Displaying items by tag: GCW627

Taiwan Cement has just commissioned a 107MWh energy storage project at its Yingde plant in Guangdong province, China. Subsidiary NHOA Energy worked on the installation and has been promoting it this week. The battery storage works in conjunction with a 42MW waste heat recovery (WHR) unit, a 8MWp solar photovoltaic unit and a proprietary energy management system. It is expected to store about 46,000MWh/yr of electricity and save just under US$3m/yr in electricity costs.

NHOA Energy, formerly known as Engie EPS before Taiwan Cement bought a majority stake in it, claims it is one of the largest industrial microgrids in the world. We can’t verify this for sure, but it is definitely large. For comparison, the 750MW Vistra Moss Landing Energy Storage Facility in California often gets cited as the largest such facility in the world. This is run by a power company, as are many other large battery energy storage systems. In its annual report for 2022 Taiwan Cement said it was planning to using NHOA’s technology to build seven other large-scale energy storage projects at sites in Taiwan including its integrated Suao, Ho-Ping and Hualien cement plants.

The aim here appears to be supplying renewable electricity to the national grid in Taiwan. Taiwan Cement is diversifying away from cement production, with an aim to derive over 50% of its revenues from other activities besides cement by 2025. In 2022 cement and concrete represented 68% of its sales, while its electricity and energy division, including power supply and rechargeable lithium-ion batteries, represented 29%. The company is also not using its own batteries at the Yingde plant. Instead it is using lithium iron phosphate batteries supplied by Ningde Times. This is worth noting, as the cement producer’s batteries are used in vehicles.

Global Cement regularly reports news stories on cement plants that are building photovoltaic solar power arrays. However, so far at least, energy storage projects at scale have been rarer. One earlier example of an energy storage system loosely associated with a cement plant includes the now decommissioned Tehachapi Energy Storage Project that was situated next to the Tehachapi cement plant in California. That project tested using lithium ion batteries to improve grid performance and integrate intermittent generation from nearby wind farms. It is also worth noting that Sumitomo Osaka Cement’s sister company Sumitomo Electric is one of the world’s larger manufacturers of flow batteries, although no installation at a cement plant appears to have happened yet. In simple terms, flow batteries are an alternative to lithium ion batteries that don’t store as much energy but last longer.

More recently, Lucky Cement in Pakistan started commercial operation of a 34MW solar power plant with a 5.59MWh energy storage unit at its Pezu plant in Khyber Pakhtunkhwa in late 2022. Reon Energy provided the equipment including a lithium-ion based battery approach to the storage. Then, in March 2023, Holcim US said that it was working with TotalEnergies to build solar power capacity and a battery energy storage unit at the Florence cement plant in Colorado. TotalEnergies will install, maintain and operate a 33MW DC ground-mounted solar array and a 38.5MWh battery energy storage system at the site. Operation of the renewable energy system is expected to start in 2025.

Away from electrical batteries, the other approach to energy storage at cement plants that has received attention recently from several quite different companies has been thermal batteries. The two prominent groups using them at different scales are Rondo Energy and Synhelion. The former company has developed its Heat Battery technology, which uses refractory bricks to absorb intermittent renewable energy and then supply the energy back as a steady stream of hot gas for use in a cement plant mill, dryer, calciner or kiln. Both Siam Cement Group (SCG) and Titan Cement have invested in Rondo Energy. In July 2023 SCG and Rondo Energy said that they were planning to expand the production capacity of a heat battery storage unit at a SCG plant to 90GWh/yr. Synhelion, meanwhile, has been working with Cemex on using concentrated solar power to manufacture clinker. It achieved this on an ‘industrially viable scale’ in August 2023. It has since been reported that the companies are working on building a small scale industrial plant at Móstoles near Madrid by 2026. Crucially for this discussion though, the process also uses a thermal energy storage unit filled with ceramic refractory material to allow thermal energy to be released at night, and thus ensure continuous operation.

The examples above demonstrate that some cement companies are actively testing out storing energy at scale. Whilst this will not solve the cement sector’s process emissions, it does potentially start to make using renewable energy sources more reliable and reduce the variable costs of renewable power. Whether it catches on remains to be seen. Most of these kinds of projects have been run by power companies and that is where it may stay. It is instructive to note that Reon Energy was the only company to state that its battery-based energy storage system has a life-span of 8 - 12 years. Our current vision of a net-zero future points to high electrical usage but it may be shaped by how good the batteries are… from our phones to our cars to our cement plants.

For more information on Rondo Energy read the January 2023 issue of Global Cement Magazine

Bangladesh: Md Alamgir Kabir, vice chair of Crown Cement, has been re-elected as president of the Bangladesh Cement Manufacturers Association (BCMA) for a two-year period until September 2025. Imran Karim, vice chair of Confidence Cement, and Abdul Khaleque Pervez, managing director of Diamond Cement, have also been re-elected as the first and second vice-presidents of the BCMA respectively. All three were re-appointed at the BCMA’s annual general meeting in Dhaka, held on 26 September 2023.

Speaking upon his reappointment as BCMA president, Kabir expressed his heartfelt thanks to all BCMA members for re-electing him as the president of BCMA. He said that the cement industry of Bangladesh was in a ‘deep crisis’ and that it must work with policy makers in order to flourish, as well as respond more effectively to the needs of consumers.

