Displaying items by tag: Northern Ireland

Northern-Ireland based cement producer Cemcor said this week that it has completed trials of a calcined clay cement product called CalcinX. The company started its trials in 2023 and it has been supported by Queen’s University Belfast and funding from Innovate UK. Work with commercial partners has involved precast concrete paving manufacturer Tobermore producing paviours made from 50% CalcinX as a CEM II replacement and Moore Concrete has also manufactured precast units using 50% CalcinX as a CEM I replacement. So far over 3000t of CalcinX has been produced in a number of industrial-scale trials.

David Millar, the managing director of Cemcor, mentioned his company’s plans for calcined clay in June 2022 when he was interviewed by Global Cement Magazine. The company that became Cemcor bought the Cookstown cement plant and a few other assets from Holcim at the start of 2022. It then changed its name to Cemcor in November 2022. At the time of the interview the company was looking to “...develop new value-added products, including low-CO₂ options. This will allow us to use the same amount of clinker to produce more cement.” Millar couldn’t give away too many details at the time, however calcined clay was cited specifically. It was also noted that the company had the right material in its quarry and that it was already working with partners on it.

Amongst all the other decarbonisation options available for cement plants, a slow trickle of calcined clay projects keep being announced. In January 2025, for example, thyssenkrupp Polysius said it had secured a front-end engineering design contract from Circlua for the construction of the world’s largest activated clay plant in Brazil. This project in Para state will have a capacity of 3000t/day, will use renewable energy sources and will “improve the CO₂ footprint in cement production.” CBMI Construction also officially launched a flash calcination clay project in Tangshan, Hebei province in China. In December 2024, Vicat signed an agreement with the US Department of Energy (DOE) Office of Clean Energy Demonstrations to develop the Lebec Net Zero (LNZ) project at its Lebec cement plant in California. This includes plans to produce calcined clay-based cement. Earlier in the autumn of 2024 Portugal-based Cimpor said it was preparing to convert a kiln at its Souselas plant to produce calcined clays, AVIC International Beijing and KHD said that they had secured a deal to build a 900t/day clay calcination plant for Ciments de l'Afrique (CIMAF) in Burkina Faso, and Holcim Česko said it was going to construct a calcined clay processing line at the Čížkovice cement plant in the Czech Republic.

One news story that stuck out in the autumn was the progress of a collaboration between Aumund and Holcim towards developing an electric linear calcination conveyor (eLCC). The two companies started work on the project in 2020 intending to look at the electrical calcination of clay using an Aumund pan conveyor. Initial tests of the eLCC reportedly demonstrated efficient thermal activation of clay through a combination of radiant heat and material circulation. The eLCC system is fully enclosed, insulated, has a compact design and can operate using electrical-powered renewable sources. The first industrial plant utilising this technology is scheduled for construction in 2025. Calcined clay technology and products by other industrial suppliers are available. The work by Aumund and its competitors show they are watching this market closely.

OneStone Consulting’s Joe Harder has found that only 14 clay calcination plants were operational worldwide in 2023 with a production capacity of just under 3.5Mt/yr. These are based in Latin America, Europe and Africa. In an article previewing a market report in the February 2025 issue of Global Cement Magazine, Harder predicts that by 2035 there will be 79 clay calcination plants with a capacity of just under 21Mt/yr. A steady growth of over 20 new plants annually is also expected subsequently from 2035 to 2050 as cement producers seek cost-effective ways to reduce their clinker factor. He identified installation costs, a lack of knowledge about clay-based cements, trouble obtaining mining rights and policy issues amongst other issues as holding back the use of clay calcination.

The current expectation is that calcined clay usage in the cement industry will be a minority option. Yet the size of global cement production can make a production share of, say, 3 - 8% a viable option for both cement manufacturers and equipment suppliers. The adoption of new cement products and standards can also take a long time and this clouds predictions of how far clay can go in the cement industry. At this point in the calcined clay story it is time to keep track of the new projects being set up.

