Displaying items by tag: Cemex USA

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.

US: Cemex USA and RTI International have secured US$3.7m in funding from the US Department of Energy for their Balcones cement plant amine technology carbon capture study. The plant in New Braunfels, Texas, will trial RTI International's non-aqueous solvent (NAS) system, licensed by energy and technology company SLB. Resources News has reported that the system will have a CO₂ capture capacity of 670,000t/yr. RTI International's principal project investigator Vijay Gupta said that NAS capture has a 30 - 40% lower energy penalty than preceding solvent-based technologies.

Cemex USA president Jaime Muguiro said "We remain committed to exploring technologies that can help us meet our targets as we build a more sustainable future. We are striving to cut emissions across all our operations, and this study with RTI International is one of the many steps Cemex is taking to achieve our objectives."

US: A coal pile collapse at Cemex USA's Knoxville, Tennessee, cement plant killed one worker at the plant earlier in November 2022. Local press has reported that Thomas Mitchell, aged 21, died at the scene.

Cemex says that it is cooperating with an on-going investigation into the disaster.

US: The Board of County Commissioners of Boulder, Colorado, has denied Cemex USA’s application for a 15-year extension to its Dowe Flats quarry mining licence, following its expiry on 30 September 2022. Commissioner Claire Levy cited dust, traffic, noise and disturbances to wildlife as reasons behind the decision.

Cemex USA’s nearby Lyons cement plant has previously relied on the quarry for the supply of 760,000t/yr of limestone.

US: Cemex USA has applied for a permit to continue mining at Dowe Flats to support operations at its integrated Lyons cement plant in Colorado. It has asked the Boulder County Community Planning and Permitting department to allow it continue mining for 15 years until 2037, according to the Daily Camera newspaper. It then says it will close the cement plant. Its existing mining permit will end later in 2022.

US: Cemex has increased production of Portland limestone cement (PLC) at its Lyons plant in Colorado. PLC is expected to become the plant’s primary product by the summer of 2022. The blended cement has been produced at the site for over 15 years. However, Cemex says it is growing production to meet the company’s carbon reduction goals and meet increased demand for lower carbon materials.

Cemex USA has also increased PLC production at its plants in Brooksville, Florida, and Demopolis, Alabama. The start of PLC production or further increases is planned for other cement plants later in 2022.

US: Cemex USA has begun selling Portland limestone cement produced at its Brooksville, Florida, and Demopolis, Alabama, plants across the Southeastern US. The producer says that the cement retains the durability of ordinary Portland cement or is more durable while reducing CO₂ emissions by 10%. Cemex USA aims to increase its PLC production at the plants, and possibly to begin producing it at other US cement plants, in early 2022.

President Jaime Muguiro said "At Cemex, we acknowledge that climate action is one of the most important issues facing our world, and we are committed to being part of the solution. Our company has ambitious emission-reduction targets, and by offering lower carbon products that deliver brilliant performance like PLC, we can continue to work toward those goals while encouraging customers to join us in the journey."

US: Cemex USA has sold its headquarters in West Palm Beach, Florida for US$13.4m. The South Florida Business Journal newspaper has reported that the company will vacate the property in early 2022. It will relocate to a nearby smaller office. Cemex USA has occupied its current headquarters since 1983. According to sources quoted by the newspaper, it no longer requires the 20,000m2 space due to increased rates of remote working by staff.

US: Cemex USA has upgraded two Florida cement terminals, the Pensacola and Palm Beach terminals, at a cost of US$8m. The upgraded terminals will serve to increase Cemex USA’s cement supply to the region through marine shipments from its global operations. The Palm Beach terminal is also involved in the distribution of assorted cementitious materials including granulated blast furnace slag (GBFS) and fly ash for cement production.

USA executive vice president Matthew Wild said “Florida is growing rapidly, and Cemex’s strong network makes our company well-positioned to implement supply chain and operational enhancements to meet the high demand for building materials in Florida and beyond.” He added “On the cement side, increased demand has outpaced supply at times, and we expect our supply chain enhancements to help alleviate that issue.”

