Displaying items by tag: Upgrade

Kenya: East African Portland Cement Company has resumed production at its 0.6Mt/yr Athi River cement plant. The producer successfully replaced the shell of the plant’s kiln. Managing director Oliver Kirubai said that the upgrade will enable the plant to increase its cement production by 50%, and reduce the price of its Blue Triangle brand cement.

India: Dalmia Bharat has accelerated its commitment to net zero CO₂ cement production by 2040 with the launch of its newTransformative and Collaborative Strategy Roadmap. The roadmap provides a framework forinnovation, growth and sustainability initiatives through shared synergies with private and public entities, including Asian Development Bank and 50 local government authorities. Initiatives already underway include non-recyclable waste disposal partnerships with local administrations across India. Dalmia Bharat is supporting these initiatives with the installation of chlorine dust bypass systems at two of its cement plants, the first in India. The producer's cement operations are already 40% renewably powered and 13 times water positive.

Dalmia Bharat's environmental, social and governance (ESG) executive director and chief risk officer Arvind Bodhankar said “As a cement producer, we are attached to people’s happiness by gluing thousands of dreams into reality. We therefore strive to give our customers only the best building materials with the lowest environmental impact. In addition, we also intend to drive a net-zero emissions reality with a strategy that’s aligned with our business philosophy, Clean and Green is Profitable and Sustainable.”

Philippines: 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.

Belgium: 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.

Russia: 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.

Turkey: 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.

Argos 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.

For more information on the use of hydrogen in cement production see the proceedings from the 15th Global CemFuels Conference & Exhibition where presentations on the topic were given by Cemex and the VDZ

Zimbabwe: 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.

Zimbabwe: 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.”