Displaying items by tag: ThyssenKrupp Polysius

Europe: Sweden-based SaltX has signed a letter of intent with German engineering firm thyssenkrupp Polysius to collaborate on establishing 100% electric cement production facilities in Europe. The facilities will combine SaltX’s electric arc calciner (EAC) technology with thyssenkrupp Polysius’ material handling solutions.

CEO of SaltX Lina Jorheden said "Strong partnerships are essential for us to effectively implement our technology and reduce millions of tonnes of CO₂ emissions from the industrial sector. Our collaboration with thyssenkrupp Polysius is crucial for developing complementary systems to the EAC technology and building electrified facilities for our customers."

Northern-Ireland based cement producer Cemcor said this week that it has completed trials of a calcined clay cement product called CalcinX. The company started its trials in 2023 and it has been supported by Queen’s University Belfast and funding from Innovate UK. Work with commercial partners has involved precast concrete paving manufacturer Tobermore producing paviours made from 50% CalcinX as a CEM II replacement and Moore Concrete has also manufactured precast units using 50% CalcinX as a CEM I replacement. So far over 3000t of CalcinX has been produced in a number of industrial-scale trials.

David Millar, the managing director of Cemcor, mentioned his company’s plans for calcined clay in June 2022 when he was interviewed by Global Cement Magazine. The company that became Cemcor bought the Cookstown cement plant and a few other assets from Holcim at the start of 2022. It then changed its name to Cemcor in November 2022. At the time of the interview the company was looking to “...develop new value-added products, including low-CO₂ options. This will allow us to use the same amount of clinker to produce more cement.” Millar couldn’t give away too many details at the time, however calcined clay was cited specifically. It was also noted that the company had the right material in its quarry and that it was already working with partners on it.

Amongst all the other decarbonisation options available for cement plants, a slow trickle of calcined clay projects keep being announced. In January 2025, for example, thyssenkrupp Polysius said it had secured a front-end engineering design contract from Circlua for the construction of the world’s largest activated clay plant in Brazil. This project in Para state will have a capacity of 3000t/day, will use renewable energy sources and will “improve the CO₂ footprint in cement production.” CBMI Construction also officially launched a flash calcination clay project in Tangshan, Hebei province in China. In December 2024, Vicat signed an agreement with the US Department of Energy (DOE) Office of Clean Energy Demonstrations to develop the Lebec Net Zero (LNZ) project at its Lebec cement plant in California. This includes plans to produce calcined clay-based cement. Earlier in the autumn of 2024 Portugal-based Cimpor said it was preparing to convert a kiln at its Souselas plant to produce calcined clays, AVIC International Beijing and KHD said that they had secured a deal to build a 900t/day clay calcination plant for Ciments de l'Afrique (CIMAF) in Burkina Faso, and Holcim Česko said it was going to construct a calcined clay processing line at the Čížkovice cement plant in the Czech Republic.

One news story that stuck out in the autumn was the progress of a collaboration between Aumund and Holcim towards developing an electric linear calcination conveyor (eLCC). The two companies started work on the project in 2020 intending to look at the electrical calcination of clay using an Aumund pan conveyor. Initial tests of the eLCC reportedly demonstrated efficient thermal activation of clay through a combination of radiant heat and material circulation. The eLCC system is fully enclosed, insulated, has a compact design and can operate using electrical-powered renewable sources. The first industrial plant utilising this technology is scheduled for construction in 2025. Calcined clay technology and products by other industrial suppliers are available. The work by Aumund and its competitors show they are watching this market closely.

OneStone Consulting’s Joe Harder has found that only 14 clay calcination plants were operational worldwide in 2023 with a production capacity of just under 3.5Mt/yr. These are based in Latin America, Europe and Africa. In an article previewing a market report in the February 2025 issue of Global Cement Magazine, Harder predicts that by 2035 there will be 79 clay calcination plants with a capacity of just under 21Mt/yr. A steady growth of over 20 new plants annually is also expected subsequently from 2035 to 2050 as cement producers seek cost-effective ways to reduce their clinker factor. He identified installation costs, a lack of knowledge about clay-based cements, trouble obtaining mining rights and policy issues amongst other issues as holding back the use of clay calcination.

The current expectation is that calcined clay usage in the cement industry will be a minority option. Yet the size of global cement production can make a production share of, say, 3 - 8% a viable option for both cement manufacturers and equipment suppliers. The adoption of new cement products and standards can also take a long time and this clouds predictions of how far clay can go in the cement industry. At this point in the calcined clay story it is time to keep track of the new projects being set up.

Joe Harder will present a talk entitled ‘Calcined clay market trends by 2035’ at the Global FutureCem Conference taking place in Istanbul in early February 2025

Brazil: thyssenkrupp Polysius has secured a front-end engineering design contract from Circlua for the construction of the world’s largest activated clay plant, with a capacity of 0.96Mt/yr (3000t/day). The plant will be largely powered by renewable electricity, and will be located in Pará, utilising clay sourced from the Carajás iron ore complex. The clay contains up to 80% kaolinite content, and will be upcycled as supplementary cementitious material.

thyssenkrupp Polysius CEO Christian Myland said “We are honoured to partner on this landmark project. Leveraging high-quality local clay and our advanced activated clay technology, this plant will set a new benchmark for carbon-conscious cement production.”

Türkiye: thyssenkrupp Polysius has appointed Ugur Kacar as Head of Middle East and Turkey / Services. He has also been selected as the general manager and a board member for the local subsidiary thyssenkrupp Polysius Türkiye.