Joe Harder will present a talk entitled ‘Calcined clay market trends by 2035’ at the Global FutureCem Conference taking place in Istanbul in early February 2025

One surprise at the end of August 2024 was that Türkiye-based Çimsa has agreed to buy a majority stake in Ireland-based Mannok. The subsidiary of Sabancı Holding signed a deal to acquire just under a 95% stake in Mannok Holdings based on an enterprise value of Euro330m for 100% of the shares. The final purchase price will be determined later in the process, as will a potential completion date subject to the usual regulatory approvals.

Çimsa has described the deal as its “third major global initiative in the past three years” following expansions in the US and Spain. Çimsa started production at its 0.3Mt/yr white cement grinding plant in Houston, Texas in 2019. It is currently planning to set-up a 0.6Mt/yr grey cement grinding plant, also in Houston, with operation expected to start by the end of 2024. Its Spain-based business received a boost in mid-2021 when it purchased the Buñol white cement plant in Valencia from Cemex. Outside of Türkiye the company also operates a few terminals in Germany and Italy. Of interest to this article it established a subsidiary for sales in the UK in mid-2023.

Mannok was previously known as Quinn Group before it was rebranded in 2020. In addition to cement the company sells a range of construction products including PIR (polyisocyanurate) insulation, aircrete thermal blocks, roof tiles and precast concrete. The company is headquartered at Derrylin in Fermanagh, Northern Ireland in the UK but it operates in both Ireland and the UK. It runs a 1.4Mt/yr integrated plant at Ballyconnell, County Cavan in Ireland, just across the border from Derrylin. With the 17th Global CemFuels Conference scheduled to take place next week in Dublin, it is worth noting that this cement plant had a recent upgrade of interest to the alternative fuels sector. In 2023 the company said that it had installed the world’s first FLSmidth Fuelflex Pyrolyzer at a cement plant following an earlier pilot of the system back in 2018. It is used to replace coal with solid recovered fuels (SRF) in the pre-calcination stage of cement production. Later in 2023 Mannok said that the equipment was reducing its CO₂ emissions by 58,000t/yr.

As reported in the October 2023 issue of Global Cement Magazine, cement from the Ballyconnell plant is sold in both Ireland and the UK. In 2022, 35% of its sales were in Ireland, 30% in Northern Ireland and the remaining 35% in the rest of the UK. The company uses a storage unit at Warrenport in Northern Ireland to despatch cement to a 8400t cement storage and distribution at Rochester in Southern England.

Çimsa said that the acquisition is intended to help it to increase the share of its revenue in foreign currencies to over 70%. It is not a revelation that Çimsa might want to do this given the parlous state of the economy in Türkiye since 2018. Interest rates are high and the Turkish Lira has lost value. Çimsa raised the issues this has caused in its 2023 annual report. These include higher costs for imported goods and services such as energy, equipment and engineering services. In 2023 the company reported that 57% of its sales consisted of foreign currency-based revenue. The same year exports represented just under 40% of the company’s total revenue. Overall, Çimsa’s revenue fell slightly year-on-year in 2023, in part due to the divestment of a cement plant and other assets, but earnings rose significantly.

Buying Mannok gives Çimsa another route into the European Union (EU), via Ireland, and the UK. Crucially, this gives its first integrated grey cement production site outside of Türkiye. Both of these things are especially useful for an export-focused company facing increasing hurdles to sales in the guise of the EU Emissions Trading Scheme. It also helps the business to further hedge against negative currency exchange effects back home in Türkiye. So ‘Sláinte’ to Çimsa and Mannok, and good luck.

The 17th Global CemFuels Conference & Exhibition takes place in Dublin, Ireland on 18 - 19 September 2024

UK: Cookstown Cement has rebranded as Cemcor. The company formed in January 2022 following its acquisition of the 0.45Mt/yr Cookstown cement plant from Holcim in January 2022. It then announced investments of around Euro14m towards making environmental and process upgrades at the unit. The company also purchased a limestone quarry in Cookstown, a shale quarry in Dungannon and a terminal at Belfast Harbour.

UK: Paul Brogan has started his two-year tenure as the chair of Mineral Products Association Northern Ireland (MPANI). He is the managing director of McQuillan Companies and has worked for the company for over 25 years. Paddy Mohan, the cement sales director of Mannok, will work as vice chair. MPANI is an industry body which represents the mineral products industry in Northern Ireland.

