Displaying items by tag: US
Heidelberg Materials North America commences cold testing of pipe conveyor at Mitchell cement plant
07 June 2023US: Heidelberg Materials North America has commenced cold testing of a new 420t/hr pipe conveyor at its Mitchell cement plant in Indiana. Italy-based Bedeschi supplied the 700m-long conveyor. The supplier said that, when fully operational, the new equipment will help the Mitchell cement plant to be one of the most efficient and largest cement plants in the US.
US: Holcim US has inaugurated a waste tyre processing plant at its Alpena cement plant in Michigan. The facility will process 22,000t/yr of tyres into refuse-derived fuel (RDF) for use at the cement plant. Holcim US partner Geocycle will collect, pre-process and deliver the tyres to the new facility.
Holcim US’ North regional senior vice president of manufacturing Michael Nixon said "Holcim has invested more than US$100m in eco-friendly technologies at the Alpena plant in the past 15 years. The tyre-derived fuel facility is another strong demonstration of our commitment to reducing emissions."
HarbisonWalker International launches new branding
02 June 2023US: HarbisonWalker International has unveiled its new redesigned branding. The refractories supplier says that the new brand identity reflects it standing as the North American arm of Calderys Group. The two companies merged following their acquisition by Platinum Equity in 2022.
Calderys Group president and CEO Michel Cornelissen said “The new visual identity of HWI, as a member of Calderys, is a significant step on our journey to form a unified business that incorporates the best of both brands to create a global high-growth leader. We have undertaken this exercise with thoughtful intention to preserve the legacy of the HWI brand in the Americas, while reflecting the global stature of the Calderys brand.”
FLSmidth acquires Morse Rubber
01 June 2023US: Denmark-based FLSmidth has acquired heavy-duty rubber products company Morse Rubber. Morse Rubber's competences include advanced moulding capabilities for rubber and composite mill liners, as well as screen media and various rubber and rubber ceramic wear components. FLSmidth says that the acquisition supports its growth strategy by strengthening its offering of mill liners, where FLSmidth has been capacity constrained in some regions.
FLSmidth's service line president Joshua Meyer said “With this acquisition we will be able to offer cost and quality competitive mill liners combined with local presence, local production and proximity to our North American and Latin American customers."
Update on slag in the US, May 2023
31 May 2023Heidelberg Materials North America held an official opening ceremony this week for its upgraded slag cement plant and terminal at Cape Canaveral in Florida. The US$24m project added a new roller press to the unit to increase its production capacity. In a statement Chris Ward, the president and chief executive officer of the company, said that it had made the investment to meet sustainability and resilient construction goals. Industrial Accessories Company (IAC) said in mid-2021 that it had been named as the engineering, procurement, and construction (EPC) contractor for the project. It planned to install a hydraulic roller press supplied by FLSmidth. IAC also said it was providing instrumentation equipment, hoppers, bins, belt conveyors, bucket elevators and dust collectors amongst other kit and services.
Other recent US slag cement-related news stories have concerned terminals. In late August 2022 Royal White Cement said it had leased a site on the Houston Ship Channel in Houston, Texas to handle and store approximately 100,000t of multiple cementitous products such as slag, ordinary Portland cement and white Cement. In May 2022 Titan America announced plans to spend US$37m on an upgrade to its Norfolk terminal in Chesapeake, Virginia. The major improvement was to add a 70,000t storage dome, with enlarged truck and railway capacity, to allow the site to import and distribute raw materials such as fly ash, slag and aggregates. Completion on this one was scheduled for some point in 2023. Titan added that the project was similar to the addition of a 70,000t dome under construction at the time at Titan's import terminal in Tampa, Florida.
The United States Geological Survey (USGS) estimates that domestic sales of iron and steel (ferrous) slags in the US amounted to 15Mt in 2022. Sales were around 20Mt in the 2000s but this fell to current levels in the 2010s as blast furnaces closed. In 2022 the USGS noted that, “domestic ground granulated blast furnace slag (GGBFS) remained in limited supply because granulation cooling was known to be available at only two active US blast furnaces while, elsewhere, only one domestic plant produced pelletised slag in limited supply.” It added that the grinding of granulated blast furnace slag was only being carried out domestically by cement companies. Imports of slag were 2Mt in 2022. This is a decline from a peak of 2.6Mt in 2018 but higher than the period 2000 – 2015. The price of slag, meanwhile, hit a high of US$53/t in 2022. This is the highest price recorded by the USGS since at least 2000. It is double that of 2017.
Charles Zeynel of ZAG International noted in the June 2023 issue of Global Cement Magazine that cement producers in Florida, California, Texas, Georgia and the Carolinas are far from steel mills, so they import granulated blast furnace slag (GBFS) and other secondary cementitious materials (SCM). This certainly fits with Heidelberg Materials’ plan to upgrade its slag cement plant and terminal at Cape Canaveral. Also on the US market, Zeynel added that due to rising global demand for SCMs more of the available share of GBFS was being purchased by ‘richer’ markets such as Europe, North America and Australia. He continued that GBFS and GGBFS producers had also started increasing the price of their wares internationally. This too is apparent in the prices published by the USGS.
One final story with links to slag to note this week concerns the launch of the Alliance for Low-Carbon Cement & Concrete (ALCC) in Europe. The group brings together companies producing products or services intended to decarbonise the cement and concrete sectors. Two of the members – Ecocem and Hoffman Green Cement Technologies – are Europe-based slag cement producers. Two other members – Fortera and TerraCO2 – are companies based in North America that are marketing and selling low-carbon SCMs.
