Displaying items by tag: Waste Heat Recovery

Oman: Oman Cement Company will spend US$300m on the new 10,000t/day Line 4 as part of the upcoming upgrade and expansion of its Rusayl cement plant in Muscat governorate. The Oman Observer newspaper has reported that Switzerland-based PEG Resources will carry out the work. Oman Cement Company CEO Salem bin Abdullah al Hajri said that the new line will help Oman to achieve cement self-sufficiency by 2024.

The company said “The new 10,000t/day production line will be the largest in Oman and will have more cost-effective production, for the company to sustain its success and competitiveness in the local and international cement markets in a long run.” It added “The company will focus on utilising state-of-the-art production technology resulting in lower power consumption, potential for waste heat recovery (WHR), higher fuel efficiency, realisable use of alternative fuels (AF), improved productivity and the best environmental standards.”

Oman Cement Company is also expanding the Rusayl plant’s Line 3 by 25% to 5000t/day from 4000t/day, prior to decommissioning its other two lines.

Portugal: Cimpor has announced plans for the establishment of 1MW solar power plants at each of its three cement plants in Portugal. The Dinheiro Vivo newspaper has reported that the measure comes under a planned Euro130m investment package in upgrades to its cement operations before 2030. The plans include the expansion of the solar power plants to a total capacity of 10MW by 2025. Additionally, the producer will install two waste heat recovery (WHR) plants with a combined capacity of 8MW at its Alhandra and Souselas cement plants. The company is aiming to reduce its indirect CO₂ emissions by 30%. It also has an alternative fuel (AF) substitution rate target of 70% by 2030 - compared to 3% in 2020, when it used 150,000t of AF.

Cimpor has previously invested a total of Euro7.2m in dedicated sustainability-related measures.

India: Ambuja Cements has commenced commercial production at its new 3Mt/yr Marwar cement plant in Nagaur, Rajasthan. The plant has and an additional 2Mt/yr of grinding capacity. The Orissa Diary newspaper has reported that the producer invested US$316m in its construction. The Marwar cement plant increases Ambuja Cement’s installed capacity by 20% to 29.7Mt/yr.

Managing director Neeraj Akhoury said “Ambuja has ambitious growth plans to expand its capacities in India, and the Marwar plant is a step in that direction. We are very proud that it is a ‘green plant’ designed to meet our ambition for a sustainable future. The plant has deployed all modern equipment and technology to produce cement in a more environmentally friendly manner. It has a waste heat recovery (WHR) system that converts waste heat derived during the production process into energy.”

Egypt: Suez Cement is planning to invest US$20m on an 18MW waste heat recovery unit at its integrated Helwan plant. The subsidiary of Germany-based HeidelbergCement started the project in mid-2021 and expects to complete it by the end of 2022. It is currently negotiating with suppliers and hopes to appoint one soon with construction scheduled for 2022.

Pakistan: DG Khan has connected its upgraded Hub cement plant and power infrastructure to the national grid. The Pakistan Observer newspaper has reported that the facilities generate 40MW of power via a 10MW waste heat recovery (WHR) plant and 30MW coal-fired power plant. China National Building Material (CNBM) subsidiary Sinoma Energy Conservation provided engineering, procurement and construction (EPC) services for both power plants.

India: The total new waste heat recovery (WHR) unit capacity of cement producers is expected to reach 175MW in the two years ending on 31 March 2022. Rating agency ICRA has valued the total investment in new WHR units over the period as up to US$230m, according to the Press Trust of India. A market report by ICRA reports that power generation using WHR costs around US$0.02/kWh compared to US$0.7/kWh from a captive coal power plant. Cement companies that replace 25% of total power capacity with WHR can potentially save around 15% from existing power costs.

India: Holcim subsidiary Ambuja Cements has launched trial production at its new 3.0Mt/yr Marwar integrated cement plant in Rajasthan’s Nagaur district. The launch follows a total investment of US$316m in the plant’s construction. The plant is equipped with an additional 2.0Mt/yr of grinding of grinding capacity and a waste heat recovery (WHR) plant.

Managing director and chief executive officer Neeraj Akhoury said “It’s a proud moment for us at Ambuja Cements. Our endeavour shall always be to become a strong partner and a builder of progress for India."

There has been a significant investment in the South Korean cement industry this week with the news that Hanil Hyundai Cement has ordered a steam-based waste heat recovery (WHR) system from Japan-based Kawasaki Heavy Industries. The 22.6MW system will be used on two of the production lines at the Yeongwol plant in Gangwon Province. The supplier says that installation is expected to generate about 30% of the energy the plant needs and save around 10,000t/yr of CO₂ in the process. Delivery is scheduled for late 2022.