UK: Northern-Ireland-based Cookstown Cement plans to invest around Euro14m on environmental and process upgrades to its integrated 0.45Mt/yr plant in Cookstown. The company is managed and co-owned by David Millar, a sales director with Lafarge, according to the Belfast News Letter newspaper. Holcim announced the sale of its cement business in the region in late January 2022. Cookstown Cement has acquired a cement plant, a limestone quarry in Cookstown, a shale quarry in Dungannon and a terminal at Belfast Harbour.

UK: Holcim has sold its cement business in Northern Ireland to Cookstown Cement for Euro67m. The latter is a newly formed local construction company established by a longstanding business partner of Holcim. It will take control of Holcim’s integrated 0.45Mt/yr Cookstown cement plant.

Miljan Gutovic, Region Head EMEA at Holcim, said, “This divestment advances our ‘Strategy 2025 – Accelerating Green Growth’ with a focus on consolidating our leadership in core markets to become the global leader in innovative and sustainable building solutions. With Cookstown Cement, we are pleased to have found a strategic and trusted owner for the business, better positioned to continue investing in its long term growth. We are delighted about Cookstown Cement’s vision, offering a solid platform for the team to continue to thrive.”

UK: Northern Ireland-based Terex Materials Processing has appointed Matt Dickson as Business Line Director for Terex Finlay and General Manager of its Omagh site, and Barry O’Hare as Business Line Director for EvoQuip. Paul O’Donnell, the previous Business Line Director for Terex Finlay, will become the Director of Strategic Sourcing at Terex Materials Processing.

Dickson has led the EvoQuip business for the last four years and holds a commercial and engineering background. He previously worked for Terex Finlay in Omagh for over 10 years, eventually becoming its Engineering Director.

O’Hare holds experience in the crushing and screening industry, having worked in several positions for Powerscreen and Terex MPS over the past 12 years. Most recently, he worked on strategic and operational sales for EvoQuip and led the development and management of territory sales.

UK: Lafarge Cement, part of Aggregate Industries and LafargeHolcim, has appointed John Mulgrew as the new plant manager of its Cookstown integrated cement plant in County Tyrone, Northern Ireland. He succeeds Russell Larmour who is to retire after 40 years within the company. Mulgrew will report to Barry Hope, Head of Cement on the Executive Committee at Aggregate Industries.

Mulgrew joined the LafargeHolcim Group as a quality co-ordinator in 2001, holding almost 20 years of experience in the cement industry. He became production manager at the Cookstown plant in 2016. The company says that the plant achieved its best results to date in 2019 after being ranked in the top 10 of LafargeHolcim’s European cement plants when evaluated against industrial benchmarks.

Jason Bowman will succeed Mulgrew as the new production manager at the plant. He has been promoted from his current role as manufacturing manager at Cookstown.

UK: Northern Ireland’s Telestack plans to invest Euro5.8m towards upgrading its Omagh plant. The mobile bulk material handling system producer will build a new 4180m³ plant next to its existing site. The new unit will include production lines, a research and development centre and new office premises.

“Telestack has grown rapidly over the last number of years and we have firm plans to double our revenue again in the next three and a half years. We have out-grown our current facility and we need to extend our manufacturing footprint to meet the international demand for our products. We have made a conscious decision, even in the face of Brexit uncertainty, to invest locally” said Telestack’s managing director Martin Dummigan.

UK: Lafarge Cement is celebrating 50 years of production at its Cookstown plant in Northern Ireland. The plant opened in 1968 and today it employs almost 100 staff both in Cookstown and at a cement terminal in Belfast. Lafarge Cement was later acquired by Aggregate Industries in 2015 as part of the merger between Lafarge and Holcim that created LafargeHolcim.

“Fifty years is a significant milestone and follows the successful 60th anniversary celebrations that took place at our sister cement plant in Cauldon in 2017,” said plant manager Russell Larmour. “The success at Cookstown is testament to the many generations of people here in County Tyrone who have helped shape the business today. As we now look to the future, and many more years of production, we are committed to maintaining our position as a leading, sustainable business partner at the heart of the UK’s construction industry.”