Displaying items by tag: Upgrade

Zimbabwe: PPC Zimbabwe has announced that it has entered into a preliminary agreement with a Zimbabwe-based energy investor “with technical partners in South Africa” that will build and operate the company’s planned 32MW solar power plant in Matabeleland South. 16MW will power PPC Zimbabwe’s cement production and the rest will be fed in the national electricity grid, according to the Herald newspaper. The unit will be located adjacent to PPC Zimbabwe’s 0.5Mt/yr integrated Colleen Bawn plant.

US: Vicat subsidiary National Cement has received a fine of US$148,000 from the Alabama Department of Environmental Management (ADEM) for exceeding mercury emissions regulations over a 123-day period between May 2019 and February 2020 at its integrated Ragland plant in Alabama. The Daily Home newspaper has reported that unexpectedly high mercury levels in coal and other raw materials burned as fuel during that time caused the breach, which the company immediately reported to ADEM.

National Cement president Spencer Weitman said, “The issue took several months to fix.” Multiple upgrades and operational changes solved the issue, including installation of a US$400,000 mercury absorption carbon injection system. ADEM said, “National Cement did not economically benefit from the emissions violations.”

In January 2020 National Cement began work on construction of a new US$250m kiln line, due for completion in 2022.

Pakistan: Power Cement says it has started commercial operation of its new 7700t/day clinker production line at its Nooriabad plant. It completed the procurement and installation of machinery for the new line in mid-2019. It was supplied by Denmark’s FLSmdith.

Austria: Lafarge Zementwerke, OMV, Verbund and Borealis have signed a memorandum of understanding (MOU) for the joint planning and construction of a full-scale plant by 2030 to capture CO₂ and process it into synthetic fuels, plastics or other chemicals. As part of the ‘Carbon2ProductAustria’ (C2PAT) project the companies intend to build the unit at the integrated Mannersdorf cement plant and capture all of the 0.7Mt/yr of CO₂ emitted.

"We are committed to leading the industry in reducing carbon emissions and shifting towards low-carbon construction. We have worked consistently and successfully on the reduction of the CO₂ footprint of our cement plants, products and solutions. Ultimately, CO₂-neutral cement production can only be possible with the implementation of breakthrough technologies, like carbon capture, which is why we have great expectations for the C2PAT project", said Lafarge’s local chief executive officer (CEO) José Antonio Primo.

The project aims to use hydrogen produced by Verbund to allow OMV to transform the captured CO₂ into a range of olefins, fuels and plastics. Borealis would then use some of these products as a feedstock to manufacture plastics. However, the companies say that, “taking the next steps towards a Zero CO₂ economy will require the right financial as well as favourable regulatory framework conditions. The success of C2PAT will largely depend on whether the right financial and regulatory framework conditions are created both at the European Union and Austrian national level.”

The joint project is designed in three phases. In phase one, the partners are currently evaluating and developing a joint strategy for project development, business modelling and process engineering. Based on the results of phase one, a cluster of industrial pilot plants in the Eastern part of Austria could be technically developed and built in the mid-2020s in phase two. Phase three entails building a full scale CO₂ capture and utilisation unit at a cement plant.

Lafarge Zementwerke is the Austrian subsidiary of building materials manufacturer LafargeHolcim. OMV produces and markets oil and gas, energy and other petrochemical products. Verbund is an Austrian-based electricity generator, with a focus on hydroelectric power. Borealis is a chemical company and a producer of polyolefins, base chemicals and fertilisers.

Russia: Sibtsem Holding Company subsidiary Timlyuy Cement has announced the completion of essential upkeep on raw material mills five and ten at its Timlyuy Cement plant. Improvements included the replacement of exhausted plate feeders with bucket feeders for accurate dosing, “improving the quality of the finished product while lowering cost,” according to Timlyuy Cement process control chief expert Vladislav Zarubin. A new conveyor belt with an electric drive, strain gauges and control system was also included under the US$57,500 upgrades.

