Displaying items by tag: Texas

US: Welding Alloys has released information about a project to rebuild a FCB Horomill at Buzzi Unicem’s Maryneal cement plant in Texas in early 2018. The engineering company’s Mexican subsidiary Welding Alloys Panamericana has experience of rebuilding these types of mills and it collaborated with the group’s American wing, Welding Alloys USA, on the project.

US: US Cement is in the process of obtaining a draft air permit from the Texas Commission on Environmental Quality to build a white cement plant in Brady, Texas. A public hearing on the application will be made in late June 2018. The subsidiary of Royal White Cement plans to build a single line 0.5Mt/yr white cement plant.

US: The Portland Cement Association (PCA) has announced the winners of the 2018 Safety Innovation Awards. The awards recognise creative safety-enhancing projects in the cement industry. Winners were determined by a panel of judges that evaluated submissions from across the country for milling/grinding, distribution, pyroprocessing and general facility.

Cemex USA’s Miami plant Florida won the milling/grinding category with its new process to load ball mills. The site developed a new mill loading process that uses a small hopper for grinding media, and an incline transport system with buckets to convey the grinding media directly to the mill. This new system eliminates the interaction between the employee and the machine, reduces the number of people needed to load the mill from five to two, and eliminates the need for employees to stand on top of the mill. This new system also improves mill loading rates from seven drums/hr to 30 drums/hr.

Cemex USA’s Houston operations in Texas won the pyroprocessing category for it use of drones for hazardous inspections. It has implemented a system for using protected air drones to inspect enclosed and confined spaces. Visual inspections of enclosed areas (preheater towers, tanks, silos, process ducts, etc) normally require intrusive equipment, long delays for system cooling, and placement of employees on scaffolding in confined spaces. These drones utilise an outer protective cage to minimize the risk of breakage due to impact. The drone program has eliminated the risk of putting staff in confined spaces, reduced the cost of scaffolding, and reduced the overall time for inspections.

LafargeHolcim US’ Corporate Program in Chicago won the distribution category for its X-Factor barge cover. It has developed a process for barge cover removal that reduces the risk of falls from employees stepping on to the barge. The X-Factor barge cover, developed over the last three years with a contractor, uses the latest technology and a no-touch design to allow a crane operator to perform all functions associated with barge lid handling without additional human assistance. Barge workers will no longer be required to step onto the barge to remove or replace barge covers, eliminating a potential fall risk.

Ash Grove Cement’s Louisville plant in Nebraska won the general facility category for its use of magnets as duct hole patches. Ash Grove has developed a hole-patch technique using magnets. Magnetic patches are quick, simple, and effective at preventing or limiting the release of materials from holes created in ducts caused by abrasion, leading to a cleaner plant, reduced slip, trip and fall risks, and fewer related Mine Safety and Health Administration housekeeping citations.

Cemex USA’s Brooksville in Florida also won the general facility category for its filters moved to ground level project. It redesigned the blower housings to move the filter from the top of the blower housings to an easily accessible location at ground level. The redesigned blower housing eliminates the need for employees to climb up and down a ladder, reducing overexertion and fall hazard.

US: A US$2.3m air pollution settlement in 2006 from the Holcim US Midlothian cement plant in Texas has ended. The Sue Pope Pollution Reduction Fund has made its last donation of about US$75,000 to the Midlothian school district’s special needs programs, according to the Dallas Morning News newspaper. The final payment came from interest remaining from the original settlement between Holcim US, the Environmental Protection Agency (EPA) and the Downwinders at Risk environmental group. As part of the deal Downwinders at Risk agreed to stop fighting Holcim’s plans to expand cement production at the site in return for US$2.25m funding towards local projects and an understanding that the cement plant would upgrade its emission filters.

HeidelbergCement made Italy’s Cementir Holding its Valentine last week in the form of a deal for the Italian company to buy up the remaining shares in Lehigh White Cement in the US. Cementir takes control of the former joint venture by upping its share to 63.25% for US$107m and one of the other partners, Cemex, increases its share to 36.75% for US$34m. Despite making the announcement on Valentine’s Day HeidelbergCement then described the sale in fairly unromantic language, “As a niche product with small volumes, the standalone production of white cement does not fit to the strategic focus on efficiency of HeidelbergCement.” Maybe they could just send flowers to each other next year instead!

More seriously, this latest deal by Cementir is yet another intriguing evolution of the Italian multinational building materials producer. The company says it is the largest white cement producer in the world through subsidiaries like Aalborg Portland in Demark, Sinai White Cement in Egypt and Lehigh White Cement in the US. Its plant at El-Arish in Egypt is the largest white cement unit in the world. In 2016 it reported a white cement production capacity of 3.3Mt/yr from six plants in Denmark, Egypt, China, Malaysia and the US. Its volume sales of white cement were 2.2Mt at this time or a capacity utilisation rate of 67%. In the US it operates two white cement plants located in Waco, Texas and York, Pennsylvania with a total capacity of 0.26Mt/yr, as well as a distribution network throughout the country, which is also used to distribute white cement imported from its partners across North America. In 2017 Cementir produced 10.3Mt of Ordinary Portland (grey) Cement and white cement, a rise of 24.6% year-on-year from 8.25Mt in 2016. The boost was delivered by the acquisition of Compagnie des Ciments Belges. Like-for-like sales volumes increased by around 1.7% year-on-year.

Cementir left the Italian market in 2017 when it sold Cementir Italia to HeidelbergCement for Euro315m. As this column commented as the time (GCW320) the deal seemed cheap given that HeidelbergCement paid Euro315m for five integrated cement plants plus extras. However, Cementir appeared to actually make a profit on Sacci which it picked up cheaply in 2016.

Now HeidelbergCement has returned the favour by selling Cementir the controlling stake in Lehigh White Cement. The German cement producer may have grumpily rubbished the sale in its press release but the language makes one wonder whether this was a quiet part of the Cementir Italia deal in 2017. The white cement industry is miniscule compared to the OPC one but HeidelbergCement has just handed even more control of it to Cementir. From Cementir’s perspective this probably seems very efficient.