Displaying items by tag: Plant

Russia: Eurocement has resumed the packaging line at its Oskolcement plant. It sells products in 50kg bags. The packaging line uses equipment from Germany’s Haver & Boecker and Beumer.

Nigeria: BUA Group has ordered a 48MW power plant from Finland’s Wärtsilä for a new production line at its Sokoto cement plant. The power plant will operate without connection to an electricity grid and it will operate on five Wärtsilä 34DF dual-fuel engines, running primarily on liquified natural gas (LNG) but with the capability to switch to low pour fuel oil (LPFO) if necessary. The site’s two existing power plants operate on heavy fuel oil (HFO).

The Wärtsilä equipment is scheduled for delivery at the end of 2019, and the new plant is expected to become operational in mid-2020. No price for the order has been disclosed.

Nigeria: David Umahi, the governor of Ebonyi state, has approved plans to set-up the Ebonyi Cement plant (Ebocem) at Ogboto in Ishielu. The local government will hold a 10% stake in the project, according to the Nigerian Tribune newspaper.

US: Lehigh Cement and Argos USA have agreed to pay a US$1.5m fine for alleged Clean Air Act violations at the Martinsburg cement plant in West Virginia. Argos has owned the plant since December 2016 and Lehigh Cement was the previous owner. The violations occurred from 2013 to 2016. Neither Lehigh Cement nor Argos USA admitted liability for the alleged violations as part of the settlement.

The Environmental Protection Agency (EPA) cited the companies for various Clean Air Act violations based on responses to EPA information requests and data collected and reported under the plant’s permit. These included exceeding particulate matter emissions, non-compliance with opacity testing, failing to comply with requirements for operating a kiln with dioxin/furan emission limits, failing to perform required stack testing on a kiln’s exhaust in a timely manner and other violations.

Good news for Cemex Colombia this week with an agreement reached to open its Maceo cement plant in Antioquia. Local media was reporting that the cement producer has struck a government-brokered deal with CI Calizas y Minerales to lease the land it built its plant on. Finally, the new(ish) US$350m integrated plant can start operation.

For those unfamiliar with the debacle, Cemex has been fighting the fallout publicly since 2016, following a dodgy land deal at the site. The 1Mt/yr integrated Maceo plant was originally announced in 2014 with full operation scheduled for late 2016. Then, in October 2016 Cemex fired several senior staff members in relation to the project and its subsidiary’s chief executive resigned. This followed an internal audit and investigation into payments worth around US$20m made to a non-government third party in connection with the acquisition of the land, mining rights and benefits of the tax free zone for the project. Other irregularities are also alleged to be linked to the project. As well as the Colombian authorities being involved, the US Department of Justice is also running its own investigation into the affair with wider implications for Cemex’s operations in other Latin American countries. Some of the sacked staff members and others have since been investigated on corruption charges.

Graph 1: Cement production in Colombia, 2010 – 2018. Source: DANE.

Looking at the wider Colombian market though, it does make one wonder whether the long-delayed plant is really necessary. As Graph 1 shows, cement production rose steadily year-on-year to 2015 before it hit a downturn. It reached a high of 13Mt in 2015 before declining. Production in 2018 grew slightly compared to 2017 but not at the same rate seen previously. In Antioquia specifically despatches increased by 1.3% in 2018, above the national average of 0.2%. Despatches now appear to have continued into January and February 2019.

Cemex Colombia started to benefit from an improved fourth quarter in 2018 as the general economy picked up. Despite this its overall net sales and operating earnings fell in 2018. However, it did flag its earnings margin as a concern with higher freight and energy costs in the fourth quarter of 2018, although it partially offset this with higher prices. Cementos Argos, the other big producer in Colombia, reported a similar picture to Cemex, although in a better position. Its cement volumes fell slightly for the year in 2018 but picked up fast in the fourth quarter. Annual revenue was down slightly, as were adjusted earnings. In its opinion the construction industry improved in the second half of 2018 due to an improved housing market and infrastructure projects.

Given the downturn in production since 2015 the thought does occur whether the opening of the Maceo plant being delayed accidentally helped Cemex or not. It has probably been losing money by not running the plant but if, for example, the company had some sort of insurance to protect it against unexpected delays it might still benefit. However, if evidence of serious wider misconduct in both Colombia and other Latin American countries are found by the US authorities, then things could get expensive. This would be unfortunate, particularly in Colombia, given that the market looks set to recover.

Pakistan: Maple Leaf Cement has commissioned a new 7300t/day production line at its Iskanderabad plant. The upgrade will increase the unit’s total production to 18,000t/day. The line was supplied by Denmark’s FLSmidth. The total cost of the project was US$184m. Commercial production on the new line is scheduled to start in late April 2019.

Saudi Arabia: Arabian Cement says that the National Electricity Transmission Company plans to complete an expansion to a high-voltage plant in Rabigh by the third quarter of 2021. The project has been delayed but the cement producer said that this will have no financial impact, according to Mubasher. Arabian Cement originally signed an agreement with the National Electricity Transmission Company to supply electricity to its Rabigh plant in 2015. In November 2018 it said that an upgrade to its cement mills was 80% complete.

Botswana: Rachit Josh, the managing director of Matsiloje Portland Cement, say that the company will struggle to reopen without government support to block imports. The cement producer closed its plant at Matsiloje, near Francistown in January 2018, according to the Monitor newspaper. Josh blamed cement imports from South Africa as being a particular concern.

In June 2018 the Ministry of Industry, Trade and Investment said it was starting to introduce restrictions on imports restricting imports to 70% locally sourced product. However, it is unclear when these measures will be implemented.

Matsiloje Portland Cement is a subsidiary of Nortex Group. Its integrated plant had a production capacity of 30,000t/yr. The company produced the lime it used for its cement and it sourced other raw materials from South Africa and fly ash from a power station at Morupule.

Colombia: Cemex Colombia has reached a deal with the Attorney General allowing it to operate its Maceo cement plant in Antioquia. Under the terms of the government-brokered agreement Cemex will lease the land from CI Calizas y Minerales for around US$15,000/yr, according to the El Espectador newspaper. The lease has a duration of 21 years and this can be extended by another 10 years.

In 2016 Cemex fired several senior staff members in relation to the Maceo project and its subsidiary’s chief executive resigned. This followed an internal audit and investigation into payments worth around US$20.5m made to a non-governmental third party in connection with the acquisition of the land, mining rights and benefits of the tax free zone for the project. The US Department of Justice is also investigating the project.

Austria: Unitherm Cemcon has launched the MAS DT rotary kiln burner, a new product in its Mono Airduct System (MAS) product line. The new burner is already in operation at six cement plants in Austria, Germany and France.

The new design uses a more efficient primary air injection, resulting in higher effective momentum and optimised combustion. Placing the adjustable primary air openings directly at the burner tip leads to unobstructed injection of the air jets into the kiln. With minimum losses at the air nozzles, the entrainment of secondary air is improved by approximately 15%.

The new primary air system, with discs instead of flexible hoses, requires less space inside the primary air channel. Therefore, the burner is smaller in diameter and lighter in weight, which reduces investment costs. Unitherm Cemcon says that the cooling of the outer jacket tube with the MAS system (hose and disc design) is superior to that of other rotary kiln burners, as 100% of the primary air is used for cooling. With the new disc system, the cooling of the burner tip is improved even further. The producer added that all new MAS DT burners showed improved lifetime of the refractory lining at the burner. On average the refractory lifetime is extended by approximately 20%.