Displaying items by tag: Slag

Finland: Geoprime producer Betolar has named Riku Kytömäki as its new president and CEO. Riku's professional background is in materials technology, having served as president and CEO of Exel Composites and held senior positions in Switzerland-based ABB. Kytömäki holds board positions in several international companies and organisations, including polymers producer Teknikum Group. He has management experience in Asian markets where Betolar has expanded during the past few years.

Betolar said "Riku will lead Betolar through its next growth phase as its Geoprime solution is entering active production. Geoprime is a next-generation, low-carbon solution and sustainable alternative to cement: it delivers 80% fewer emissions and 100% cement-free building materials with the same performance as traditional concrete."

Austria: Rail logistics company ÖBB Rail Cargo Group (RCG) says that its haulage of 80,000t/yr of granulated blast furnace slag (GBFS) and clinker to and from w&p Zement's Wietersdorf cement plant in Carinthia by rail has removed 3200 trucks/yr from the road since its start in 2019. RCG's trains deliver the plant's clinker to the Peggau-Deutschfeistritz railway station in Styria, and return to the plant laden with GBFS from steel producer Voestalpine's nearby Leoben refinery.

RCG said that w&p Zement is currently working to increase its operations' reliance on rail, adding "Further innovative transport solutions are already being worked on."

US: Bulk material handling equipment supplier MDG America says that it delivered four chain bucket elevators for Drake Cement's upgrade of its Paulden cement plant in Arizona. Drake Cement installed a new vertical mill grinding plant for cement, granulated blast furnace slag (GBFS) and raw materials grinding at the 0.7Mt/yr integrated plant. The supplier says that two of the elevators will work in a pair, conveying material from a feeder belt, while a third will convey it to the new mill. The fourth elevator will then collect the material for further grinding and metal discharge.

Drake cement secured approval to mine pozzolan for use in the Paulden's plants cement production at Bill Williams Mountain earlier in October 2022. As part of minimising the future mine's impacts, Drake Cement has offered to help the US Forestry Service to thin local woodland as part of local anti-fire management efforts.

Italy: Buzzi Unicem has obtained technical evaluation certification for CEM II/C-M Portland composite cement products to be manufactured at its Trino, Vernasca, Settimello, Guidonia, Barletta and Augusta plants. The new cements will be part of its C-Green product line and the sustainability objectives from its 2030 roadmap. The new products will reduce their clinker factor by using granulated blast furnace slag, fly ash, pozzolan and limestone. They potentially offer up to a 40% reduction in CO₂ emissions per tonne compared to CEM I equivalents. They will be available in 32.5 N/R and 42.5 N/R strength classes for a range of applications. The cement producer hopes that the new products will quickly establish themselves in the market and even becoming the “standard cement” in Italy by 2030.

Bangladesh: The high rate of the US Dollar against the Bangladeshi Taka is forcing local cement producers to raise their prices despite an increase in imports of volumes of raw materials. The country imported 5.12Mt of clinker, granulated slag, limestone, gypsum and fly ash in July and August 2022, a rise of 34% year-on-year, according to the Daily Star newspaper. Golam Kibria, the general manager of Premier Cement, said that the negative currency exchange effect was the main cause of local price rises for cement since the cost of raw materials on international markets had remained stable in recent months.

The country imported 36.1Mt/yr of raw materials for cement production in the 2021 – 2022 financial year. These materials mostly came from Thailand, Vietnam and China through ports in Chattogram and Mongla. This compares to imports of 16.8Mt in the 2017 – 2018 financial year.

US: Royal White Cement has leased a site on the Houston Ship Channel in Houston, Texas. Local press has reported that the company plans to build its second cement terminal in the city there. Houston Peninsula Terminals will operate unloading systems for the storage of cement across three facilities at the site. It is also equipped with multiple railway tracks and heavy truck loading facilities. Royal White Cement owner Marcel Fadi said that the move would help the producer to expand its footprint in Houston and beyond.

Fadi said "We have long operated in the Houston market, but this direct access to storage and bulk unloading along the channel will provide greater efficiencies and flexibility, allowing Royal White Cement to handle and store approximately 100,000t of multiple cementitious products such as slag, grey cement, and white cement."

UK: Bunting plans to promote its magnetic separator and metal detector products at the Powtech trade fair taking place in Germany in late September 2022. The company will be displaying a number of high-strength rare earth magnetic separators including its Plate Magnet Housing (PHMS), Drawer Magnet (HFS), Grate Magnet, Plate Magnet and Bullet Magnet products. Each magnetic separator effectively removes fine tramp iron from a wide range of granules and powders at different locations within a plant. The company promotes its products to the aggregate, quarrying, recycling and slag processing sectors amongst others.

