Displaying items by tag: Plant

Sierra Leone: IFC, a member of the World Bank Group, has announced a US$24m financing package for MACCEM Industries to build and operate a new cement grinding plant in Freetown. The project aims to reduce Sierra Leone’s reliance on cement imports, improve access to locally produced building materials and create new jobs. The package includes a US$12m loan from IFC’s own account and an additional US$12m from the IDA20 IFC-MIGA Private Sector Window Blended Finance Facility. The new plant has a planned capacity of 657,000t/yr and is expected to meet up to 65% of the country’s domestic cement demand. It will also reportedly integrate solar energy into its operations.

Ahmad Mackie, CEO of Maccem Industries, said “Together we are building the country’s first cement grinding plant in four decades, a project that will reduce import dependency, create jobs, empower local businesses, and set a stronger foundation for sustainable and inclusive growth.”

Abdu Muwonge, World Bank Group joint country representative in Sierra Leone, added “IFC’s partnership with MACCEM will support the development of housing and vital infrastructure such as roads, housing, water systems and energy projects.”

Mexico: The government of Campeche and directors of La Cruz Azul Cooperativa have officially launched the construction of the company’s new 1.0Mt/yr cement plant in Seybaplaya, Campeche. This will be the company’s fifth cement plant.

Gustavo Cruz Vega, director of new projects, said the plant will be “a modern automated facility, with 432 vibration measurement points, 600 temperature and vibration sensors, digital management and 100% advanced artificial intelligence, in addition to being able to generate clean energy and use alternative fuels.” He added that the plant’s systems will ‘guarantee zero dust emissions’ and low levels of pollutants.

He Xiaolong, vice president of China National Materials Group Corporation (SINOMA) and president of China National Building Material Group (CNBM) and Equipment Group (TCDRI), said this will be the first smart production line the consortium has built outside China, with 90% of the equipment designed and manufactured by its own engineering teams.

Zimbabwe: Construction of the Chegutu cement plant by Chinese investor Shuntal Investment has reportedly reached the halfway stage, with production scheduled to begin in early 2026, according to the government-owned newspaper The Sunday Mail. The plant will produce 800,000t/yr of cement and is the second cement plant under development in Mashonaland West, alongside WIH-Zim’s Magunje plant, also set to open in 2026.

Shuntal Investment general manager Zhou Bin said the project is on schedule. “The entire project is expected to be completed before the onset of the 2025/2026 rainy season. This timing is deliberate so that production will not be disrupted during the critical rainy months,” he said  

He added that the plant will adopt modern technology, including a pipe spray cooling system, bag-type dust removers reportedly capable of reducing 99% of dust emissions, and fully enclosed, spill-proof production lines. Raw materials will be sourced from the nearby Lambourne quarry site, reducing Zimbabwe’s dependence on imports. Around 200 local workers are currently employed, building staff housing, storage facilities, warehouses and plant infrastructure.

Ropafadzo Chafesuka, a female truck driver at the site, said 'There are several female workers here, and this has empowered us. We are certain that once the plant starts production, more women will be employed, reducing early marriages and helping fight drug and substance abuse.”

Local press in Zimbabwe previously reported in August 2025 that Shuntai Holdings was in a legal battle with a local school over the construction of the plant 497m from the school’s boundary. Construction has reportedly continued despite a High Court judge ordering construction to cease.

Cameroon: The Central Africa Cement (CAC) plant in Koukoue, Edéa district, was inaugurated on 19 September 2025, in a ceremony chaired by Minister of Mines, Industry and Technological Development Fuh Calixtus. The event was also attended by the Minister of Transport and local leaders. The US$21m project has a production capacity of 1Mt/yr, and will use local resources such as limestone and pozzolan, while importing clinker. Cement output will serve both domestic demand and export markets, according to Afrik Info.

The new facility will reportedly create 121 direct jobs and boost local supply with affordable cement. It also reinforces Cameroon’s position as a cement hub in Central Africa and aligns with the African Continental Free Trade Area (AfCFTA) and Economic Partnership Agreements (EPAs), which aim to increase competitiveness in international trade.

Nigeria/Botswana: Nigeria-based producer Dangote Cement has announced plans to expand into Botswana with a new plant, which would increase its presence on the continent to 12 countries. The plan was disclosed by Emmanuel Ikazoboh, newly appointed chair of Dangote Cement, during a presentation at the Nigerian Exchange Group.

“We are fully aware of the challenges in South Africa, which is why we’re opening a plant in Botswana, geographically close to the market,” Ikazoboh said. “South Africa currently imports cement, and while we have urged the government to curb imports, progress has been slow.”

According to the company, the Botswana blending plant will help boost production and improve profitability, with Dangote Cement targeting 66.4Mt/yr across all of its operations by 2030, a 28% increase from its current capacity of 52Mt/yr.

Pakistan: The Punjab government has approved the construction of a new Gharibwal Cement plant in Chakwal. The Punjab Finance Minister Mujtaba Shuja-ur-Rehman described the approval of a new cement plant in Chakwal as a milestone for industrial growth that would support the construction sector and stabilise the local economy.

There have been a few burner and related stories to note in the cement industry news this week. Firstly, Canada-based PyroGenesis announced that it had signed a deal with an unnamed-European cement company to supply a plasma torch system for a ‘calcination furnace.’ Around the same time UBE Mitsubishi Cement (MUCC) revealed that it had successfully tested natural gas co-firing at MUCC’s Kyushu Plant using a newly developed burner.

