Displaying items by tag: Ash
Netherlands: EMC Cement and HES International plan to build a 1.2Mt/yr plant in Amsterdam to produce an alternative cement that contains 70% volcanic ash. The cement will also include recycled concrete fines. Production will be carbon neutral and consume 90% less energy than traditional ordinary Portland cement production. The Amsterdam plant is scheduled for commissioning by early 2026.
EMC Cement CEO Atle Lygren said "Our EMC Technology, by replacing 70% of Portland cement clinker, enables significant climate action without the need for costly carbon capture and storage, aligning with the demands of the United Nations Framework Convention on Climate Change and the Intergovernmental Panel on Climate Change."
Kyrgyzstan: The state-owned Bishkek heat and power plant has secured a US$437,000 contract to supply its waste ash and slag to two cement plants in Kemin, Chüy Region. The cement producers party to the contract will be responsible for extraction and transport, commencing in August 2024.
The Bishkek heat and power plant has previously invested US$280,000 in clearing its waste dump. The government says that it has also received interest from a China-based autoclave aerated concrete blocks producer in its waste.
Adani Group to establish cement plant in Santhal Pargana
22 January 2024India: Adani Group has announced plans to build a new cement plant, possibly at Godda, in Jharkhand’s Santhal Pargana Division. The Times of India newspaper has reported that producer recently established a 1.6GW power plant in Godda.
The group said “In keeping with our group’s expansion plans, we are conducting a feasibility study to set up a cement factory, most probably in Godda. A proposal will be sent to government soon. The proposed plant will further boost the economy of Godda and Santhal Pargana. The proposed plant will utilise fly ash from our existing power plant here as raw material. At present, the fly ash is being sent to the ACC cement plants in Jhikpani and Sindri.”
Update on Kyrgyzstan, January 2024
03 January 2024Kyrgyzstan had a couple of prominent stories in the press towards the end of December 2023 with news of a new plant and continuing data showing that cement production has grown.
The Chüy project was first announced by the government in mid-2022 when it signed an investment agreement with a consortium comprising representatives from Terek-Tash and ZENIT. More information on the unit emerged this week when the Russian-Kyrgyz Development Fund revealed that it made a loan of US$45m towards the scheme based in the northern Chüy region of the country. The plan is to build a 1.7Mt/yr plant with a budget of US$160m. Equipment to build the plant is reportedly being sourced from companies in China and Russia. Special features of the project include a waste heat recovery unit and the use of ash from the Bishkek Thermal Power Plant in the production process. The plant is expected to be launched in 2024.
Graph 1: Cement production in Kyrgyzstan, 2018 - 2023. Source: National Statistical Committee of the Kyrgyz Republic.
One reason why the government might be keen to build a new plant is because cement production has mostly grown in each of the past five years, with the exception of 2020, when the Covid-19 pandemic began. In 2022 it increased by 7% year-on-year to 2.7Mt and the latest data from the National Statistical Committee indicates that it rose by 11% year-on-year to 2.6Mt in the 11 months to the end of November 2023. If this rate held in December 2023 then it looks likely that the country will have produced just under 3Mt in 2023. At the same time the country’s exports of cement have also been falling. In November 2023 the government of Kazakhstan’s Jambyl Region said that it had found investors to support construction of a railway line between the locale and Kyrgyzstan due to a ‘building boom’ in the latter country.
Earlier in 2023 the Eurasian Development Bank (EDB) said it had earmarked US$48m for the modernisation of equipment at the Kant Cement plant, operated by Kazakhstan-based United Cement Group (UCG), also in Chüy region. The plant is the biggest in Kyrgyzstan, running five wet process production lines, according to the Global Cement Directory 2023. The EDB linked its investment to a hydroelectric project in the country that it is also funding, pointing out that such structures require lots of cement and concrete. This follows a previous upgrade project by owner Kazakhstan-based United Cement Group (UCG) at the plant from 2021 to March 2023. This involved efficiency and environmental gains such as installing bag filters and converting a cement grinding mill to a closed circuit. China-based and CNBM subsidiary China Triumph International Engineering was the lead project partner. In early December 2023 UCG announced that it had signed another contract with China Triumph International Engineering over the summer to build a new dry production line at the site with a clinker capacity of 0.8Mt/yr. At the time of the announcement it said that preparation of the construction site had started and that work had begun on installing a pile foundation.