Sri Lanka: Insee Cement has broken ground on its construction of a 45,000m³-capacity storage facility at Hambantota International Port. When commissioned in early 2023, the facility will store ground granulated blast furnace slag (GGBFS) for use in Insee Cement's cement production. Daily News has reported the cost of the facility's construction as US$3m. At 17,300m², the Hambantota storage facility will be the largest warehouse at any port in Sri Lanka.

Insee Cement chair and CEO Nandana Ekanayake said "Hambantota Port is a vital link in our raw materials supply chain. Insee Cement has been using this port since 2018 and so far we have cleared around 1.7Mt of bulk cargo through the port, of which we did a little over 1Mt in 2021. Today, we laid this foundation as another step to strengthen our partnership with Hambantota International Port Group." Ekanayake concluded "We see great potential in developing channels through Hambantota International Port and we will double our investment in the future."

A trio of slag cement stories have been in the sector news this week with reports from Australia, France and Sri Lanka. Of note from the first two reports is a focus on supplies of slag.

The first concerns Hallett Group’s US$80m supplementary cementitious materials (SCM) project in South Australia. This will see the company process slag and fly ash sourced from sites in the region to manufacture blended cement products and standalone SCMs. These will be principally milled, blended and distributed from a site at Port Augusta. However, an additional distribution site at Port Adelaide is also planned that can both import and export the company’s products in a bid to cut down on supply chain risk, particular for its mining customers. The company says it will replace up to 1.15Mt/yr of cement when fully operational, although initial production looks set to be about a third of this based on local media reports. Commissioning of the Port Adelaide distribution hub is scheduled for May 2023, following by the Whyalla Granulator in January 2024 and the Port Augusta processing plant in June 2024. Pointedly, Hallett Group is explicit about where is plans to source its SCMs from: Nyrstar Port Pirie and, potentially, Liberty GFG.

The second slag-themed story hails from France, where Hoffmann Green Cement has acquired ABC Broyage, which operates a slag grinding plant in North Dordogne. Like the project in Australia above, Hoffmann Green is focused on its supply chain. With this acquisition it will be able to grind its own blast furnace slag instead of buying it. Raw blast furnace slag will be imported via the port of La Rochelle where the company has storage silos. It will then be ground at the former ABC Broyage site and sent on to Hoffmann Green’s H1 and H2 production sites, located at Bournezeau in the Vendée region. Finally it will use it to manufacture its H-UKR and H-IONA cement products. There is no mention of how much the acquisition is costing Hoffman Green. Instead the emphasis, according to company founders Julien Blanchard and David Hoffmann, is very much to, “strengthen our control over our supply and secure our margins in the current highly inflationary context.”

Finally, the week’s third slag-themed cement story is from Sri Lanka, where local media reports that Insee Cement has started producing Portland Composite Cement, using SCMs such as slag, at its Ruhunu grinding plant. This story follows the trend of cement producers around the world switching to greater usage of blended cements, often for sustainability reasons. Unfortunately, political events in Sri Lanka are overshadowing everything else locally, with the president having fled amid social unrest provoked by the ongoing and severe economic crisis. To this end Insee Cement has astutely also donated medical supplies this week to the intensive care unit at the Colombo National Hospital.

These slag stories are important for the cement sector can be demonstrated by a recent update to the Center for International Climate and Environmental Research - Oslo’s (CICERO) research on global CO₂ emissions from cement production. When it published its estimate for 2021 it found that overall emissions were 2.6Bnt in 2021 or just over 7% of the world’s total CO₂ output. What is worse though, is that its data suggests that cement-based emissions have steadily grown year-on-year from 1.2Bnt in 2002. Apart from a dip in 2015 they have kept on rising! This can mostly be attributed to the growth of the Chinese cement industry in the early 2000s suggesting that a tipping point may be reached in the current decade as lowering cement production CO₂ intensity finally kicks in.

Slag and other SCM-based blended cements fit in here as they are one of the ‘easiest’ ways to reduce the clinker factor of cement and concrete and thereby reduce the sector’s CO₂ levels. Hence they keep popping up on the various roadmaps and reports for the cement industry to reach net zero. The flipside of this however is that slag is becoming harder to source as the demand for granulated blast furnace slag increases and less new steel plants get built, especially in North America and Europe. Hence the focus on the supply of slag in the first two news stories above. Blended cements may be the future but getting there will be far from simple.

Sri Lanka: Insee Cement's Ruhunu cement plant in Galle has begun producing Portland composite cement (PCC) using slag and fly ash. Insee Cement first produced PPC at its Puttalam cement plant.

Insee Cement's head of products and solutions Moussa Baalbaki said "Insee Cement introduced PCC for the first time to the local market in 2021 as part of a two-pronged approach: to create value for our customers by augmenting the sustainability performance in their constructions, and also to steer Sri Lanka's construction industry towards ambitious, globally benchmarked sustainable goals." Baalbaki continued "We are truly encouraged by the growing demand across the local market for PCC, and trust our production expansion to Galle is testimony to our commitment towards sustainable production practices."