Displaying items by tag: Plant

US: Alamo Cement has completed a new solar power unit that supports its integrated cement plant in San Antonio, Texas. The unit has a capacity of 17,800MWhr and is situated on an 18 hectare site. It is expected to generate up to 15% of the plant’s annual power consumption and reduce electricity costs.

US: The Environmental Protection Agency (EPA) has announced that 10 cements plants have received its Energy Star certification in 2022 from a total of 86 manufacturing plants across all industries. The certification is awarded to the top 25% performers in energy efficiency in each sector. The EPA cited examples of how Titan America’s Troutville plant in Virginia and its Medley plant in Florida had converted production to Portland Limestone Cement (PLC), and achieved a 12% reduction in electricity use and an 18% reduction in CO2 emissions, respectively, thanks to improved energy management. It also mentioned Cemex’s Miami plant in Florida, which increased its energy performance in 2022 by modifying a finish mill, optimising the ball charge on the largest mill and identifying and correcting potential energy losses while also increasing the production of PLC.

Cement plants awarded the Energy Star certification in 2022 include: Drake Cement’s Paulden plant and Salt River Materials Group’ Clarkdale plant in Arizona; GCC’s Pueblo plant in Colorado, Cemex’s Miami plant and Titan America’s Medley plant in Florida; Argos USA’s Harleyville plant in South Carolina; GCC’s Rapid City plant in South Dakota; Buzzi Unicem USA’s Chattanooga plant in Tennessee; Titan America’s Troutville plant in Virginia; and Ash Grove Cement’s Seattle plant in Washington.

China/Uzbekistan: Anhui Conch has released an update on some of its major development projects. Its new plant at Tashkent in Uzbekistan has an investment of around US$260m. The company reports that 30,000m² of equipment and materials have arrived, the rotary kiln supporting wheels have been hoisted in place, the main body installation of the coal mill has been completed, the structure of the dormitory building has been capped and the main factory area has begun to take shape. It is also building a plant at Brakbash District in Andijan State. Civil engineering and main engineering construction are reportedly underway. The company also has a third cement plant in the country. So far the group has built over 10 cement plants outside of China.

In China, Anhui Conch is building a CO₂ energy storage demonstration project at its Baimashan cement plant in Wuhu, Anhui province. The group says that, once complete, the project will be the world's first commercial demonstration project of a CO₂ energy storage system. It says that during the low power consumption period, the excess power will be used to compress CO₂ at normal temperature and pressure into a liquid. The heat energy generated during the compression process will be stored. The stored heat energy will then be used to heat the liquid CO₂ back into a gas, driving the turbine to generate electricity, reducing the cost of electricity. The demonstration project has an area of 40,000m².

The cement producer says it is working towards a model of ‘one base and five industries’ where cement production links to other industries such as new energy, new materials, environmental protection, the digital economy and the promotion of international trade.

Kenya: National Cement Company expects to commission its upcoming West Pokot clinker plant in September 2023. The cement company says that the plant will produce clinker for export to neighbouring countries in Central and East Africa. A previous survey by the Kerio Valley Development Authority proved reliable reserves of 1.2Mt/yr of limestone in the area. When commissioned, National Cement Company expects the new plant to generate 2000 direct jobs.

Vietnam: Xuan Thien Group has secured permission for the construction of a US$1.25bn, 10Mt/yr cement plant in Hoa Binh Province. Việt Nam News has reported that the plant will occupy a 48 hectare site in Lac Thuy District. Construction will also involve the clearance of 48 hectare of jungle. Xuan Thien Group is currently also engaged in the construction of a lime plant and solar panel assembly plant in the district.

Germany: Austria-based Rohrdorfer has started up an amine-based carbon capture system at its Rohrdorf cement plant in Bavaria. The producer plans to ultimately expand the system up to a capture capacity of 1500t/day. The inauguration follows a successful continuous trial of the technology since August 2022, excluding a regular kiln maintenance period over winter. Austria-based Andritz designed the system specifically for the Rohrdorf cement plant. It yields CO₂ that is suitable for numerous applications, including in food and beverages and in intermediate products in pharmaceuticals production. The Rohrdorf cement plant also hosts a formic acid plant which uses captured CO₂.

Rohrdorfer aims to achieve carbon-neutral cement production by 2038. Alongside production-related optimisations, the producer plans to realise its aim through a future expansion to the Rohrdorfer plant’s carbon capture system and the implementation of a further carbon capture upgrade at a second cement plant in Austria.

Pakistan: Bestway Cement has announced the successful commissioning of its Hattar cement plant's new 2.63Mt/yr Line 2. The line increases Bestway Cement's installed capacity by 21% to 15Mt/yr. It is equipped with a 9MW waste heat recovery (WHR) plant. The Nation newspaper has reported that the producer completed the project in under 15 months.

