Displaying items by tag: Plant

Mexico: Workers at Holcim Mexico’s 1.6Mt/yr Hermosillo cement plant in Sonora have voted to award a contract for their collective union representation to Confederation of Workers of Mexico (CTM) member Cement Industry Worker’s Union (STIC). The El Economista newspaper has reported that 50 workers at the plant, which employs 95 people, voted for the STIC. The runner up, the National Union of Mine, Metal, Steel and Allied Workers of the Mexican Republic (SNTMMSSMR), garnered 17 votes.

The STIC said, “In the framework of this day, under an atmosphere of respect and civility, with rich and enthusiastic participation, the workers have chosen the Cement Industry Workers Union as responsible for continuing to represent with honour the workers of this noble industry."

Pakistan: France-based Schneider Electric will provide a ‘comprehensive electrification solution’ to improve the efficiency and sustainability of cement production at DG Khan Cement’s 3.2Mt/yr integrated Hub cement plant in Karachi, Balochistan. The Nation Newspaper has reported that the supplier’s ECOStruxure product will give operators ‘a full view of energy use across the plant,’ according to the company. Additionally, “artificial intelligence (AI)-powered software will help the company to take a predictive approach to maintenance,” it said.

Hub cement plant general manager Arif Bashir said, “Our goal is to monitor and manage power across our infrastructure efficiently, find electrical faults sooner, fix issues quicker and achieve a faster return on investment. Schneider Electric’s energy efficiency solutions that will improve our performance.”

Uzbekistan: State-owned Uzpromstroymaterialy has announced the start of cement production at a new 0.1Mt/yr integrated cement plant, called the Qurilish Ashyo Sifat Servis cement plant, in Fergana Region following a total investment of US$25.0m. The company has reported that the new plant represents part of the country’s efforts to increase its installed cement capacity by 60% to 20.0Mt/yr in 2020 from 12.5Mt/yr in 2019.

Turkey: Germany-based IKN has announced its appointment by Kentçim Çimento for engineering and installation of a 4500t/day kiln line at the company’s upcoming 1.6Mt/yr Muğla integrated cement plant in Muğla Province. Production manager Mehmet Fatih Ekici said, “May it be good and auspicious for our country.”

Uzbekistan: Uzpromstroymaterialy and South Korea-based Caris have formed an 80:20 public-private partnership for the establishment of a 1.5Mt/yr integrated cement plant in Berinuy region at a cost of US$350m. The Cement and Applications Journal has reported that the upcoming plant, called the Caris Karakalpak Cement, will generate sales worth US$182m/yr and profit of US$126m/yr, according to the owners.

Turkmenistan: Turkmencement’s Lebap cement plant in Koytendag, Lebap region produced 419,000t of cement over the first seven months of 2020, up by 0.4% from 417,000t over the corresponding period of 2019. Turkmenportal News has reported that the rise is due to the start of addition of porphyritic basalt to the clinker mix.

Vietnam: The government has adopted a cement industry development strategy under which all plants below 0.9Mt/yr capacity must make investments to improve their productivity, product quality, energy saving and environmental protection by 2025. In order to facilitate this, the government says it will improve institutions and policies and improve the efficiency of raw materials exploitation, scientific research and industrial application, promoting domestic consumption, increasing available training and tightening environmental protections, according to Việt Nam News. Plants which fail to increase productivity in the specified ways will face closure.

The government says that strategy aims, “to develop the cement industry to an advanced and modern level, to produce cement of international standard quality with economical and efficient use of energy, giving high competitiveness in the international market, while meeting the needs of the domestic market, completely eliminating out-dated, natural resource-consuming and polluting technology for production.” The measure specifically targets the country’s overcapacity issue in its efforts to develop demand and its emphasis on product quality.

India: Metals producer Hindalco has won a contract to supply fellow Aditya Birla subsidiary UltraTech Cement with 1.2Mt/yr of bauxite residue from its aluminium operations, up by 180% from 250,000t in the 2020 financial year, which ended on 31 March 2020. The Economic Times newspaper has reported that UltraTech Cement will use the bauxite residue – or ‘red mud’ – in cement production at 14 of its plants across seven states. As a result of the deal, Hindalco, the world’s largest producer of rolled aluminium, will have full bauxite residue utilisation across three of its refineries. Managing director Satish Pai said, “We have been working with producers to develop high-grade inputs for the cement industry.”

Mozambique: China-based International Cement Group has confined builders working on the construction of its integrated Salamanga cement plant in Maputo Province to the site of the upcoming plant since March 2020. BBC news has reported that 60 Mozambicans have been living in temporary accommodation without being able to leave the site “in order to prevent possible transmission of coronavirus from workers,” according to the company. The group agreed to permit workers to leave from 23 August 2020 following action by a local lawyer.

In case you missed it, last week we covered a news story about Taiheiyo Cement’s plans to step up its lithium-ion battery recycling business at its integrated Tsuruga plant. It’s the latest step in the Japan-based cement producer’s collaboration with recycling company Matsuda Sangyo. The work is timely given that electric cars accounted for 2.6% of global car sales in 2019 and this share is growing. Many of these electric vehicles use lithium-ion batteries and moving away from fossil fuel powered transport creates new problems such as how to manage old batteries that can no longer be used.

Figure 1: Lithium-ion battery recycling process by Taiheiyo Cement and Matsuda Sangyo. Source: Translated from Taiheiyo Cement CEMS technical magazine.

Taiheiyo Cement and Matsuda Sangyo have been working on their process since 2011. First, they dismantle the batteries to extract base metals and plastics. They then heat the batteries in a dedicated ‘roaster’ using waste heat from the cement production process, before crushing and sorting them to remove cobalt, lithium, aluminium and scrap iron. Hydrogen fluoride produced in this stage is sent to the kiln where it is detoxified by calcium. Remaining elements from the battery that are not reclaimed are then used as an alternative fuel by the cement plant.

Taiheiyo Cement says that its roasting equipment can process up to 10t/day but it’s difficult at this stage to assess what demand for this service they might encounter. If, one estimate of 2m/yr used lithium-ion batteries by 2030 is correct and Taiheiyo Cement’s processing rate doesn’t get much higher, then 500 cement plants could possibly solve this problem. Yet, Taiheiyo Cement and Matsuda Sangyo have made no mention of the economics of their process. Other recycling methods also exist and research into new ones is ongoing. Cement plants recycling batteries might be economic compared to these alternatives or it might not, only time will tell.

The wider point here is that here is yet another industrial and logistical process that can potentially be linked to cement production. It follows well known ones, such as using alternatives fuels or captive power plants, or more novel ones, such as CO₂ or hydrogen networks. In each case the business of making cement changes as new methods are learned, new commodities are sought and new markets are connected. The cement company then has a choice about how involved it wants to become with each new process. The classic example here is the waste processing companies that surround co-processing, with some cement companies having their own dedicated subsidiaries, for example LafargeHolcim and Geocycle.

As it all becomes more complicated the role of a cement plant slowly becomes redefined. If a cement plant disposes of municipal waste and car batteries for its local community, generates electricity from its solar or wind plant for a nearby city and uses its CO₂ to either produce biofuels, plastics or baking soda is it still just a cement plant? The pivot by building materials manufacturers in recent years from a focus on cement to concrete suggests that once the societal or economic conditions are right it could change. For the time being cement plants remain cement plants but give it a thought next time you buy a new car.