Displaying items by tag: Plant

US: The death of a maintenance worker has been reported at Buzzi Unicem USA’s Hercules Cement at Stockertown in Pennsylvania. The cause of the fatality has not been released pending an investigation by state authorities and the Mine Safety and Health Administration, according to the Express Times newspaper. The incident occurred on 26 July 2021.

Holcim has started to unify its low carbon cement product range this week with the launch of its ECOPlanet label globally. The products are already available in Germany, Romania, Canada, Switzerland, Spain, France and Italy. The plan is to extend this to 15 countries by the end of 2021 and then to double its ‘market presence’ by the end of 2022.

The headline news is that the range will include what Holcim says is the world’s first cement product with 20% recycled construction and demolition waste. This appears to be an improvement on the group’s Susteno cement products that use fine fractions from concrete and demolition waste. This product is currently sold in Switzerland where it is advertised as saving 10% of CO₂ emissions compared to a standard cement product. Both Holcim and HeidelbergCement already sell concrete products that use the coarse waste from building demolition. Other than this, Holcim says that the range will also include cements that contain calcined clay. In June 2021 subsidiary Lafarge France announced that it would produce a cement product under the ECOPlanet banner using kaolin clay with its proprietary ProximA Tech process at its integrated La Malle cement plant in Bouc-Bel-Air.

We will have to wait and see how far Holcim goes in standardisng the range between different countries. Yet, judging from what the countries that are already selling ECOPlanet are doing, it looks like it will be a variety of blended cements. At present, for example, Holcim Germany offers four products in the ECOPlanet range. These are all slag cements, with three having effective CO₂ reductions of up to 70% and the fourth, ECOPlanet Zero, reaching 100% through a carbon offsetting scheme in conjunction with MoorFutures. Holcim Italy also launched a product in the range called ECOPlanet Prime using calcined clay in June 2021.

Incidentally, LafargeHolcim US announced a research project this week with the US Army about using demolition waste. It’s going to start working with the US Army Corps of Engineers’ Engineer Research and Development Center and Geocycle to look at how construction and demolition materials from military installations can be used for energy recovery and mineral recycling. Group resources at Geocycle’s Holly Hill Research Center in South Carolina, US and Holcim’s Global Innovation Center in Lyon, France will be used in the scheme.

Other low carbon cement products are available of course. Holcim is far from alone in launching low CO₂ cement and concrete products. Yet the use of worldwide brand names is different. Cemex is doing something similar with the global rollout of its Vertua concrete products. It first launched Vertua in France in 2018 before going global in 2020. Holcim started to launch ECOPact Concrete in 2019. Now, Holcim has gone further by doing the same thing with cement. Given how localised cement and concrete products are, it will be instructive to see how global branding for low carbon cementitious products helps these companies. For instance, who is the target audience? It could be eco-minded self-build customers or project specifiers or government departments or industry lobbyists. Or perhaps it is simply another marketing channel to reinforce the sector’s sustainable offerings.

The other point worth considering is when will the multinational cement producers start selling sustainable cements and concretes in less rich parts of the world? While Holcim was playing with blended cements and marketing this week, Dangote Cement said that it was ready to start commissioning its new 6Mt/yr integrated plant at Okpella, Edo State in Nigeria. Another 5Mt/yr plant is also on the way in the country from Madugu Cement. It has just signed a contract for China-based Sinoma International Engineering Company to build it. When Holcim and the other cement companies start selling low carbon cements in places like Nigeria then the rise of these products will be complete.

For more information on low CO₂ cement production read our feature in the February 2021 issue of Global Cement Magazine

Russia: Sibirsky Cement has appointed Dmitry Kireev as the managing director of the Krasnoyarsk cement plant and Vladimir Afanasin as the managing director of the Angarskcement plant.