The PyroGenesis project is a potential game-changer for the sector because it alters the way cement production lines are heated. Roughly one third of CO₂ emissions associated with cement manufacture arise from the fossil fuels used to heat the kiln and the pre-calcination system. Cut out some of that and the specific CO₂ emissions of cement production drop. PyroGenesis’ approach uses electricity to generate high-temperature plasma. This then gives the cement plant the option of obtaining its electricity from renewable sources. PyroGenesis signed a memorandum of understanding with the power conversion division of GE Vernova in March 2025. This had the aim of targeting high temperature processes, such as cement production, with electric plasma torches. The current deal with a cement producer has been valued at US$871,000 with delivery to the client scheduled for the first quarter of 2026.

We don’t know who the mystery client might be. However, Heidelberg Materials reportedly operated a 300kW plasma-heated cement kiln at its Slite cement plant in February 2025 as part of the ELECTRA project. The producer said it had achieved 54 hours of continuous operation, with 60% CO₂ concentration in the flue gas. The aim was to reach 99%. It then said that it was planning to build a larger 1MWel furnace at its Skövde cement plant in 2026 with tests to continue in 2027. In an interview with Global Cement Magazine in May 2025, Heidelberg Materials said that it was using commercially supplied CO₂ as the ionising gas in the plasma generator but that it was considering using captured CO₂ from the production process in the future. It also mentioned issues from its trials such as the effective ‘flame’ being hotter than the conventional process but not as long. This increased the reactivity of the resulting clinker. Finally, Heidelberg Materials noted from a feasibility study that a 1Mt/yr cement plant would need around 170MW of plasma generation, but that typical plasma generators topped out at around 8MW. Hence, any full set-up would likely require multiple plasma generators. For more on non-combustion style kilns see GCW561.

UBE Mitsubishi Cement’s burner installation is more conventional but again it is concerned about sustainability. In this case the line has tested burning natural gas. The cement producer says it is the first such installation at a cement plant in Japan to do so commercially. The burner was jointly developed by UBE Mitsubishi Cement, Osaka Gas and Daigas Energy. Firstly, the plant will consider switching to natural gas. This will reduce the unit’s CO₂ emissions from fuel combustion. However, a later step being considered is to move on to e-methane. This is a synthetic methane made from CO₂ and hydrogen using renewable energy.

Finally, another recent story on this theme is the installation of a new satellite burner by Northern Ireland-based Mannok at its Derrylin cement plant in August 2025. This is Phase One of a two-part project to upgrade the pyro kiln system at the site. The cement company worked with FLSmidth on the €2.5m upgrade. The new burner has now allowed the plant to burn solid recovered fuel (SRF) by up to a 30% substitution rate in the kiln. This followed a project, also with FLSmidth, to install a FuelFlex Pyrolyzer in 2022. This is used to replace coal with SRF in the pre-calcination stage of cement production. Phase two will be an upgrade of the main burner to a new Jetflex burner. Once this part is completed, Mannok is aiming for an overall substitution rate of 65 - 70% on the whole pyro-processing system.

Burners at cement plants are replaced fairly commonly. However, the supplier companies don’t advertise every installation due to the commercial relationships with their clients and other factors. Hence the more interesting upgrades tend to get the publicity. Typically this means if a burner uses new technology, meets sustainability goals and so on, we find out about it. It’s a similar situation when a new heating technology such as plasma is trialled. Changing trends in fuel types for cement plants suggest different types of conventional burners. Some of this can be seen in the burner stories above with the trend moving towards ever higher rates of alternative fuels usage. Combustion in cement kilns is here to stay for the time being but plasma trials will be watched carefully.

The 18th Global CemFuels Conference & Exhibition on alternative fuels for cement and lime 2025 will take place in Milan on 17 - 18 September 2025

India: Industries Minister D Sridhar Babu has appealed to the union government to revive the defunct Cement Corporation of India (CCI) plant in Adilabad. At a meeting with senior officials, the proposals for restoration were reviewed. CCI management indicated that about US$227m would be needed to modernise the facility with ‘advanced’ equipment. Once operational, the unit could reportedly employ nearly 3000 people, according to Telangana Today.

Sridhar Babu said Adilabad would greatly benefit from the plant’s revival, but that it should remain under the government’s control and not become privatised. He also said that more than 809 hectares of limestone deposits are available in the region, providing long-term raw material security and ensuring the plant’s viability.

India: JK Cement has commenced construction of a US$340m greenfield cement plant in Jaisalmer, Rajasthan. The new facility, spread across 212 hectares, is scheduled for completion by early 2027. The plant will reportedly ensure long-term raw material security through access to local limestone reserves, while also being close to high-demand markets in Rajasthan, Gujarat and Haryana.

Oman: Raysut Cement has appointed Khalid Ramis as the General Manager of its Salalah plant and Raashid Ali as its Group Chief Financial Officer.

Khalid Ramis holds over 30 years of experience in the bank, finance and cement industries. He has worked for Raysut Cement since 2019. Before this he held positions with Bank Muscat and BankDhofar.

Raashid Ali holds over 30 years of financial experience in the automative, facilities management, real estate and retail sectors. He has held senior roles at DAMAC, Jumeirah International and Renaissance. He is a chartered accountant.