Displaying items by tag: Lime plant

The Hillhead Quarrying, Construction and Recycling Show is in full flow this week, taking place near Buxton in Derbyshire. As one delegate marvelled on the panoramic minibus journey down to the quarry, “It’s like a music festival without the music and… other stuff.” Indeed. Of course what one doesn’t find at Glastonbury and the like is a near comprehensive range of suppliers, over 600 of them, to the industry all in one place… in a quarry! Where else can one get up close and see the new hydrogen-powered generators and excavating vehicles that are being piloted? The official attendance figures don’t get released until after the event but on the ground it looks as busy as ever. It’s truly the place to be this week.

The show gives us a reason to take a look at the UK cement sector. Like many other countries around the world it is an election year in the UK, with a General Election scheduled for 4 July 2024. The result of this should determine the next Prime Minister and the ruling party. So, naturally, the MPA, the trade association for the aggregates, asphalt, cement, concrete, dimension stone, lime, mortar and industrial sand industries, is taking the opportunity to remind the political parties what its priorities are. The quick version is: support for decarbonisation; a streamlined planning system; and better delivery of projects. This sounds familiar to priorities in other countries but one British spin on this includes the UK’s carbon border adjustment mechanism (CBAM).

Graph 1: Domestic cement sales and imports in the UK, 2017 – 2022. Source: MPA.

Edwin Trout’s feature on the UK cement sector in the June 2024 issue of Global Cement Magazine presents a good overview of the last 12 months. The general UK economy has faced shocks in recent years such as Brexit, Covid-19 and the war in Ukraine. However, this has been further compounded by a downturn and high interest rates since late 2022 when the then Prime Minister Liz Truss caused market turbulence in the wake of a badly received government financial statement. As Trout relates, sales of heavy building materials have been in relative decline since mid-2022 with more of the same expected in 2024. Production of cement in 2023 is currently uncertain given the reporting time lag from the MPA but up until 2022 domestic cement sales fell somewhat but imports grew. This has created a situation where overall cement sales in 2022 were 12Mt, not far behind the annual level in the early 2000s. However, the share of imports has nearly doubled since then. More recent MPA data on mortar and ready-mixed concrete sales throughout the first nine months of 2023 suggest that market activity has decreased and poor weather at the start of 2024 looks set to have made this worse.

Despite the apparent slowdown in building materials sales the cement companies have been conducting smaller-scale maintenance and upgrade projects at their facilities and supply chain schemes such as the cement storage unit for deep sea shipping lines that Aggregate Industries said in February 2024 it was going to build at the Port of Southampton. The news the cement companies want to show off has been a steady stream of information about ongoing decarbonisation projects in the cement sector. C-Capture started a carbon capture trial at Heidelberg Materials’ Ketton cement works in Rutland in May 2024, Capsol Technologies said in March 2024 that it had been selected to conduct a study on its carbon capture technology at Aggregate Industries Cauldon cement plant in Staffordshire, Heidelberg Materials' Ribblesdale cement plant in Lancashire announced in March 2024 that it was taking part in a study to assess the use of ammonia as a hydrogen source for fuelling cement kilns and Heidelberg Materials awarded Japan-based Mitsubishi Heavy Industries (MHI) a front end engineering design contract for a carbon capture installation at its Padeswood cement plant in Flintshire in February 2024. Finally, on the divestment front, CRH completed the sale of its UK-based lime business to SigmaRoc for €155m in March 2024. The business operates from sites in Tunstead and Hindlow with five permitted lime kilns.

That’s it for this short recap on the UK for now. For a longer look at the UK cement sector read Edwin Trout’s feature in June 2024 issue of Global Cement Magazine.

Hillhead 2024 runs until 27 June 2024

Peru: The Gloria Group is set to expand its operations with a new lime plant in Lima's industrial zone, according to CE NoticiasFinancieras. This development is promoted by the group’s cement, concrete and lime subsidiary Cemento Yura. The proposed plant, will have a production capacity of over 350,000t/yr and will serve both domestic and export markets. Currently, the group operates Cal y Cementos Sur (Calcesur), which produces quicklime and hydrated lime in Juliaca with a capacity of 1Mt/yr. With lime demand rising, particularly from the mining and construction sectors, Gloria Group is also considering further plant projects.

The company is reportedly confident that the procedures for obtaining operating permits for new projects in the mining sector will be expedited in order to stimulate the demand for lime. It also did not rule out the implementation of new plants.