Finally, one more Kyrgyz news story of note in recent months was the announcement in October 2023 that the government had effectively nationalised the Kurmentinsky Cement plant in Issyk-Kul Region. The reason why it had done so was unusual because it said that a 93% share in the company running the plant had been transferred to the State Property Management Agency following the death of its former owner. The former owner was one Kamchybek Kolbaev, an organised crime boss who had been listed on the US Department of State Transnational Organized Crime Rewards Program and was reportedly killed by state security services in early October 2023. The remaining shares in the plant have been passed to its workers and the government further said that it intends to upgrade the site.
The cement sector in Kyrgyzstan is modest and in need of modernisation. It appears to be having a resurgence at the moment though with production mounting and at least two major plant projects underway. The country is in a compelling position economically and geopolitically given its membership of the Russia-backed Commonwealth of Independent States (CIS) and its proximity to China. Various projects backed by the latter’s Belt and Road Initiative, both underway and forthcoming, would certainly appear to benefit from more efficient local cement production and higher volumes.
Bangladesh: The government inaugurated the Dasherkandi sewage works, the largest sewage treatment plant in South Asia, in Dhaka on 13 July 2023. United News of Bangladesh has reported that the plant will incinerate dried sewage sludge to produce 16,400t/yr of ash. The plant will supply this to the local cement industry for use as a raw material.
The Dasherkandi sewage works is one of five planned new sewage plants expected to process 100% of Dhaka's sewage by 2030.
Golden Bay Cement secures bottom ash supply
09 May 2023New Zealand: Golden Bay Cement has signed a deal with Genesis Energy for a supply of bottom ash from Huntly power plant for use in cement production at its Portland cement plant in Northland. Genesis Energy generates 20,000t/yr of bottom ash at the Huntly plant, situated in Waikato, 260km south of the Portland cement plant. The plant currently uses 15,000t/yr of fly ash from the Huntly power plant in its operations. The producer was previously investigating the use of volcanic ash in cement production in 2022. It currently uses waste tyres and wood waste as alternative fuels (AF) to produce its EcoSure low-carbon general-purpose cement.
Golden Bay Cement's general manager Gian Raffainer said "We are driven to decarbonise and achieve 30% less carbon by 2030. Contributing to waste reduction at a large scale for the benefit of all New Zealanders is incredibly exciting. It is a win-win for the environment and for Kiwis who want to use more environmentally friendly products."
Europe: The Carbon Negative Biofuels from Organic Waste (Carbiow) project has received EU funding under the Horizon Europe initiative. Carbiow seeks to develop a dense, dry homogenous marine and aviation biofuel by carbonising gasification ash with oxygen and captured CO2 from cement plants. 12 consortium members from the Benelux, Germany, Nordic countries, Slovenia and Spain are participating in the project.
South Korea: SK Ecoplant is at the centre of an initiative in partnership with the city administration of Seoul to co-process 52,000t/yr of incineration ash and 110,000t/yr of sewage sludge from the city in local cement production. AJU News has reported that the waste management company expects to supply the raw materials to make 150,000t/yr of cement production under the initiative.
Seoul generates 113,000t/yr of incineration ash and 200,000t/yr of sewage sludge. Currently, recycled incineration ash is used in concrete block and paving slab production, which have a limited strength when using the material.
South Korea: SK Group subsidiary SK Ecoplant has partnered with CMD Group to launch pilot production of building materials made using up to 60% recycled bottom ash from waste incinerators. The partners say that an exothermic reaction in the presence of non-sintered inorganic binders and expansion-reducing reactants increases the compressive strength of the end product to match that of concrete containing ordinary Portland cement (OPC).
AJU News has reported that South Korean waste incinerators produced 2.16Mt of bottom ash from 9.12Mt of waste in 2020.
UK: Aggregate Industries and Coomtech have partnered to develop low-energy kinetic drying technology for pulverised fuel ash (PFA) from power plant. The partnership will see Aggregate Industries use Coomtech’s kinetic dryers in its PFA processing, as part of its effort towards increasing the volume of waste materials incorporated in its products to 3Mt/yr from 1.5Mt/yr by 2025. The project has attracted funding from the UK government Department of Business, Energy and Industrial Strategy (BEIS).
Chief commercial officer Chris Every said “We’re delighted to have the support of Aggregate Industries in this grant project. Coomtech is especially pleased to have the business’ ongoing technical and commercial input to the project operation and analysis of performance. In addition, the opportunity to work together with a brand that is leading the way in creating new materials that will prove fundamental to the future of the construction sector and meet net zero objectives.” Every continued “The added benefit of our new drying technology is its flexibility - providing the potential to dry a wide range of materials being considered to aid the greening of the cement industry, including limestone, ground blast furnace slag (GBFS), natural pozzolans and other crushed and milled minerals that can offer an activated character to combine in cement and concrete mixes.”