Displaying items by tag: Plant
UK: Mexico-based Cemex has confirmed its decision to mothball the 0.8Mt/yr integrated South Ferriby, Lincolnshire cement plant following a consultation period with employee and union representatives. The company estimates that the majority of redundancies of the plant’s 110 staff will happen in July 2020.
It said, “Cemex customers will be supplied from the company’s existing cement network. Cemex’s supply chain plan and commercial management will ensure that customer service will be maintained at all times. Cemex remains committed to the UK and will continue to have a strong national presence.”
Germany: HeidelbergCement has reported the successful resurfacing of a section of Federal Motorway 5 (BAB 5) between Karlsruhe and Frankfurt using a concrete made from low-alkali cement produced at its 1.4Mt/yr-capacity Schelklingen, Baden-Württemberg integrated cement plant. The company used over 3600t of cement to produce the 12,000m3 of concrete required for the 3.2km stretch of road. Traffic infrastructure product manager Klaus Felsch said, “The cement’s low alkali content significantly reduces the risk of an alkali-silica reaction and maximizes the durability of the concrete.”
Mozambique: Dugong Cimentos says that construction of its new 1.8Mt/yr integrated cement plant in Matutuíne District, Maputo Province, is 90% complete. The Noticias newspaper has reported that the plant cost US$330m and was paid for by private Chinese investors. It will permanently employ 500 people, including 400 Mozambicans, when operational. The plant will consume 400,000t/yr of coal and produce cement as well as clinker for grinding at other Mozambique plants that currently import it.
Ambuja Cement digitises supply chain
13 July 2020India: Ambuja Cement has modernised its logistics operations by digitising its supply chain to “improve visibility, deliver quality customer service and optimise cost.” The Economic Times newspaper has reported that the company has integrated all aspects of raw material, fuel and equipment supply and product deliveries on a single online platform in order to “enhance overall efficiency and productivity.” Company director Martin Kriegner said additionally that the digitisation will aid in, “fuel mix optimisation and strategic sourcing, helping to mitigate rising input costs.”
Ambuja Cement’s 3.0Mt/yr greenfield expansion to its integrated 1.5Mt/yr Marwar Munda, Rajasthan plant is scheduled for commission by 1 January 2021. The company has a master supply agreement with ACC aimed at maximising the consistency of cement supply to the Rajasthan market once the new 4.5Mt/yr plant becomes operational.
Vicat to implement Carbon8 Systems carbon capture and use system at Montalieu cement plant
10 July 2020France: UK-based Carbon8 Systems has announced plans for the commercial implementation of its carbon capture and use (CCU) system at Vicat’s Montalieu integrated cement plant in France. It follows successful demonstration projects at cement plants in the UK and Canada.
The company’s CO2ntainer product will be deployed directly onsite at the plant and integrated into Vicat's existing industrial processes. It will capture CO2 directly from the plant's flue gas emissions and use this as part of its Accelerated Carbonisation Technology (ACT) process. This accelerates the carbonation of cement bypass dust into lightweight aggregates. In its first phase of operation it will process and convert up to 12,000t of cement bypass dust.
Mexico: Two workers died after falling in a crane basket from a height of 35m at Cooperativa La Cruz Azul’s integrated Oaxaca cement plant in El Barrio de Soledad Municipality. Noticias Financieras newspaper has reported that the victims died on impact and that the causes are under investigation.
China: Henan Province has announced a planned rise in water and energy tariffs for cement producers that fail to meet current emissions standards and clean transportation requirements. Reuters News has reported that companies subject to the measures will pay US$0.07 – US$0.14/m3 more for water and up to US$0.01/kWh more for electricity. Henan enacted ‘ultra-low’ emissions limits of 10Mg/Nm3 of dust, 50Mg/Nm3 of NOx and 100Mg/Nm3 of SO2 in 2018. Cement plants in the province produce 105Mt/yr of cement.
Young Investment Group Industry Company Limited and China Gezhouba Group form joint venture to establish cement plant
09 July 2020Myanmar: Young Investment Group Industry Company Limited (YIGICL) has entered into a joint venture with China-based China Gezhouba Group Cement (CGGC) and China Gezhouba Group Overseas Investment (CGGOI) with the aim of establishing an integrated cement plant in Mandalay, Mandalay region. The joint venture, which is held 30:70 by YIGICIL and the Chinese partners respectively, will also set up a limestone mine.
