US: Buzzi Unicem USA’s Maryneal cement plant in Texas hit a production record of 1.03Mt of clinker and 1.18Mt of cement in 2022. The figures were more than 4% over the year’s budgeted figures. The plant says it achieved the result through consistent communication and a positive culture. Managers at the unit also shared updated production figures at daily meetings, kept all employees actively engaged and created an encouraging atmosphere. The plant has set new goals for 2023.

Antonio Corea Cruz, Operations Manager at the plant, said, “We’ve implemented strategies to keep reliable assets which allow the team members to work on continuous improvement. This affects the efficiency and productivity of all aspects of the plant.”

US: The Portland Cement Association (PCA) has announced the winners of its 2023 Safety Innovation and Chairman's Safety Performance Awards.

The Safety Innovation Award Program recognises companies that have developed innovative practices, projects and programs that improve safety at cement plants in the US. Entries are judged in five areas: innovation, ease of use and ease of construction, effectiveness and risk prevention. The recipients were:

• Distribution: Continental Cement, Continental Port Allen Terminal, Chesterfield, Missouri
• Quarry: CalPortland Company, CalPortland Oro Grande Plant, Oro Grande, California
• Pyroprocessing: GCC of America, GCC Tijeras Plant, Tijeras, New Mexio
• General Facility: Mitsubishi Cement Corporation, Mitsubishi Cushenbury Plant, Lucerne Valley, California

The Chairman’s Safety Performance Awards are given to member cement plants that did not have a reportable injury or illness during the year. Fifteen plants achieved this in 2023, which represented more than 10% of all active cement facilities in the US and its territories. The recipients were:

• Argos USA, Atlanta, Georgia
• Argos USA, Newberry, Florida
• Argos Puerto Rico Corp, Dorado, Puerto Rico
• Ash Grove Cement Company (CRH), Durkee, Oregon
• Ash Grove Cement Company (CRH), Midlothian, Texas
• Buzzi Unicem USA, Chattanooga, Tennessee
• Buzzi Unicem USA, Maryneal, Texas
• CalPortland Company, Rillito, Arizona
• GCC of America, Odessa, Texas
• Heidelberg Materials, Bellingham, Washington
• Martin Marietta Materials, New Braunfels, Texas
• Martin Marietta Materials, Midlothian, Texas
• Martin Marietta Materials, Tehachapi, California
• National Cement Company of California, Kern, California
• St Marys Cement (Votorantim), Detroit, Michigan

US: Lhoist North America says it intends to add lime production capacity in Texas. It stated that population growth in the south of the country had created increased demand for its calcium-based products, with customers having announced new steel mills, liquefied natural gas (LNG) export facilities, lithium hydroxide production plants and water treatment facilities. In its view these expansions in multiple markets require lime both in the initial infrastructure build and in longer-term production processes.

The subsidiary of Belgium-based Lhoist said in mid-September 2023 that it was expecting to file permits for the expansion in the coming weeks and the location for the new production capacity will be revealed at a later date.

Greece/Germany: Greece-based cement producer Titan Group and Germany-based Orcan Energy have entered a partnership to explore the development and deployment of Orcan’s innovative modular waste heat recovery (WHR) solutions across Titan’s international cement production base. Orcan’s solution converts cement process waste heat into electricity that it says can accelerate decarbonisation while reducing operational costs. As a first step, the partners will undertake an assessment of where Orcan Energy's WHR systems can be applied across Titan's facilities. The study will encompass a thorough pilot site evaluation, starting at several plants within the group. The initial focus will be on recovering waste heat from pre-heaters and clinker coolers.

Samir Cairae, Chief Technology Officer at Titan said “The collaboration with our waste heat recovery partner Orcan Energy has the potential to transform waste heat into zero-carbon clean energy, with a novel but well-proven modular approach."

Andreas Sichert, chief executive officer at Orcan Energy, said “We are thrilled to partner with Titan to use its vast and valuable waste heat resources. Our technology will help not only to reach the group’s extraordinary decarbonisation ambitions but also to significantly save electricity expenses. Our modular approach will allow Titan to flexibly respond to outside changes in uncertain times.”

Look out for an interview with Orcan Energy in the forthcoming November 2023 issue of Global Cement Magazine