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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.

Turkey: Batıçim has appointed Akif Geçer as its general manager and as a member of its executive board. Arif Alp Dündar has also been appointed as chief financial officer and as a member of the executive board.

Geçer was the general manager of construction company Türkerler Holding from 2011 to 2015. Prior to this he held management positions at Çimko Cemento and Şanlıurfa Çimento and production roles at OYAK and Denizli Cement dating back to the early 1990s. He is a graduate in chemical engineering from the Middle East Technical University in Ankara.

France: Hoffmann Green Cement Technologies has appointed Stéphanie Bondoux as its director of certification and accreditation. In her new role, Bondoux will help the company to comply with France’s technical norms and standard practices. In order to ensure that it continues to meet the highest industry standards, she will assess the performance, the sustainability of solutions and the safety of the various applications while fostering Hoffmann Green Cement Technologies’s policy of innovation. This will involve close collaboration with both the producer’s testing segment and accreditation bodies.

Bondoux was previously head of accreditations and regulatory frameworks for Liechtenstein-based building materials producer Hilti's Western Europe business, having begun her career as a fastening product manager there. She holds a master's degree in marketing from Sorbonne University, Paris.

Saudi Arabia: Mansour Balghonaim has taken a seat on the board of Saudi Cement, effective retroactively from 30 June 2021. Blaghonaim has 16 years’ experience in banking and is head of business development wholesale banking at Gulf International Bank. He acquired his degree in finance from King Saud University, Riyadh.

Austria: Baumit has invested Euro5.6m in a new waste heat recovery (WHR) system at its Wopfing cement plant in Lower Austria. The producer claims that the installation will enable it to make energy savings of almost 20GWh/yr, corresponding to the energy consumption of 1000 households.

Commercial director Georg Bursik said “We have been using the waste heat for drying systems in the plant for decades. Thanks to this investment, the use of waste heat can be further increased – saving 4000t/yr of CO₂.

Australia: Adbri’s first-half sales in 2021 were US$545m, up by 7% year-on-year from US$508m in the first half of 2020. The group’s cement and clinker volumes increased by 11%. It said that this was due to a rise in demand in the eastern states of Australia and the recommencement of regular supply to a customer in South Australia. The group increased its earnings before interest and tax (EBIT) to US$64.0m, up by 81% from US$35.3m. Its net profit increased by 95% to US$41.1m from US$21.1m.

CEO Nick Miller said “Adbri delivered a robust first half financial performance for 2021 recording solid growth in revenue and profits with improving margins as demand for construction materials rebounded, supported by increased residential housing activity and infrastructure spending.” He added that full-year 2021 earnings would increase less sharply year-on-year than first-half earnings have, due partly to the anticipated impacts of the opening of a rival cement terminal in New South Wales in the second half of the year.

Colombia: Cementos Argos has signed a contract with Klaveness Digital for the supply of the latter’s CargoValue cement terminal logistics platform throughout its supply chain. The move follows a successful trial project carried out by the parties during the second quarter of 2021. Cementos Argos says that it solidifies its digitisation agenda to preserve its strong market foothold in the Americas.

Trading and business intelligence senior director Gabriel Ballestas said “Our business model is focused on the customer and on creating added value for our stakeholders. CargoValue has enabled us to digitise existing processes to improve visibility and make better decisions throughout the supply chain towards that goal.” He added “This wider rollout will improve collaboration between stakeholders and allow us to identify and improve supply chain efficiencies between sites.”

Morocco: The government of Morocco has tightened cement and clinker quality standards. The Le Matin newspaper has reported that the new standards will see cement and clinker assessed on the basis of higher consistency and final product durability standards than previously.

Pakistan: The All Pakistan Cement Manufacturers Association (APCMA) has received a request from the Pakistan government to lower cement prices. The International News newspaper has reported that Finance and Revenue Minister Shaukat Tarin spoke with APCMA representatives about trends in cement pricing in the three years prior to August 2021 and the importance of cement in stimulating economic growth. Tarin encouraged the establishment of a consultative session between the association and relevant stakeholders, with the task of proposing a sustainable pricing mechanism.

Algeria: An Egypt-based investment company has initiated legal action against Algeria over issues relating to two cement plant projects. The Global Arbitration Review newspaper has reported that the company is seeking to claim US$900m in damages.