India: Anjani Portland Cement has appointed Rajesh Kumar Dhoot as its chief financial officer. He succeeds RS Ramanjaneyulu following his resignation. Dhoot is a chartered accountant with over 25 years of professional experience in the cement, sugar, pipe and textile sectors. He has worked in the cement industry for over 15 years, most recently with Chettinad Cement since 2014. Prior to this he held positions with UltraTech Cement from 2006 to 2014.

Pakistan: Pioneer Cement has appointed Talha Saif as its company secretary. He succeeds Abdul Wehab in the role. The company also appointed Jan Mohammad as Head of Internal Audit. He replaces Jamal Uddin.

Türkiye: Cimpor Global Holdings has appointed Erol Tosun as Operational Technologies Unit Manager. He worked as Operational Technologies Chief for OYAK Çimento since 2019 and was the Information Technology Chief for OYAK Modern Beton from 2005 to 2019.

Other appointments at Cimpor Global Holdings include the move by Burak Demir to Industrial Digitalisation Unit Manager. He previously worked for OYAK Çimento since 2017 in a number of process roles. Prior to this he worked for Cementir in Türkiye.

Pınar Özmen Söylemez has been appointed as Data Analytics & Planning Unit Manager. She has worked for OYAK Çimento since 2017 first as a Performance Controller and then Industrial Program and Analysis Chief. Before this she worked for Votorantim Cimentos for two years.

Greece/Germany: Greece-based cement producer Titan Group and Germany-based Orcan Energy have entered a partnership to explore the development and deployment of Orcan’s innovative modular waste heat recovery (WHR) solutions across Titan’s international cement production base. Orcan’s solution converts cement process waste heat into electricity that it says can accelerate decarbonisation while reducing operational costs. As a first step, the partners will undertake an assessment of where Orcan Energy's WHR systems can be applied across Titan's facilities. The study will encompass a thorough pilot site evaluation, starting at several plants within the group. The initial focus will be on recovering waste heat from pre-heaters and clinker coolers.

Samir Cairae, Chief Technology Officer at Titan said “The collaboration with our waste heat recovery partner Orcan Energy has the potential to transform waste heat into zero-carbon clean energy, with a novel but well-proven modular approach."

Andreas Sichert, chief executive officer at Orcan Energy, said “We are thrilled to partner with Titan to use its vast and valuable waste heat resources. Our technology will help not only to reach the group’s extraordinary decarbonisation ambitions but also to significantly save electricity expenses. Our modular approach will allow Titan to flexibly respond to outside changes in uncertain times.”

Look out for an interview with Orcan Energy in the forthcoming November 2023 issue of Global Cement Magazine

Uzbekistan: Hengyuan Cement has held a ground-breaking ceremony at the site of its up-coming cement plant in the Kattakurgan district of Samarkand. The plant, a joint-venture between Chinese and Uzbek partners, will have a capacity of 3Mt/yr and cost US$350m to construct. Cement will be sold in the local market and, according to developers, exported to as far afield as the European Union.

At the opening ceremony, the Hokim of Samarkand region Erkinjon Turdimov and Chinese partners noted that cooperation between Uzbekistan and China has been developing steadily in recent years. The project will lead to 600 new direct jobs. The long-awaited cement plant was first announced in 2018, but has repeatedly been delayed, particularly by the Covid-19 pandemic.

Colombia: Data from DANE, the Colombian national statistics authority, shows that the country produced 1.22Mt of grey cement in July 2023, a 1.7% increase compared to July 2022. Of this, 1.05Mt was consumed domestically, a 6.5% fall year-on-year, with exports increasing to compensate. The July 2023 production figure is 9.2% higher than for the July 2019, the year before the onset of the Covid-19 pandemic. DANE also recorded that Colombia produced 557,900m3 of ready-mix concrete in July 2023, a 3.1% decline compared to July 2022, when 575,800m3 was produced.

Spain: Cement consumption in Catalonia fell by 11% in August 2023, while production fell by 2.7%, and exports by 32.7%, according to regional cement association Ciment Català. During the 12 months, to 31 August 2023 consumption decreased by 2.9% to 2.24Mt, while production fell by 4.4% to 3.15Mt and exports fell by 3.7% to 1.74Mt. Ciment Català’s president, Salvador Fernández, attributed these declines to the poor economic situation in the autonomous region, a lack of investment and ‘the challenges of the decarbonisation process,’ according to Europa Press.

Ireland/US: CRH has completed the move of its primary listing to the New York Stock Exchange. The group will retain a standard listing on the London Stock Exchange.

It said it had made the transition because “We believe a US primary listing will bring increased commercial, operational and acquisition opportunities for our business, further accelerating our successful integrated solutions strategy and delivering even higher levels of profitability, returns and cash for our shareholders.” It added that the North America market represents around 75% of the group’s earnings before interest, taxation, depreciation and amortisation (EBITDA) and that the US is expected to “be a key driver of future growth for CRH due to continued economic expansion, a growing population and significant construction needs.”

Albert Manifold, the chief executive officer of CRH, commented, “Today marks an important milestone in CRH’s development which will enable us to fully participate in the significant growth opportunities that lie ahead for our business”.