Timlyuy Cement says that per unit productivity has increased by 37% to 55t/hr from 41t/hr. Managing director Vladimir Klichko said, “For the Timlyuy Cement plant, improving the reliability of process equipment is traditionally one of the primary tasks. The modernisation of raw materials grinding, performed at the proper level, is the key to stable and efficient operation of the enterprise - a guarantee that even at the peak of the construction season, consumers will receive high-quality products on time, and in the right amount.”

Norway: Norcem, a subsidiary of HeidelbergCement, has signed an agreement with Aker Solutions to order a CO₂ capture, liquification and intermediate storage plant at its integrated Brevik cement plant. The final decision for the project depends on funding from the Norwegian government, which is expected to approve the unit in its national budget for 2021.

The project will use Aker Solutions’ Advanced Carbon Capture (ACC) technology and its S26 amine solvent. Once complete the unit will capture 0.4Mt/yr of CO₂. This will be transported to the Northern Lights project for permanent storage offshore beneath the North Sea.

Nigeria: Sinoma Construction Nigeria says it has completed the construction of a second 6000t/d line at BUA Group subsidiary Obu & Edo Cement’s Edo cement plant, bringing the plant’s total integrated capacity to 5.5Mt/yr. The subsidiary of China-based Sinoma said that it completed the work in spite of an outbreak of malaria and electricity shortages. It said, “The successful fulfilment of the project has laid a solid foundation for the company's in-depth localised operation and comprehensive cooperation with the BUA Group.”

Germany/Vietnam: Loesche says that it has dispatched two LM 53.3+3 CS vertical roller mills from its plant in North Rhine-Westphalia for a new line at Thanh Thang Group Cement’s integrated Bong Lang cement plant. The mills have a combined capacity of 180t/hr and grind clinker to a fineness of 4000 Blaine. The new line, installed by Sinoma-NCDRI, will be commissioned in late-2021. Loesche will also supply two cellular wheel feeders, metal detectors and sealing air blowers.

Russia: Iskitimcement has completed the modernisation of the grinding plant at its 2.1Mt/yr integrated Iskitimcement plant in Novosibirskskaya following the installation of a closed-circuit dynamic separator and bag filter supplied by Christian Pfeiffer at a cost of US$3.69m. Iskitimcement director general Vladimir Skakun said that the upgrade aims, “to provide customers with separated cement that surpasses the quality of products produced with open-circuit grinding.”

The company said that the closed-circuit unit has increased productivity and reduced the temperature of cement. Dust emissions have fallen by over 90%, bringing the plant in line with current environmental strictures. “We are ready to meet the customers’ demand for quality products even at the peak of the construction season,” said Skakun.

Iskitimcement says that it is planning a modernisation of its stacks with the installation of new filters by 2024.

US: A lawsuit raised by the US Equal Employment Opportunity Commission (EEOC) against CCC Group alleges that black construction workers were subject to racial discrimination and harassment during the construction company’s work on an upgrade at the Lafarge Ravena cement plant in 2016. The EEOC says that the workers were the target of racial language, were threatened and made to carry out more dangerous and physically taxing tasks. It added that it only took legal action after first attempting to reach a pre-litigation settlement through the agency’s conciliation process.

CCC Group says it investigated the claims from one former employee in 2017 about ‘inappropriate comments’ after it was reported to the EEOC. However, it says that the complaint was never reported internally and that the EEOC refused to share information about the allegations. Subsequently, it was unable to determine what happened. The construction company only became aware of the other allegations when the EEOC filed its lawsuit in June 2020. CCC Group said, “We take all such allegations very seriously and continue to thoroughly investigate these claims. Regardless, CCC Group will continue its commitment to ensure that any such conduct is not tolerated or allowed to occur in our workplaces.”

800 workers were involved in the upgrade to the plant in New York State, which brought it to its present integrated capacity of 2Mt/yr.

This story was updated on 16 June 2020 following comment from CCC Group