Various start-up companies have been emerging on a regular basis in both North America and Europe with the aim of decarbonising cement and concrete in various different ways. The formation of the ALCC can be seen as part of this trend as the more successful non-traditional cement-concrete-aggregate companies establish themselves. One point that cement producers in North America are likely to be well aware of is that concrete is becoming less linked to clinker as the cost of carbon mounts and the clinker factor of cement lowers. Slag supplies may be finite but Heidelberg Materials North America’s latest investment in Florida is further acceptance that one doesn’t just need clinker to make concrete.
Heidelberg Materials North America inaugurates expanded Port Canaveral slag cement plant and terminal
26 May 2023US: Heidelberg Materials North America has inaugurated the Port Canaveral slag cement plant and terminal in Florida, following an expansion. MENAFN News has reported that the producer invested US$24m in the installation of a new roller press at the facility.
Heidelberg Materials North America said "Heidelberg Materials' investment in the Port Canaveral slag cement facility is reflective of our commitment to supporting sustainable and resilient construction projects in the state of Florida and throughout the country. It is also aligned with our goal to significantly reduce our carbon footprint by 2030 and another milestone in our overall strategy to grow our portfolio of more sustainable products, technologies and customer-focused solutions on the path to Net Zero."
US: Continental Cement has ordered a Fuelflex Pyrolyzer alternative fuels combustion system from Denmark-based FLSmidth for installation at its Davenport plant in Buffalo, Iowa. The supplier says that its product offers a lower capital expenditure compared to competing systems, can control NOx emissions without the need for ammonia water and can be installed without a long shutdown period. This is the first commercial installation of the Fuelflex Pyrolyzer system following a pre-commercial installation at the Mannok cement plant in Northern Ireland, UK, in 2022.
David Loomes, the president of Continental Cement, said “We’re very excited about what the Fuelflex Pyrolyzer will do for our process.” He added, “We’re planning to achieve 55% fossil fuel replacement across the plant, utilising non-hazardous waste that would otherwise go to landfill or incinerators. The economic and environmental benefits of this technology are very significant and a key element of executing our carbon reduction commitment.” Continental Cement, a subsidiary of Summit Materials, has been incorporating waste materials as fuels for more than 30 years.
Jens Jonas Skov Larsen, Head of Capital Sales at FLSmidth, said “Mannok has called the Fuelflex Pyrolyzer a game-changer for the cement industry.” He continued, “This system effectively rearranges the order of the combustion process to make use of hot preheater meal, which is the heat source for the waste fuel pyrolysis. It’s a more efficient way of burning alternative fuels and it comes with a host of benefits, including reduced emissions and a more stable process.”
The installation at Davenport cement plant is expected to start operation in 2024. The full commercial launch for the system is scheduled by 2025. No value for the order has been disclosed.
US: Eagle Materials reported sales of US$2.1bn in 2022, up by 15% year-on-year from 2021 levels. The producer's earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 19% to US$782m. Its cement sales rose by 7% to US$1.1bn due to increased prices, despite a drop in volumes. Throughout the year, the company increased its production of Portland limestone cement (PLC).
President and CEO Michael Haack said "Looking ahead, we anticipate continued attractive fundamentals in our markets, despite headwinds relating to higher interest rates and affordability constraints in single-family residential construction. Among the favourable demand factors we expect will affect our results in future periods are projected funding increases for infrastructure projects and healthy demand for heavy industrial projects and multi-family residential construction. We remain well-positioned to capitalise on these conditions, given our geographical footprint across the (Central) US Heartland and fast-growing Sun Belt (Southern US) and our financial strength and flexibility."
Unacem increases first-quarter sales in 2023
19 May 2023Peru: Unacem recorded consolidated sales of US$380m during the first quarter of 2023, corresponding to year-on-year growth of 2.6%. Despite this, the producer's earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 7.4% to US$105m. Unacem attributed its sales growth to 'strong' cement sales volumes in the US, as well as increased prices across its markets. The domestic Peruvian market contributed US$247m (65%) of Unacem's sales, up by 0.5% year-on-year. Peruvian cement volumes fell by 8%, while high fuel costs there contributed to a local decline in earnings.
Looking ahead to the full 2023 financial year, Unacem CEO Pedro Lerner expects the group's consolidated sales to rise year-on-year. He forecast a 10% drop in Peruvian cement volumes to 6Mt. Lerner said that the company is 'monitoring events' in neighbouring Ecuador, but considers it inevitable that on-going political disturbances will 'affect economic conditions' in the market.
Heidelberg Materials North America to install carbon capture system at Mitchell cement plant
18 May 2023US: Heidelberg Materials North America has secured funding for a feasibility study for a 2Mt/yr carbon capture installation at its Mitchell cement plant in Indiana. The study will also investigate possible storage and utilisation solutions for a future installation. The producer says that the US government's Department of Energy has pledged US$5m in funding towards the US$10m study.
Heidelberg Materials North America president and CEO Chris Ward said “We are pleased for this additional federal funding to help move our Mitchell carbon capture project forward. Heidelberg Materials recognises the significant role that carbon capture will play in achieving its goal of net zero carbon, and we are very excited to take the next steps in exploring this technology at our new cement plant in Mitchell.”