Hattar cement plant was Bestway Cement's original cement plant. It opened in 1998, with a capacity of 1Mt/yr.

Congratulations to Lafarge France for launching the first calcined clay cement unit in Europe. The subsidiary of Holcim says that the unit, based at the integrated Saint-Pierre-la-Cour cement plant, is the first of its kind on the continent. It is using the company’s proprietary proximA Tech technology and will produce up to 500,000t/yr of cement in its ECOPlanet range. The operation is also powered with biomass alternative fuels and uses a waste recovery system to further drive down overall CO₂ emissions. Once production ramps-up the producer expects that 30% of cement from the Saint-Pierre-la-Cour plant will be from the ECOPlanet range by 2024.

The investment at Saint-Pierre-la-Cour was Euro40m. Holcim is also producing calcined clay cement at its La Malle plant in France. It received an investment of Euro6m in 2022 to produce low-carbon cements. Together, both plants are aiming to produce over 2Mt/yr of calcined clay cement by 2024. As is usual for these kinds of projects, the French government partly funded the clay calcination unit at Saint-Pierre-la-Cour as part of the ‘France Relance’ scheme investing in large-scale decarbonisation and energy efficiency initiatives.

Calcined clay cements in Europe aren’t exactly new, but Holcim’s new unit in France does appear to be the first full-scale line located at a cement plant. Research by OneStone Consulting, for example, reckons that the first flash activated clay unit expressly set up to supply the cement sector was commissioned in 1995 in Toulouse, France. More recently, Hoffmann Green Cement inaugurated its 50,000t/yr pilot plant at Bournezeau in France in 2018. This site produces cements made from flash calcined clay and blast furnace slag, although it is unclear how demand for the different products varies. A new 0.25Mt/yr plant in the Vendée department was scheduled for commissioning in the second half of 2022. Another 0.25Mt/yr plant in Dunkirk is expected to be commissioned in the second half of 2024.

Cementir Group launched its calcined clay cement product FUTURECEM in Denmark in 2021 with production via a pilot plant. It then extended this to the Benelux and French cement markets in 2022. As part of its industrial plan for 2021 - 2023 it was planning to build a clay calcination unit to support the growth of FutureCem. FLSmidth revealed in June 2021 that it had won a contract to build a 400t/day clay calcination unit for Vicat’s Xeuilley integrated cement plant. The deal was worth around Euro27m and commissioning is scheduled for 2023.

Firstly, it is interesting to see a focus on France for some of the projects above. The presence of Lafarge’s technical centre in Lyon may explain the interest for that company. However, Hoffmann Green Cement and Vicat are also active in the field. It is worth noting that France also holds a busy secondary cementitious material market with standalone operators including Ecocem, Cem’In’Eu and Hoffmann Green Cement. Secondly, despite the early start, clay calcination for cement is currently more active outside of Europe. In Africa, for example, there is at least one live full production line and a number of other projects on the way. Various other pilots and projects are also happening elsewhere around the world, often in conjunction with the limestone calcined clay cement (LC3) initiative. Where calcined clay cement production in Europe goes from here is uncertain at present as it is one solution among many for lower carbon cement products in the future. Yet, the projects that have made it so far to the commercial scale will be watched closely by the companies that have invested in them - and their competitors.

Pakistan: Balochistan's local government minister has called for the cancellation of the allotment of a large area of land to a cement plant in Hub, adding that he would take the matter to court. Mohammad Saleh Bhootani said the Mines and Minerals Development Department had allotted 18,200 hectares of land that he says belonged to the people of Hub and Lasbela districts.

The allotted land comprises mountains, agriculture lands, hundreds of villages, farms and graveyards, he said, arguing that there was no justification for allotting such a vast area to a cement plant. Bhootani warned locals that fences would soon be erected around the site, forcing those that live there out of their homes. He urged Chief Minister Abdul Qudoos Bizenjo to “show mercy on the poor people of the area and cancel the allotment.” The minister said that if the allotment was not cancelled, he and the people of the area would take legal action.

The parliamentary leader of the Balochistan National Party-Mengal, Naseer Ahmed Shahwani, condemned the allotment and demanded the government withdraw its decision. 'If such practices continue, what will be the future of Balochistan?' he wondered.

Philippines: Century Peak Cement Manufacturing has started distributed its cement products to the Visayas region. Its blended hydraulic and ordinary Portland cement product received quality standard certification from the Department of Trade and Industry in January 2023.

Century Peak Cement operates a plant at Pinamungajan in Cebu with associated limestone reserves. The unit has its own pier.