Zambia: Chilanga Cement has started lime production at its Ndola plant. The new lime unit at the plant has a production capacity of 108,000t/yr, according to the Times of Zambia newspaper. The project had an investment of US$5m. The subsidiary of Switzerland-based Holcim has launched a new lime produced called ‘PAWA Lime’ targeted at the mining and industrial sectors.

China: Switzerland-based Maerz has commissioned two lime kilns for Guizhou Gangli Xinmin New Material’s plant in Guizhou province. The new plant includes a 600t/day R4S kiln and an 800t/day R5S kiln. Both kilns are coal fired. This is the first time Maerz has supplied kilns to Guizhou Gangli. As part of the project, Maerz supplied engineering and key equipment as well as technical support services for the commissioning and firing of the kilns. Maerz’s long-standing local partner Shanghai Maiyao built the turnkey plants and will operate them on behalf of the customer for the next few years.

Europe: Ireland-based CRH has agreed to sell its European lime business to UK-based SigmaRoc for US$1.1bn. The business controls 16 sites across the Czech Republic, Germany, Ireland, Poland and the UK. CRH says that the first phase of the transaction, which is scheduled for completion in early 2024, will hand over control of the Czech Republic, Germany and Ireland businesses to SigmaRoc, while control of the Poland and UK business will pass over in two subsequent phases.

CRH chief executive officer Albert Manifold said “The decision to divest at an attractive valuation follows a comprehensive review of the Business and demonstrates CRH’s active approach to portfolio management. The proceeds from the divestment will provide us with significant additional capital allocation opportunities to deliver further growth and value creation for our shareholders.”

US: Lhoist North America says it intends to add lime production capacity in Texas. It stated that population growth in the south of the country had created increased demand for its calcium-based products, with customers having announced new steel mills, liquefied natural gas (LNG) export facilities, lithium hydroxide production plants and water treatment facilities. In its view these expansions in multiple markets require lime both in the initial infrastructure build and in longer-term production processes.

The subsidiary of Belgium-based Lhoist said in mid-September 2023 that it was expecting to file permits for the expansion in the coming weeks and the location for the new production capacity will be revealed at a later date.

Sweden: SaltX Technology and SMA Mineral have agreed a joint roadmap until 2028 to work on developing and building electrified lime plants. The agreement means that mineral producer SMA Mineral plans to build several units where SaltX's electric arc calciner (EAC) technology will be installed. The companies have worked together since mid-2022.

Carl-Johan Linér, the chief executive officer at SaltX, said "We have now signed a long-term cooperation agreement in which the respective parties' roles and responsibilities are regulated, which is an important step for both parties."

SaltX Technology is intended to allow SMA Mineral to halve its CO₂ emissions by 2027. The agreement allows SMA Mineral to use the EAC technology to produce quicklime in the Nordic region. The forecast is that SaltX will receive orders for 7 - 9 EAC units from SMA Mineral during the contract period. SaltX intends to market and sell the EAC technology to lime manufacturers outside the Nordic region and other stakeholders, such as cement manufacturers, worldwide. SaltX and SMA Mineral are accelerating work on SMA Mineral’s first electric lime plant at Mo i Rana.

Peru: Switzerland-based Maerz has received an order from UNACEM (Unión Andina de Cementos) to supply a 600t/day PFR lime kiln. The kiln will be built and operated jointly at Tarma by UNACEM and Mexico-based lime producer Calidra Group. UNACEM already runs its integrated Condorcocha cement plant in Tarma. The supplier says that the kiln will be ready to install future CO₂ capture technologies due to airtight sealed charging and discharging systems. It will also save up to 20% of electrical energy compared to conventional rotary piston blowers by using high-pressure fans to provide the process air.

Planning is underway for the project and is expected to be completed by the end of 2023. Maerz’ scope of supply will include the petroleum coke firing system, skip winch, charging and discharging systems, high-pressure fans, hydraulic unit and control system. According to the schedule, commissioning should take place in the first half of 2025.

Kosovo: Alba Group has announced plans to build a lime plant in Kosovo, the first in the country. The company has appointed Switzerland-based Maerz Ofenbau to execute the project. The supplier said that it looks forward to many years of cooperation with Alba Group.

Peru: Unacem and Grupo Calidra have received clearance from the National Institute for the Defense of Competition and Protection of Intellectual Property (Indecopi) to launch a joint venture in the lime sector. Carretera News has reported that the new company will establish a 600t/day lime plant, at an investment cost of US$40m. The partners expect to commission the plant in early-mid 2025. Unacem, which holds a 51% stake in the venture, has reported that it and Grupo Calidra will fund the growth from a combination of their own finances and bank loans.