Displaying items by tag: Indiana

US: Heidelberg Materials North America has finalised award negotiations with the US Department of Energy's (DOE) Office of Clean Energy Demonstrations. The Mitchell cement plant in Indiana will receive US$300,000 to begin the first phase of its decarbonisation project, part of a broader initiative of up to US$500m in DOE funding to support full-scale carbon capture, transport and storage developments. The Mitchell cement plant has tripled its previous production capacity, with this project aiming to capture and process about 2Mt/yr of CO₂.

Chris Ward, president and CEO of Heidelberg Materials North America, said "This critical milestone of bringing our project under award with the US Department of Energy is a significant step in building the first full-scale application of carbon capture and storage for the cement industry in the US.”

US: Heidelberg Materials has successfully converted its cement plant in Speed, Indiana, into a slag grinding facility. The facility ceased Portland cement production in 2023 following the opening of a new plant in Mitchell, Indiana, and now produces slag cement using domestically sourced slag granules. The Speed site has a grinding capacity of over 400,000t/yr and also functions as a distribution hub for the Mitchell plant's cement and other products.

US: Heidelberg Materials North America inaugurated its 2.4Mt/yr Mitchell cement plant in Indiana on 14 July 2023. The plant is equipped with a 3600 bag/hr rotary packer, and also boasts a 154,000t-capacity clinker storage dome. It will produce Heidelberg Materials North America's EcoCem Portland limestone cement (PLC), alongside other products. The producer said that the new plant will help to address US cement supply chain constraints amid a planned US$110bn infrastructure overhaul.

Heidelberg Materials North America president and chief executive officer Chris Ward said "The plant will reduce CO₂ emissions per tonne of clinker by almost 30%, mainly through operating on natural gas. Our investment in the Mitchell facility helps us lower our carbon footprint, while serving the growing demand for more sustainable products in this key market.”

US: Heidelberg Materials North America has secured funding for a feasibility study for a 2Mt/yr carbon capture installation at its Mitchell cement plant in Indiana. The study will also investigate possible storage and utilisation solutions for a future installation. The producer says that the US government's Department of Energy has pledged US$5m in funding towards the US$10m study.

Heidelberg Materials North America president and CEO Chris Ward said “We are pleased for this additional federal funding to help move our Mitchell carbon capture project forward. Heidelberg Materials recognises the significant role that carbon capture will play in achieving its goal of net zero carbon, and we are very excited to take the next steps in exploring this technology at our new cement plant in Mitchell.”

US: Heidelberg Materials says that the first clinker has been produced on the new production line at its integrated Mitchell cement plant in Indiana. Construction work on the project started in 2019 and the majority of the work is now completed. The US$600m upgrade is expected to increase the production capacity at the unit to over 2.4Mt/yr. It will also create 50 new full-time jobs at the site, bringing the total to 170.

Chris Ward, president and chief executive officer of Heidelberg Materials North America, said “We are extremely pleased to have the new Mitchell kiln online and producing clinker.” He added “With the capabilities of the new facility, we will be able to supply our customers more efficiently, consistently and sustainably than ever before.”

US: The Department of Energy’s (DOE) Carbon Storage Assurance Facility Enterprise (CarbonSAFE) initiative has awarded funding of US$8.9m to Heidelberg Materials North America to study the subsurface geology for suitability for the storage of carbon dioxide at the Mitchell integrated cement plant in Indiana. The proposed project will geologically characterise several prospective reservoirs under the Mitchell plant for storage of more than 50Mt of CO₂ over a 30-year timeframe.

The award, which is managed by the National Energy Technology Laboratory, will be issued to the Illinois State Geological Survey at the University of Illinois (ISGS) as the prime contractor, with the company acting as a technical and industrial partner. Heidelberg Materials is contributing about US$1.5m in funding while ISGS will be contributing approximately US$0.6m for a project total of US$11.1m. The funding was part of a DOE initiative that generated nearly US$125m in funding for 10 projects to characterise suitability for carbon storage across the US.

Heidelberg Materials’ Mitchell cement plant is being upgraded with a new production line. Full production on the new line is anticipated to start in early 2023.

Congratulations are due to the National Cement Company of Alabama and Vicat for the inauguration of the new production line at the Ragland cement plant in Alabama. The event took place on 21 July 2022.

