarted to support the local market. The announcement follows the start of a project to use hydrogen at the unit that began in late August 2022. The plant also plans to increase its use of alternative fuels, move to using more CO2-free materials and increase its use of additives over the next five years.
Birla Corporation aiming for 30Mt/yr cement production capacity by 2030
05 September 2022India: Birla Corporation plans to increase its cement production capacity to 30Mt/yr in 2030 from 20Mt/yr at present. It made the proclamation in its annual report for the 2021 – 2022 financial year. Recent developments include the inauguration of its 3.9Mt/yr integrated plant at Mukutban in Maharashtra, run under its RCCPL subsidiary. It is the group’s fourth integrated plant and is reportedly the largest single cement production line in the state. The unit also includes a 40MW captive power plant.
Other developments include plans to expand the capacity of its Kundanganj grinding plant in Uttar Pradesh to 3Mt/yr from 2Mt/yr and a plan to build a new 1.2Mt/yr grinding plant at Gaya in Bihar. The group is also increasing production from its captive coal mines. Output from the Sial Ghoghri coal mine has been increased by 20% above its rated capacity to 30,000t/month. Development of the Bikram coal mine has been advanced and production is expected to start in mid-2023. Finally, the group is adding 8MW of solar power capacity at its Chanderia, Satna and Kundanganj plants in the current financial year and a 10.6MW waste heat recovery (WHR) unit is planned for the Mukutban plant.