Kireev worked at Sibirsky Cement’s Topkinsky cement plant from 2001 until 2013, eventually becoming the director for equipment maintenance and repair. He was then appointed as the managing director of TimlyuiCement before becoming the head of the Angarskcement plant in 2016. He is a graduate of the Belgorod Technological Institute of Building Materials and the Kuzbass State Technical University. He also holds a Master of Business Administration (MBA) degree from the Moscow International Higher School of Business (MIRBIS).

Afanasin became the deputy chief engineer at the Topkinsky cement plant in 2007. He later worked at Krasnoyarsk cement plant until 2011 as the chief engineer, technical director and the production director. In 2011, he became the head of Angarskcement and then managed the Krasnoyarsk cement plant from 2016. Afanasin is a graduate of the Belgorod Technological Institute of Building Materials and holds an MBA from MIRBIS.

France: Vicat’s consolidated sales rose by 19.6% year-on-year to Euro1.56bn in the first half of 2021 from US$1.30bn in the same period in 2020. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) increased by 41% to Euro300m from Euro213m. Sales and earnings rose in all territories on an adjusted basis as markets recovered from a poor second quarter in 2020 due to the coronavirus pandemic, particularly in India and France.

“Focused on its carbon footprint reduction targets, the group has accelerated the commercialisation of its low-carbon product lines, adapted to the global climate challenge,” said Guy Sidos, the group’s chairman and chief executive officer. The company added that the upgrade of its Ragland cement plant in the US is on track for expected commissioning in the first half of 2022 and that it is ramping up a new mill in Mali.

India: Ramco Cements plans to invest US$64m in a modernisation and capacity expansion of its Ramasay Raja Nagar cement plant in Tamil Nadu. The Hindu newspaper has reported that the project involves building a new 3000t/day clinker line to replace a 1450t/day line. This will increase the plant’s overall capacity by 32% to 1.44Mt/yr from 1.09Mt/yr. The company has placed equipment orders for the project and plans to commissions the upgrade in December 2022. It expects to receive environmental clearance for the work in September 2021.

Nigeria: Madugu Cement plant to build a 5Mt/yr cement plant at Kembu in Gombe state. The producer has awarded an engineering, procurement and construction (EPC) contract for the project to China-based Sinoma International Engineering Company. Construction will consist of two phases, each of which will establish a production line of 2.5Mt/yr capacity. The Nigerian Tribune newspaper has reported that, when commissioned, the plant will be the second in Gombe state. The state has extensive gypsum reserves and a surplus of coal and hydroelectric power.

Nigeria: Dangote Cement says that its new 6Mt/yr cement plant at Okpella in Edo state is ready to enter cement production. The Daily Independent newspaper has reported that group invested US$1bn in the plant. China-based Sinoma International Engineering Company supplied engineering, procurement and construction (EPC) services. When commissioned, the plant will employ 6000 people, according to the owner.

Dangote Cement is in the process of establishing a further 6Mt/yr cement plant at Itori in Ogun state. The launch of both plants will give the producer an active cement capacity of 41.3Mt/yr. The company says that its aim is to increase the uptake of cement in Nigeria. It said, “We still need to do more to make the cement get to the poorest of the poor.”

US: Cemex USA’s Victorville cement plant in California has won the Portland Cement Association (PCA)’s Chairman’s Safety Performance Award 2021 in the Large category. The award recognises top safety performance. The Victorville cement plant previously won the award in 2019 and 2020. Cemex USA says that the plant recorded zero incidents in 2020. Earlier in 2021, it surpassed four years without a lost time injury to any employee or contractor.

President Jaime Muguiro said “Safety is our top priority, and Victorville cement plant is demonstrating that Zero4Life is possible. We are proud of the continued commitment of our team, and their achievement is a great example of what can happen when everyone is dedicated to safety and works together to look out for one another.”

Iraq: Joint security forces have repelled militants from the Kubiasa cement plant in Al-Anbar province. Iraqi News has reported that 18 fighters from the Islamic State of Iraq and Syria (ISIS) were killed in the operation. The security forces also detonated four car bombs at the site.

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.