09 July 2019
Switzerland: LafargeHolcim has launched a four-year industrial automation plan called ‘Plants of Tomorrow.’ It includes Industry 4.0 concepts such as automation technologies and robotics, artificial intelligence, predictive maintenance and digital twin technologies for its entire production process. The plan is expected to show 15 – 20% operational efficiency gains. It also claims that the initiative is, “one of the largest roll-outs of Industry 4.0 technologies in the building materials industry.”
“Transforming the way we produce cement is one of the focus areas of our digitalisation strategy and the ‘Plants of Tomorrow’ initiative will turn Industry 4.0 into reality at our plants. These innovative solutions make cement production safer, more efficient and environmentally fit,” said Solomon Baumgartner Aviles, Global Head Cement Manufacturing.
The building materials company is presently working on more than 30 pilot projects covering all regions where the company is active. The company’s integrated cement plant at Siggenthal in Switzerland will be a trial site where the integration of all relevant modules will be tested.
One examples of where LafargeHolcim has started the plan include a partnership with Swiss start-up Flyability to use drones to increase the frequency of inspections at plants while simultaneously reducing cost and increasing safety for employees by inspecting confined spaces. The concept is being rolled out to several markets, including Switzerland, France, Germany, the UK, the US, Canada, India and Russia. It is also using a subsidiary, Maqer, to identify technology startups with promising technology. It aims to harness the potential of this through new partnership models with both manufacturing and software companies.
LafargeHolcim has already launched technology to track performance centrally and allocated resources to support the plant network in real time. More than 80% of LafargeHolcim’s cement plants are already connected to its Technical Information System that provides data transparency at plant, country, regional and global level. Some country operations have more than a decade of historic technical data available. Other systems allow the remote control of certain parts of the operations through online condition monitoring systems. Since its implementation in 2006, this system has saved over Euro70m and an additional 3Mt of cement sold through fewer breakdowns.
US: Lehigh Cement has received permission from the Indiana Department of Environmental Management for a US$600m upgrade to its integrated Mitchell plant. IDEM's Office of Air Quality granted a modification to the unit’s air permit in late June 2019 following a period of public comment, according to the Times-Mail newspaper. The subsidiary of Germany’s HeidelbergCement plans to increases the production capacity at the plant to 2.8Mt/yr from 0.8Mt/yr. Construction is scheduled to begin in 2020 and completion of the new plant is anticipated by the end of 2022. Once finished the upgrades will create 52 new jobs at the unit.
El Nahda Cement suspends production for six months 09 July 2019
Egypt: El Nahda Cement has suspended production at its 1.7Mt/yr plant at Quena for six months. It has taken the decision due to lower sales and increased supply in the local market, according to Mist News. The local industry has reported production overcapacity in recent years. In mid-2018 the 13Mt/yr government/army-run El-Arish Cement plant at Beni Suef was fully opened
Pakistan: DG Khan has signed a deal with Sinoma Energy Conservation for upgrades at the integrated Hub cement plant in Baluchistan. The agreement includes a 10MW waste heat recovery (WHR) unit and a 30MW coal power plant. No cost of the project or date of completion has been disclosed.
Myanmar: U Aung Kyaw Thu, the Hluttaw representative of Mon State Parliament and chairperson of the public budget scrutiny, finance planning and economics matters review committee has warned that cement plant projects granted licenses by the Myanmar Investment Commission (MIC) that have not implemented their plans will not be granted permission to extend their licenses. During a meeting with legislators, local farmers from Kaw Won Village, Kyaikmaraw Township in Mon State complained that the Myanmar-Korea Cement Group should not be allowed to extend its permit, as they had not implemented anything yet, according to the Mons News Agency. Normally companies that have received a permit are allowed to build at the site for three years. They can then extend this by up to three years if they provide a legitimate reason.
The June Cement Industry project has reportedly finished 15% of its construction and the Myanmar-Korea Cement Group project has finished 10% of its construction. The companies have blamed operational difficulties on the delays. They were granted permits by the MIC in 2016 and 2017 respectively.
Austria: Data from the Austrian Cement Industry Association (VÖZ) shows that cement production rose by 7.4% year-on-year to 5.2Mt in 2018. The increase has been attributed to a construction boom. Sales of cement grew by 4.7% to Euro432m. Sales continue to increase at a similar rate in the first quarter of 2019 but this has slowed down in the second quarter.
The association has said that environmental investment more than doubled in 2018 to Euro45m. The local industry’s alternative fuels substitution rate was 82% and CO2 emissions fell by 0.8% to 521kg/t of cement.
US: Hawaii’s Department of Transportation plans to use carbon-injected concrete for its new projects. This will include a new structure to protect a highway tunnel from rockfalls, according to Reuters. The Department of Transportation was testing CO2-injected concrete on an access road project with CarbonCure Technologies in May 2019. The latest decision follows a resolution by state legislators that city administrators ‘consider’ using CO2-injected concrete in city and county infrastructure where concrete is used.
In late June 2019 CarbonCure announced that its had formed a partnership with HC&D Ready Mix, a local concrete producer, to use its CO2-injected concrete process. It is the second deal with a concrete producer in the state that CarbonCure has arranged.
Mississippi Lime to buy Southern Lime 09 July 2019
US: Mississippi Lime Company has executed a definitive agreement to acquire Southern Lime, the lime business of Covia based in Calera, Alabama. No value for the transaction has been disclosed. The deal is also subject to regulatory approval.
Southern Lime supplies high-calcium quicklime and hydrated lime products to customers in the Southeastern US, and across a range of end uses and applications. The Calera operation will increase Mississippi Lime’s production facilities to nine locations, supported by a network of distribution sites throughout the country. The business will be fully integrated into existing Mississippi Lime operations.