The US$300m project was originally announced in late 2019. It then took two years to build with construction starting in January 2020. Key features include a raw vertical grinding mill, a new roller mill, a five stage preheater tower, an automatic clay storage system, a 78m tall homogenisation silo, an alternative fuels storage area for tyre-derived fuel, sawdust and wood chips, a laboratory and a new control room. The new kiln was previously reported to have a clinker production capacity of 5000t/day and it will add up to 2Mt/yr of cement production capacity to the plant. ThyssenKrupp signed up as the principal equipment supplier in 2019 and H&M was the main contractor. The production line is expected to reduce energy consumption by one third. Further change is scheduled with a switch to production of Portland limestone cement (PLC) from Ordinary Portland cement (OPC) by the start of 2023.

Vicat has repeatedly noted its affection for the plant as it was the first cement plant the group purchased outside of France, back in 1974. Indeed, Vicat’s group chair and chief executive officer Guy Sidos personally managed the Ragland plant in 2001. However, rather more prosaic reasons may also have been behind the decision to expand Ragland. According to United States Geological Survey (USGS) data, Alabama, Kentucky and Tennessee’s cement shipments grew by nearly 5% year-on-year to 7.1Mt in 2019 from 6.8Mt in 2018. Shipments are up by 3% year-on-year to 2.5Mt in the first four months of 2022 and the three states were the fifth largest region in the US for cement shipments in April 2022. A shortage of cement was also reported in Alabama in April 2022.

The other big US-based cement plant expansion is Lehigh Hanson’s US$600m upgrade to its Mitchell plant in Indiana. It also celebrated a milestone this week with a ‘topping out’ ceremony to mark the placement of the final section of steel for the stack. Another recent achievement here was the completion of a 169,000t storage dome supplied by Dome Technologies. The supplier says that the 67m diameter and 48m tall dome is the second largest clinker storage facility in Europe and North America, after one it previous built in Romania in 2008.

The Mitchell K4 project was announced in mid-2018 and then ground breaking began in late 2019. However, the start of the coronavirus pandemic delayed construction in early 2020 before it restarted in September 2020. The revised commissioning date was then moved back about half a year to early 2023. The key part of this project is that it will replace the plant’s three current kilns with just one. The new production line will increase the site’s production capacity, reduce energy usage and decrease CO₂ emissions per tonne of cement. It was reported by local press back in 2018 that the project would increase the plant’s cement production capacity to 2.8Mt/yr. The project has been linked to supplier KHD with CCC Group as the contractor.

It’s fascinating to see two major new upgrades to cement plants emerging in a mature market like the US and during an unprecedented event like the emergence of coronavirus. No doubt compelling tales will emerge of how both teams coped with managing nine-figure capital expansion projects as a global public health emergency unfolded. The US market has been on a roll in recent years, despite all the uncertainty in the world, and so far it doesn’t seem to be slowing down. With luck both of the projects feature above have timed their opening right.

US: Dome Technology has commissioned a 169,000t dome at Lehigh Cement's Mitchell cement plant in Indiana. The dome is equipped with three reclaim tunnels, enabling 83% live reclaim.

Dome Technology sales manager Lane Robertssaid “It’s a colossal project. It’s one of our bigger domes as far as storage capacity goes."

US: Buzzi Unicem USA plans to switch from producing Ordinary Portland Cement (OPC) to Portland Limestone Cement (PLC) at all of its plants by the end of 2022. It said that it intends to transition from traditional ASTM C150 type I and II (OPC) cements in favour of ASTM C595 type IL cement (PLC). So far its Cape Girardeau and Festus plants in Missouri, Greencastle plant in Indiana, Maryneal plant in Texas and Pryor plant in Oklahoma have already completed the move to the PLC. The San Antonio plant in Texas will complete its transition in June 2022, the Chattanooga plant in Tennessee will switch its product line by September 2022 and the Stockertown cement plant in Pennsylvania will complete its conversion later in 2022. The company added that its engineers will continue working to increase the limestone content in cement by up to the permitted 15% and develop High Early Limestone cement, along with other new cement products with reduced clinker content.

US: Italy-based Bedeschi has been awarded a new order for the supply of two BED RNSH 1800/6 type apron feeders for Lehigh Cement’s integrated Mitchell plant in Indiana. The new feeders will be able to process up to 1300t/hr of crushed limestone and they will be placed in the primary and secondary crushing area to replace the old existing machines. They feature super duty design with CAT type chains and a Bedeschi super duty belt. As part of the installation Bedeschi has used a three dimensional survey to define the exact room availability in the existing plant. The new feeders will join three others at the plant that were already ordered as part of an upgrade programme for clay crushing and additive dosing. No value for the order has been disclosed.

Lehigh Cement, a subsidiary of Germany-based HeidelbergCement, resumed work on its US$600m upgrade project at the Mitchell plant in February 2021. Work on the upgrade was suspended in early 2020.