Displaying items by tag: Wind

Kenya: Mombasa Cement has completed construction of a 36MW wind farm consisting of 12 3MW turbines in Vipingo. Bahrain News Agency has reported that the plant will power Mombasa Cement’s 1.6Mt/yr integrated Vipingo cement plant, with surplus to be sold to the state-owned power provider Kenya Power. The power plant will supply electricity for the completion of Mombasa Cement’s planned US$73m upgrade to its grey cement clinker production process at the Vipingo plant.

Kenya: Mombasa Cement has started building a 36MW wind farm at its integrated Vipingo plant. The project is intended to support a new grinding unit being constructed at the site, according to the Business Daily newspaper. It is intended to reduce the cost of electricity and minimise disruptions caused by power cuts. The wind farm will consist of 12 turbines with a capacity of 3MW each. The cement plant is also installing a high-power voltage line from the Kaloleni substation to improve its connection to the local electricity grid.

Argentina: Holcim Argentina has signed a deal with YPF Luz for the supply of wind power to its cement plants. The supply agreement is planned for the start of 2020. It is intended to provide 35% of the company’s emergy requriements by the end of the first half. YPF Luz will provide eletectricity from its Los Teros Wind Farm at Azul in Buenos Aires province. The contracted supply is for 142GWh from a 30MW installed base.

Belgium: WindEurope, the European Chemical Industry Council (CEFIC) and the European Composites Industry Association (EUCIA) have created a cross-sector platform to look into using glass fibres and fillers from old wind turbine blades as a raw material for cement production. Other methods, such as a mechanical recycling, solvolysis and pyrolysis, are being developed and considered.

In 2018 wind energy supplied 14% of the electricity in the European Union (EU), from 130,000 wind turbines. Wind turbines blades are made up of a composite material, which boosts the performance of wind energy by allowing lighter and longer blades. At present 2.5Mt of composite material are in use in the wind energy sector. In the next five years 12,000 wind turbines are expected to be decommissioned.

“Wind energy is an increasingly important part of Europe’s energy mix. The first generation of wind turbines are now starting to come to the end of their operational life and be replaced by modern turbines. Recycling the old blades is a top priority for us, and teaming up with the chemical and compositors industries will enable us to do it the most effective way,” said Giles Dickson, the chief executive officer (CEO) of WindEurope.

Spain: Cemex has signed a Euro117m deal with the local government to convert the land used by the Gádor cement plant in Almeria for use by new projects. These will include projects in solar and wind power generation, waste fuel production from plastics and biomass and a new concrete batching plant, according to Teleprensa. The initiative is intended to create around 400 jobs.

The cement producer has also signed a similar agreement for its Lloseta in Baleares. The company announced in mid-October 2018 that it was planning to close the two plants due to reduced demand for cement and mounting European CO₂ emissions regulations.

UK: Cemex says that it will use 100% renewable electricity at supplied sites in a partnership with energy, services and regeneration group Engie. Engie has been providing electricity to over 150 Cemex UK sites for over 10 years, also supplying gas to 33 of these sites. The current contract is to be extended for a further 12 months. All of the electricity supplied to the sites will be from 100% renewable energy sources including wind energy.

“Cement manufacture is inherently energy-intensive and we work hard to minimise energy consumption within the process constraints. The switch to electricity from renewable sources is playing a key role in our carbon reduction strategy,” said Martin Hills, Head of Energy and Carbon at Cemex in the UK.

Cemex is also using Engie’s demand side services, such as load management to avoid peak tariffs and rapid frequency response, which generates extra revenue for Cemex UK. Engie manages all contractual requirements with National Grid on Cemex UK’s behalf.

US: LafargeHolcim plans to build three wind turbines at its Paulding cement plant in Ohio to power the unit. Jamie M Gentoo, chief executive officer (CEO) of US cement operations, said that using distributed wind energy at the plant would be a first for the company in North America.

Constructing turbines will begin in December 2018 in partnership with One Energy. The three Paulding turbines are expected to generate more than 12MkWh/yr and should eliminate the equivalent of more than 9000t/yr of CO₂.

As part of a community outreach project in conjunction with the turbine build, LafargeHolcim will create three US$5000 Megawatt Scholarships (one per turbine for a total of US$15,000/yr) to be awarded each year the turbines are in operation. The Megawatt Scholarships will be awarded annually to local high school graduates pursuing a two-year or four- year STEM (science, technology, engineering and mathematics) degree. Additionally, One Energy will pay US$27,000/yr annually in local property taxes.