Lafarge Canada shows zero tolerance to hatred
09 July 2020Canada: LafargeHolcim subsidiary Lafarge Canada has dismissed an employee after a thorough investigation into a piece of racist graffiti ended in discovery of the guilty party. Canada Newswire has reported that the harmful drawing, which occurred at the company’s 1.0Mt/yr integrated St Constant plant in Quebec, has been removed. Lafarge Canada said, “To increase employee awareness and strengthen everyone's role in creating a positive work environment, we have communicated with all of our employees on all of our sites and encourage them to speak up if they see, hear or feel any concerns whatever.”
Green hydrogen for grey cement
08 July 2020Hydrogen and its use in cement production has been adding a dash of colour to the industry news in recent weeks. Last week, Lafarge Zementwerke, OMV, Verbund and Borealis signed a memorandum of understanding (MOU) to plan and build a full-scale unit at a cement plant in Austria to capture CO2 and process it with hydrogen into synthetic fuels, plastics or other chemicals. This week, Air Products and ThyssenKrupp Uhde Chlorine Engineers (TUCE) signed a strategic agreement to work together in ‘key regions’ to develop projects supplying green hydrogen. Both of these developments follow the awarding of UK government funding in February 2020 to support a pilot project into studying a mix of hydrogen and biomass fuels at Hanson Cement’s Ribblesdale integrated plant.
As the title of this column suggests there is an environmental colour code to describe how hydrogen is made for industrial use. This is a bit more codified than when grey cement gets called ‘green’ but it pays to remember what the energy source is. So-called ‘green’ hydrogen is produced by the electrolysis of water using renewable energy sources such as hydroelectric or solar, ‘Grey’ hydrogen is made from steam reforming using fossil fuels and ‘Blue’ hydrogen is similar to grey but has the CO2 emissions from the fuels captured and stored/utilised. Price is seen as the main obstacle to wider uptake of hydrogen usage as a fuel in industry although this is changing as CO2 pricing mounts in some jurisdictions and the connected supply chain is developed. A study by BloombergNEF from March 2020 forecasted that green hydrogen prices could become cheaper than natural gas by 2050 in Brazil, China, India, Germany and Scandinavia but it conceded that many barriers would have to be overcome to get there. For example, hydrogen has to be manufactured making it more expensive than fossil fuels without government policy support and its, “lower energy density also makes it more expensive to handle.”
The three recent examples with respect to the cement industry are interesting because they are all exploring different directions. The Lafarge partnership in Austria wants to use hydrogen to aid the utilisation side of its carbon capture at a cement plant. The industrial suppliers, meanwhile, are positioning themselves in the equipment space for the technology required to use hydrogen on industrial plants. Secondly, ThyssenKrupp has alkaline water electrolysis technology that it says it has used at over 600 projects and electrochemical plants worldwide. Air Products works with industrial gas production, storage and handling.
Finally, the Hanson project in the UK will actually look at using hydrogen as a partial replacement for natural gas in the kiln combustion system. A Cembureau position paper in mid-2019 identified that the challenges to explore in using hydrogen in cement production included seeing how its use might affect the physical aspects of the kiln system, the fuel mass flows, temperature profile, heat transfer and the safety considerations for the plant. Later that year a feasibility study by the Mineral Products Association (MPA), Verein Deutscher Zementwerke (VDZ) and Cinar for the UK government department that is funding the Hanson project concluded that a hydrogen flame’s high heat in a burner alone might not make it suitable for clinker formation. However, the study did think that it could be used with biomass to address some of that alternative fuel’s “calorific limitations” at high levels. Hence the demonstration of a mixture of both hydrogen and biomass.
That’s all on hydrogen but, finally, if you didn’t log into yesterday’s Virtual Global CemProducer 2 Conference you missed a treat. One highlight was consultant John Kline’s presentation on using drones to inspect refractory in some hard to reach places. Flying a camera straight into a (cool) pyro-processing line was reminiscent of a science fiction film! Global Cement has encountered the deployment of unmanned aerial vehicles in quarry and stockpile surveys previously but this was a step beyond.