Displaying items by tag: Plant

Egypt: Korra Energi has been awarded a contract to build a 20MW waste heat recovery (WHR) unit at Suez Cement’s Helwan plant. The WHR unit will serve both of the plant’s two production lines. Korra Energi says it will be the first WHR project for a cement company in the country. Korra Energi is an Egypt-based engineering company and a subsidiary of conglomerate Korra.

Morocco: LafargeHolcim Maroc is preparing to export clinker to West Africa in early July 2022. The shipment will be the plant’s second clinker export following a consignment of 40,000t to Guinea, according to the Les Eco newspaper. The plant, based near Tidsi, has been operational since late 2021.

Morocco: Holcim subsidiary LafargeHolcim Maroc has released information about its 1.6Mt/yr Agadir cement plant in Souss-Massa Region. The producer invested US$299m in the plant’s construction and it has been operational since late 2021. The plant is highly automated in line with Holcim’s Plants of Tomorrow strategy. It will run off wind power from 2023, and also uses alternative fuel (AF). 200 people work at the plant.

In conjunction with its work in setting up the new cement plant, LafargeHolcim Maroc developed drinking water networks in the surrounding area, including the construction of three solar-powered water towers.

India: Gujarat Sidhee Cement has stopped its kiln for a temporary period of 15 – 20 days due to high clinker inventory levels. Cement grinding and despatch will continue unabated. The cement producer operates an integrated plant at Sidheegram in Gujarat.

India: Shree Cement’s board of directors has approved the company’s plans to establish a new US$321m cement plant in Andhra Pradesh’s Guntur district.

Shree Cement currently commands an installed capacity of 46.4Mt/yr. In the 2022 financial year, it produced 30Mt of cement, corresponding to a capacity utilisation of 30%.

Russia: Akkermann Cement reportedly plans to invest US$442m in its construction of the upcoming 3.5Mt/yr Kaluga cement plant. The company says that it expects to complete the project in late 2027. State-owned Prime News has reported that, when operational, the plant will generate 400 new jobs in Kaluga Oblast.

Akkermann Cement acquired the site of the upcoming plant in April 2022.

Coolbrook has been in the news recently with collaboration deals struck with Cemex and UltraTech Cement. First the Finland-based company officially launched its Roto Dynamic Heater (RDH) technology with a memorandum of understanding signed with Cemex in May 2022. Then, this week, it signed a similar agreement with UltraTech Cement.

The specifics of either agreement are unknown but the target is clearly to build an industrial pilot of an electric kiln – or something like it - at a cement plant. Coolbrook says it has run a pilot of its RDH technology in Finland. Further tests are now scheduled to continue for two years starting from September 2022 at the Brightlands Chemelot Campus at Geleen in the Netherlands. Commercial scale demonstrations are scheduled from 2022 with the hope of commercial use from 2024. Links with Cemex and UltraTech Cement seem to suggest progress. At the same time Coolbrook will be testing its RotoDynamic Reactor (RDR) technology, which promises to electrify the steam cracking process used in plastic manufacturing.

Publically available details on the RDH technology are light. In its promotional material Coolbrook says that it can achieve process temperatures of up to around 1700°C. This is crucial to achieve full clinker formation in a cement kiln. Reaching this temperature with non-combustion style kilns, such as solar reactors, has previously been a problem. Notably, Synhelion and Cemex said in February 2022 that they had managed to produce clinker using concentrated solar radiation. Retrofit possibilities and compact equipment size are also mentioned in the promotional material for the RDH. The former is an obvious attraction but size of equipment footprint is increasingly emerging as a potential issue for cement plants looking to reduce their CO₂ emissions. Rick Bohan from the Portland Cement Association (PCA) presented a summary of the potential and problems of emerging carbon capture and utilisation/storage (CCUS) technologies for cement plants in the US at the Virtual Global CemCCUS Seminar that took place on 14 June 2022. He noted that installing CCUS equipment makes cement plants start to look different (more like petrochemical plants in the view of Global Cement Weekly) and that they may require more space to install it all.

Coolbrook hasn’t been the only organisation looking at kiln electrification. The installation with the most available information on kiln electrification has been the Decarbonate project, led by the VTT, formerly known as the Technical Research Centre of Finland. The project has built a pilot rotary kiln with a length of 8m inside a shipping container. It has a production capacity of around 25kg/hr. The system reportedly uses fixed radiant heating coils around the kiln, surrounded by insulation materials. Early results presented to the 1st Virtual Global CemPower Seminar in late 2021 were that the kiln started up, sufficient calcination was occurring and the system was operated continuously for three days at a temperature of 1000°C with no problems reported. Further research was scheduled to carry on into 2022 with longer trials planned for three different materials.

HeidelbergCement’s subsidiary in Sweden, Cementa, completed a feasibility study on implementing electrified cement production at its Slite plant in 2019. It then said that it was conducting further study with electricity producer Vattenfall as part of CemZero project. This consists of three projects running to 2025. Namely: heat transfer with plasma in rotary kilns; direct separation of carbon dioxide from calcination of carbonate-based raw materials in the production of cement clinker and burnt lime; and carbon dioxide-free products with electrified production - reactivity of cement clinker with secondary additives. HeidelbergCement has since announced plans to build a full scale 1.8Mt/yr carbon capture and storage (CCS) plant at the Slite cement plant by 2030.

How this would fit with any kiln electrification plans is unknown. However, one attraction of moving to an electrical kiln, for all of the projects above, is to cut out the 40 – 50% of a cement plant’s CO₂ emissions that arise from the fuel that is burnt. Taking a kiln electric also makes CO₂ capture easier. Much of the remainder of the CO₂ released comes from the decomposition of limestone during calcination when clinker is created. Substitute out fossil or alternative fuels and the flue gas becomes much purer CO₂.

It is early days for cement kiln electrification but progress is happening both commercially and scientifically. The next step to watch out for will be the first pilot installation at a cement plant. One point to finish with is a comment that Rick Bohan made at the IEEE-IAS/PCA Cement Industry Technical Conference that took place in May 2022: carbon capture is expected to double a cement plant’s energy consumption. Kiln electrification is one potential route for cement production to reach net zero. CCUS is another. If one or both occur then a low carbon future could be a high energy one also.

Watch out for Global Cement’s forthcoming interview with Coolbrook in the September 2022 issue of Global Cement Magazine

For more on CCUS, download the proceedings pack for the Virtual Global CemCCUS Seminar 2022

For more on Synhelion and Cemex read the interview in the December 2020 issue of Global Cement Magazine interview

Tajikistan: Fon-Cement has laid the first stone in the construction of its upcoming Ayni cement plant in Sughd Province. Once operational, the plant will create 120 jobs locally.

Egypt: Misr Cement Qena's board of directors has voted for the company to continue operating its Qena cement plant after the end of a management contract with Arab Swiss Engineering Company (ASEC) on 30 June 2022.

Misr Cement Qena reported an operating incomeUS$5.69m in the first quarter of 2022, up by 59% year-on-year from US$3.58m in the first quarter of 2021. Its net profit in the quarter rose by 74% to US$2.56m from US$1.47m.

Pakistan: Fauji Cement has ordered three MVR vertical roller mills from Germany-based Gebr. Pfeiffer for its upcoming Salar cement plant in Dera Ghazi Khan/Punjab Province. The supplier says that the order consists of a 520t/hr MVR 5600 R-4 mill for grinding raw materials and two 180t/hr MVR 5000 C-4 mills for cement grinding. China-based Hefei Cement will handle the order.