Tunisia: Ciments de Bizerte is planning to upgrade the cement grinding capacity by 20% at its plant in Bizerte. Other anticipated upgrades include the installation of a new 10,000t cement silo and the contruction of a captive wind farm, according to the L'Economiste Maghrébin magazine.

Argentina: President Mauricio Macri has inaugurated a 24MW expansion to the Parque Eólico Rawson wind farm that will supply Loma Negra. Energy company Genneia has invested around US$40m on the project, according to Renewables Now news service. The unit has a 20 year contract to supply electricity to the cement producer. The renewable power purchase agreement between private companies is a first for the country.

Just before the Christmas break one of the Global Cement editorial staff noticed how many solar projects have been popping up in the industry news of late. Looking at stories on the Global Cement website tagged with ‘solar’ five occurred in a six month period of 2017 out of a total of 13 since 2014. It’s not a rigorous study by any means but projects in the US, South Korea, India, Namibia and Jordan all suggest a trend.

All these new projects appear to be providing a supplementary energy source from photovoltaic (PV) solar plants that will be used to supply a portion of a cement plant’s electrical power requirements at a subsidised cost. Typically, these initiatives are preparing to supply 20 - 30% of a plant’s electricity over a couple of decades. These schemes are often supported by government subsidies to encourage decarbonised energy sources and a general trend in societies for so-called ‘greener’ energy sources in the wake of the Paris agreement on climate change.

Global Cement is familiar with this model of solar power in the cement industry from its use at the HeidelbergCement Hanson plant at Ketton in the UK. The project was realised by Armstrong Energy through local supplier Lark Energy and it provides around 13% of the cement plant’s electrical energy needs. Originally the array started off by supplying 10MW but this was later increased to 13MW in 2015. A key feature is that as part of the agreement with Armstrong Energy, Hanson receives 35% of the solar power generated for free and buys the remaining 65% at a fixed rate. Even at this rate the plant expects to save around Euro11m in energy costs over the lifetime of the solar array. In addition it will save 3500t/yr of CO2.

Most of the new solar projects announced in 2017 are of a similar scale and ambition to what Hanson Cement has done at Ketton. However, JSW Group’s plans are a magnitude larger. The Indian cement producer wants to build a 200MW solar plant next to its cement grinding plant at Salboni in West Bengal for US$124m. However, it has hedged its bets somewhat by saying that it might build a 36MW thermal power plant instead if its proposal fails.

LafargeHolcim and Italcementi have also experimented with concentrated solar power (CSP) plants for the cement industry. In 2007 LafargeHolcim and the Solar Technology Laboratory of the Paul Scherrer Institute and the Professorship of Renewable Energy Carriers at ETH Zurich started researching using high-temperature solar heat to upgrade low-grade carbonaceous feedstock to produce synthetic gas. The intention was to use the synthetic gas as a substitute for coal and petcoke in kilns.

Italcementi’s project at the Aït Baha plant in Morocco uses a CSP process that can be used with the plant’s waste heat recovery unit. Its moveable trough-style solar collectors follow the sun throughout the day to warm up a heat-transfer fluid during the day and store the heat in gravel beds overnight. In this way the CSP process allows for continuous operation over 24 hours. Before Italcementi’s acquisition by HeidelbergCement in 2016 the company had long-term ambitions to roll-out its CSP process across plants in the Middle East and North African region.

New battery technology of the kind backing the growing electric car industry may be further pushing the cement industry’s preference to PV over CSP power. The other renewable energy source slowly being built to support cement plants has been wind. Like PV it too suffers from cyclical disruptions to its power. Technological entrepreneur Elon Musk (of Tesla car fame) notably supplied the world's largest lithium-ion battery to Southern Australia to support one of its wind farms in late 2017. Around the same time local cement producer Adelaide Bighton announced in a separate deal that it had struck a deal to use wind power to part-power some of its facilities in the same region. At present it doesn’t look like solar power will be completely powering cement plants in the near future but perhaps a renewable fuels rate along similar lines to an alternative fuels rate might be a growing trend to watch.

The Global Cement CemPower conference on electrical power, including waste heat recovery, captive power, grinding optimisation and electrical energy efficiency, will return in January 2019.