Holcim Schweiz hit a milestone recently with the aerial drone programme at its Siggenthal cement plant. The project with Voliro, a Switzerland-based technology start-up, has started to use multi-rotor drones to conduct official measurement flights. They used them to take measurements to determine the steel wall thicknesses of the cement kiln and the cyclone preheater. The work has been part of Holcim’s ‘Plants of Tomorrow’ industrial automation plan with unmanned aerial vehicles (UAV). Key features of the particular drones being used are that they can be rotated around all axes by a special rotor system and can even fly upside down.

Holcim has been using drones in and around cement plants for a few years now. When it launched the Plants of Tomorrow plan in 2019, Switzerland-based drone supplier Flyability said that the cement company had chosen its Elios 2 model to perform confined space inspection. Earlier in 2017 another supplier, SenseFly, said that LafargeHolcim Tanzania had been using its fixed-wing products. Holcim is also far from alone in its use of drones. A few examples among many include Cemex USA’s work with Kespry earlier in 2021, HeidelbergCement’s work in North America and Germany in 2020 and 2021 and Votorantim’s testing at its Córdoba and Niebla plants in Spain back in late 2015. 

UAV usage by armed forces dates back to examples like unmanned incendiary balloons being deployed in the 19^th century to Azerbaijan’s reported decisive use of drones in its war against Armenia in late 2020. The current era of industrial UAVs began after 2000 when governments starting issuing civilian permits, miniaturisation occurred and improvements in cameras, sensors and computing power followed. For the mineral processing sector the trend started with drones being used for stockpile management and quarry surveying. At present this is the main area that UAVs are used for by the sector, often coupled with photogrammetry techniques. CalPortland’s Adam Chapman’s paper at the 2021 IEEE-IAS/PCA Virtual Cement Conference described one company’s use of UAVs in the cement industry since 2016, looking at licensing, cost, quality of data, drone technology, fleet management and field experiences.

More recently though, tests of drones used to survey cement plant buildings and structures have started being publicised such as Holcim’s work at Siggenthal. A presentation by consultant John Kline and Chris Place of Exelon Clearsight summarised the use of drones for structural inspection at cement plants at the Global CemProducer 3 webinar in January 2021. The key benefits they promoted of using an UAV in this way were: improved safety because workers have reduced risk from climbing, working at height or in confined spaces; less time to conduct a survey; higher resolution photographs and video; better coverage through grid method surveying; and an overall lower cost. However, on that last point, other commentators have noted that market-leading drones for surveying are relatively expensive and easy to damage. Drones have since been used to start going inside structures at cement plants with Kline demonstrating their use to inspect the condition of refractory within the cooler, kiln, pre-heater and cyclone of a production line at the Global CemProducer 2 webinar in July 2020. HeidelbergCement has also been doing similar things, with an inspection trial using a drone of the kiln at the Schelklingen plant in Germany during the 2021 maintenance shutdown period at the site.

So far the use of drones by the cement industry has mostly been in a surveying or inspection capacity. Given the short time that UAVs have been used like this there is likely to be scope for lots more development both within existing fields and new ones as the sector works out how best the technology can be used. One application we couldn’t find in the research for this short article was the use of drones for security and surveillance tasks at cement plants and quarries although this may be happening already. However, there could be a more active role for drones if or when a company finds a way for them to start making basic repairs or carrying out simple maintenance in those hard to reach areas that drones excel at accessing. Research examples exist of UAVs being used to spray concrete or repair materials onto minor defects in concrete structures. Yet considerable challenges face these kinds of applications such as the weight of a loaded multi-rotor drone or damage from rebound. Before we all get too worried about drones replacing our jobs though it is worth considering that Amazon’s plan to deliver packages by UAV was first announced in 2013 and it still hasn’t happened yet. It may yet, but for now in most situations humans remain cheaper and more practical than robots or drones.