September 2024
Dewan Cement reduces loss in 2023 financial year 28 September 2023
Pakistan: Dewan Cement’s turnover rose by 22% year-on-year to US$69.8m in the year to 30 June 2023 from US$57.1m in the same period that ended in 2022. Its cost of sales increased by 29% to US$68.3m from US$52.8m. It reported a loss of US$2.03m compared to US$2.43m previously.
East African Portland Cement raises prices 28 September 2023
Kenya: East African Portland Cement (EAPCC) has raised the price of its 50kg bags of cement by around 3%. It said that it made the decision due to higher input costs, according to the Standard newspaper. In a statement David Kilonzo, acting head of commercial at EAPCC, said “Due to the continuous surge in raw materials prices, operating overheads and our commitment to maintain the premium brand quality that our customers have enjoyed over the years, we will be revising our prices upwards.”
Switzerland-based Holcim holds a 42% stake in EAPC through its subsidiaries, the National Social Security Fund (NSSF) holds a 27% stake and the Kenyan government, through the National Treasury, holds a 25% share in the company.
FLSmidth strikes deal with FCT ACTech on quality control equipment 28 September 2023
Denmark: FLSmidth has signed a deal with Australia-based FCT ACTech to provide a new product for the online analysis of raw materials. Under the agreement, FLSmidth will incorporate FCT ACTech’s X-ray fluorescence (XRF) and X-Ray diffraction analysis (XRD) analysers in its new QCX Cube products. The partnership was formalised in August 2023.
Jens Asbjørn Pedersen, Global Product Manager for Sampling, Preparation and Analysis at FLSmidth, said “We are very pleased to be able to integrate FCT ACTech analyser units in our new QCX Cube analysis solutions for cement plants.” He continued, “We are starting with the launch of QCX Cube X10, which primarily targets raw meal applications, but it is our ambition to utilise FCT ACTech's innovative range of analyser units to also deliver advanced online XRD analysis solutions for clinker and cement.” He added that the company believes that such integrated solutions will provide ‘critical’ support for cement plants during the green transition, as alternative fuels and new secondary cementitious materials drive a need for further process and chemistry optimisation.
The QCX Cube X10 online elemental analyser is FLSmidth's newest analysis product for cement raw meal. Offering plug-and-play functionality, it includes sampling components, an energy dispersive X-ray fluorescence (EDXRF) analyser and a fully programmed local control system that are delivered pre-assembled in an air-conditioned container. Analysis results for calcium, silicon, aluminium and iron are provided as standard. Sodium and magnesium analysis can be provided with the addition of a helium purge, while other elements are available on request after a site-specific evaluation. The product is designed to be integrated with FLSmidth’s optimisation software QCX/BlendExpert.
FCT ACTech is the analytical instruments division of FCT International. It has developed and supplied a continuous on-stream analyser for more than two decades with products now covering raw mix, clinker quality and cement blend control.
Buzzi Unicem USA’s Maryneal cement plant hits production record in 2022 28 September 2023
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.”
Lhoist North America to add lime production capacity in Texas 28 September 2023
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.
Portland Cement Association announces winners of 2023 Safety Innovation and Chairman's Safety Performance Awards 28 September 2023
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
Storing energy at scale at cement plants 27 September 2023
Taiwan Cement has just commissioned a 107MWh energy storage project at its Yingde plant in Guangdong province, China. Subsidiary NHOA Energy worked on the installation and has been promoting it this week. The battery storage works in conjunction with a 42MW waste heat recovery (WHR) unit, a 8MWp solar photovoltaic unit and a proprietary energy management system. It is expected to store about 46,000MWh/yr of electricity and save just under US$3m/yr in electricity costs.
NHOA Energy, formerly known as Engie EPS before Taiwan Cement bought a majority stake in it, claims it is one of the largest industrial microgrids in the world. We can’t verify this for sure, but it is definitely large. For comparison, the 750MW Vistra Moss Landing Energy Storage Facility in California often gets cited as the largest such facility in the world. This is run by a power company, as are many other large battery energy storage systems. In its annual report for 2022 Taiwan Cement said it was planning to using NHOA’s technology to build seven other large-scale energy storage projects at sites in Taiwan including its integrated Suao, Ho-Ping and Hualien cement plants.
The aim here appears to be supplying renewable electricity to the national grid in Taiwan. Taiwan Cement is diversifying away from cement production, with an aim to derive over 50% of its revenues from other activities besides cement by 2025. In 2022 cement and concrete represented 68% of its sales, while its electricity and energy division, including power supply and rechargeable lithium-ion batteries, represented 29%. The company is also not using its own batteries at the Yingde plant. Instead it is using lithium iron phosphate batteries supplied by Ningde Times. This is worth noting, as the cement producer’s batteries are used in vehicles.