This order may be the first investment following the announcement in late June 2021 that the state-owned Korea Development Bank had pledged around US$870m towards supporting the cement sector in making carbon reduction upgrades by 2025. These are intended to include moving away from burning fossil fuels in cement production and increasing the use of recycling materials. At the time of the agreement between the bank and the Korea Cement Association (KCA), Hanil Hyundai Cement noted that the local alternative fuels substitution rate was 24% compared to 46% in the European Union and 68% in Germany.

Graph 1: Cement production in South Korea, 2010 – 2020. Source: Korea Cement Association

By European or American standards South Korea kept its coronavirus cases under control in 2020. A robust testing and contract tracing regime (K-Quarantine) managed to prevent the country enforcing stricter measures until late in 2020. A fourth wave of infections, currently underway in July 2021, due to the more contagious Delta variant, has started to change this. Despite being able to keep its economy open though, the construction sector still took a hit although not as bad as initially feared.

Cement production fell by 6% year-on-year to 47.5Mt in 2020 from 50.6Mt in 2019 following a downward trend since 2017. The KCA expected worse after a poor third quarter in 2020 when it was preparing for shipments to fall below the level last seen in the midst of the International Monetary Fund (IMF) crisis in the late 1990s. On top of this the industry was also potentially facing a new tax on production towards the end of 2020. One large local producer, Ssangyong C&E, reported a 5% year-on-year drop in sales to US$864m in 2020 from US$910m in 2019. However, it managed to increase its operating profit over the same period. So far in 2021 the sector faced supply shortages in the spring. The KSA blamed the winter plant maintenance schedule and a lack of railway wagons and trucks.

The timing of the Korea Development Bank investment in the cement sector is interesting given the movement on the European Union carbon border adjustment mechanism. Cement exports seem unlikely to be affected but business lobbyists like the Federation of Korean Industries are well aware of the effects schemes like this might have upon commodities like steel and aluminium in the first phase and then the implications for car production later on. Target markets for cement exports such as the US, Peru, Chile and the Philippines might all become vulnerable should carbon-based trade restrictions become more prevalent. Of course export markets remain vulnerable to more usual hindrances. For example, in March 2021 the Philippines extended its safeguard measures on cement imports to various countries including South Korea.

Following a round of market consolidation in the late 2010s, the South Korean cement sector now appears to be entering a phase of sustainable realignment. In late May 2021 Prime Minister Moon Jae-in announced plans to hasten the country’s carbon reduction targets ahead of the United Nations Climate Change Conference scheduled for November 2021, including a carbon tax. With cement production on a downward trend since 2017 and the coronavirus crisis far from gone it will be instructive to see how far the intervention of the Korea Development Bank will go.

South Korea: Hanil Hyundai Cement has placed an order with Japan-based Kawasaki Heavy Industries for the design and installation of a 22.6MW waste heat recovery (WHR) unit at its Yeongwol cement plant in Gangwon. The WHR plant will generate power from heat from two of the plant’s production lines when commissioned in December 2022. The supplier says that it will serve 30% of the plant’s energy needs. Kawasaki Heavy Industries says it has previously supplied WHR units to Japan, Germany, South Korea, Turkey, China, Vietnam, India, Pakistan and elsewhere.

Portugal: Semapa subsidiary Secil is spending Euro86m on modernising its Outão cement plant in Setúbal. The Dinheiro Vivo has reported that the work will turn the facility into ‘the most sustainable cement plant in Europe,’ according to the company. It will reduce CO₂ emissions by 20%, end fossil fuel use and establish waste heat recovery to supply 30% of the plant’s electrical power needs. The government has granted the ‘Project of National Interest’ Euro14.5m in funding. The project will also expand the cement plant’s capacity by 30% to 1.3Mt from 1.0Mt.

Chief executive officer Carlos Abreu said "We have the ambition of reaching carbon neutrality in 2050 and this project is a step in that direction. Others will follow." He added "The Asian and American blocs are not always facing that direction, but the path is made by walking... and we will get there." Regarding the timing of the project, Abreu said "Secil was a very brave company here. The project was decided in 2019 before the pandemic broke out... We kept it, despite the fact that knowing that the pandemic was going to be, and is being, very difficult, but we believe that we had no other alternative."