Kacar has worked for thyssenkrupp and its subsidiary thyssenkrupp Polysius since 2018. He started as Account Manager – Cement in Türkiye before becoming the Head of Sales - Middle East and Turkey for thyssenkrupp in 2021. Prior to this he held maintenance and project management positions with Çimsa, Limak Cement and Çimko Çimento. He holds an undergraduate degree in mechanical engineering from Cukurova University in Adana and a master of business administration (MBA) qualification.

Germany: thyssenkrupp Polysius has appointed Philip Glörfeld as Head of Business Development & Sales. He will succeed Lukas Schoeneck in the role from the start of January 2025. Schoeneck became the head of Operating Unit Green Solutions in October 2024.

Glörfeld has worked for thyssenkrupp since 2015 in business development roles. In 2020 he became the Director Business Development & Sales Europe, Africa & CIS for the Polysius business unit that later became thyssenkrupp Polysius. Prior to his time at thyssenkrupp he worked at Siemens. He is a graduate from the Steinbeis Hochschule Berlin and holds a master of business administration from the University of Plymouth.

US: Eagle Materials has awarded thyssenkrupp Polysius a contract for the modernisation and expansion of its Laramie, Wyoming cement plant. The modernisation project will result in an expansion of the plant's manufacturing capacity to approximately 1.1Mt/yr of cement. The project also includes the installation of an alternative fuel substitution system. The modernisation of the cement plant is expected to deliver benefits such as cost reductions, achieved with lower-cost alternative fuels and natural gas, simplified maintenance and improved operational efficiencies. The production expansion from the new finish mill will supplement the grinding capacity of the existing plant, which already operates with an integrated polysius booster mill. The polytrack ECO cooler will facilitate heat recovery and clinker cooling while improving process reliability. The project, which has received primary regulatory approvals, is slated to commence immediately [in November 2024], with construction scheduled for completion by the second half of 2026.

Greece: ThyyssenKrupp Polysius has signed a front-end engineering design contract with Titan Group for the Ifestos carbon capture project at Titan’s Kamari cement plant. The project will equip the plant’s two kilns with oxyfuel systems to reduce CO₂ emissions by 1.9Mt/yr, ‘almost completely’, said ThyssenKrupp. The captured CO₂ is then liquefied and transported to a permanent storage site in the Mediterranean region. Full operation is expected by the end of 2029.

Cetin Nazikkol, chief strategy officer at ThyssenKrupp Decarbon Technologies, said “With the oxyfuel technology we have developed, around 1.9Mt/yr of CO₂ can be captured at the Kamari plant alone. This corresponds to around 12% of greenhouse gas emissions from all Greek industries. We are thus making a significant contribution to one of the largest CO₂ capture projects in Europe.”

Christian Myland, CEO of ThyssenKrupp Polysius, said “For our customer Titan Group, we will be using the latest CO₂ separation technology. We will design and equip the first kiln line with the proven oxyfuel technology. When modernising the second kiln line, the latest generation of this technology will be used with the pure oxyfuel system. Overall, this will enable us to capture almost 100% of CO₂ emissions.”

France: The Eqiom Lumbres cement plant, part of CRH, has commissioned ThyssenKrupp Polysius to construct a fine grinding plant. The new plant will include the Polysius booster mill and the Sepol ultra-fine classifier, along with necessary auxiliary equipment. ThyssenKrupp Polysius is set to deliver the equipment by late summer 2025, aiming for commissioning in the fourth quarter of 2025. It will also provide on-site service and technical support for performance optimisation.

Project Manager Layal Haddad said "We are proud to be contributing to decarbonisation with the ultra-fine grinding plant and reducing the CO₂ footprint of cement. This is the first ultra-fine grinding plant based on a Polysius booster mill to be sold worldwide. We look forward to a successful project together with the Eqiom/CRH team."

Taiwan: Taiwan Cement Corporation has signed a memorandum of understanding (MoU) with ThyssenKrupp Polysius. Under the MoU, the partners will implement carbon capture projects aimed at capturing 100,000t/yr (10%) of Taiwan Cement Corporation’s CO₂ emissions by 2030. This will involve the development of a new generation of pure oxygen carbon capture technology in Line 1 of Taiwan Cement Corporation’s Hualien Heping cement plant. This technology aims to increase the concentration of captured CO₂ to over 90% and reduce the energy consumption of carbon capture. The Hualien Heping plant project will conclude in 2026, with the commercialisation of the technology to follow before 2030. Taiwan Cement Corporation plans to supply its own captured CO₂ to various other industries, including industrial welding, chemicals and food processing.

Taiwan Cement Corporation chair Zhang Anping said "Cement has created the civilised society we live in today, and Taiwan Cement Corporation will continue to participate in energy transformation and support the development of future civilisation. This cooperation with Polysius, a golden brand in the cement industry, is to solve the problem of greenhouse gas emissions, creating the future not only for the cement industry but for the whole world."

US: Mexico-based GCC has hired ThyssenKrupp Polysius North America to build a 3000t/day clinker production line at its Odessa plant in Texas. When commissioned in late 2025, the line is expected to more than double the plant’s clinker capacity to 2Mt/yr across three kilns. The supplier says the project will also lower the plant’s annual CO₂ emissions by 13%.

GCC chief executive officer Enrique Escalante said "We remain strongly committed to delivering strong stakeholder value, while investing in the future growth of our business. With the expansion of the Odessa plant, we will ensure GCC is prepared for a new phase of the industry cycle."