Global Cement regularly reports news stories on cement plants that are building photovoltaic solar power arrays. However, so far at least, energy storage projects at scale have been rarer. One earlier example of an energy storage system loosely associated with a cement plant includes the now decommissioned Tehachapi Energy Storage Project that was situated next to the Tehachapi cement plant in California. That project tested using lithium ion batteries to improve grid performance and integrate intermittent generation from nearby wind farms. It is also worth noting that Sumitomo Osaka Cement’s sister company Sumitomo Electric is one of the world’s larger manufacturers of flow batteries, although no installation at a cement plant appears to have happened yet. In simple terms, flow batteries are an alternative to lithium ion batteries that don’t store as much energy but last longer.
More recently, Lucky Cement in Pakistan started commercial operation of a 34MW solar power plant with a 5.59MWh energy storage unit at its Pezu plant in Khyber Pakhtunkhwa in late 2022. Reon Energy provided the equipment including a lithium-ion based battery approach to the storage. Then, in March 2023, Holcim US said that it was working with TotalEnergies to build solar power capacity and a battery energy storage unit at the Florence cement plant in Colorado. TotalEnergies will install, maintain and operate a 33MW DC ground-mounted solar array and a 38.5MWh battery energy storage system at the site. Operation of the renewable energy system is expected to start in 2025.
Away from electrical batteries, the other approach to energy storage at cement plants that has received attention recently from several quite different companies has been thermal batteries. The two prominent groups using them at different scales are Rondo Energy and Synhelion. The former company has developed its Heat Battery technology, which uses refractory bricks to absorb intermittent renewable energy and then supply the energy back as a steady stream of hot gas for use in a cement plant mill, dryer, calciner or kiln. Both Siam Cement Group (SCG) and Titan Cement have invested in Rondo Energy. In July 2023 SCG and Rondo Energy said that they were planning to expand the production capacity of a heat battery storage unit at a SCG plant to 90GWh/yr. Synhelion, meanwhile, has been working with Cemex on using concentrated solar power to manufacture clinker. It achieved this on an ‘industrially viable scale’ in August 2023. It has since been reported that the companies are working on building a small scale industrial plant at Móstoles near Madrid by 2026. Crucially for this discussion though, the process also uses a thermal energy storage unit filled with ceramic refractory material to allow thermal energy to be released at night, and thus ensure continuous operation.
The examples above demonstrate that some cement companies are actively testing out storing energy at scale. Whilst this will not solve the cement sector’s process emissions, it does potentially start to make using renewable energy sources more reliable and reduce the variable costs of renewable power. Whether it catches on remains to be seen. Most of these kinds of projects have been run by power companies and that is where it may stay. It is instructive to note that Reon Energy was the only company to state that its battery-based energy storage system has a life-span of 8 - 12 years. Our current vision of a net-zero future points to high electrical usage but it may be shaped by how good the batteries are… from our phones to our cars to our cement plants.
For more information on Rondo Energy read the January 2023 issue of Global Cement Magazine
Bangladesh: Md Alamgir Kabir, vice chair of Crown Cement, has been re-elected as president of the Bangladesh Cement Manufacturers Association (BCMA) for a two-year period until September 2025. Imran Karim, vice chair of Confidence Cement, and Abdul Khaleque Pervez, managing director of Diamond Cement, have also been re-elected as the first and second vice-presidents of the BCMA respectively. All three were re-appointed at the BCMA’s annual general meeting in Dhaka, held on 26 September 2023.
Speaking upon his reappointment as BCMA president, Kabir expressed his heartfelt thanks to all BCMA members for re-electing him as the president of BCMA. He said that the cement industry of Bangladesh was in a ‘deep crisis’ and that it must work with policy makers in order to flourish, as well as respond more effectively to the needs of consumers.
India: Anjani Portland Cement has appointed Rajesh Kumar Dhoot as its chief financial officer. He succeeds RS Ramanjaneyulu following his resignation. Dhoot is a chartered accountant with over 25 years of professional experience in the cement, sugar, pipe and textile sectors. He has worked in the cement industry for over 15 years, most recently with Chettinad Cement since 2014. Prior to this he held positions with UltraTech Cement from 2006 to 2014.
Pakistan: Pioneer Cement has appointed Talha Saif as its company secretary. He succeeds Abdul Wehab in the role. The company also appointed Jan Mohammad as Head of Internal Audit. He replaces Jamal Uddin.