September 2024
Tarmac completes repairs on excavator at Dunbar quarry 24 September 2021
UK: Tarmac has completed a seven-week repair job on its PC2000 backhaul excavator at its Dunbar, East Lothian, quarry. The East Lothian Courier newspaper has reported that the work consisted of a rebuild of all major components, including the 11t bucket, pins and bushes. The equipment has been in service since 2014. It will next require servicing in 2026. Marubeni Komatsu carried out the work.
Quarry manager Mark Grieve said “With the excavator playing an absolutely key role in our process, this was a major project for Tarmac Dunbar.”
Askari Cement orders three Gebr. Pfeiffer MVR vertical roller mills for Nizampur cement plant 23 September 2021
Pakistan: Askari Cement has awarded a contract to Germany-based Gebr. Pfeiffer for the supply of three of its MVR vertical roller mills to replace the existing mills at its Nizampur cement plant. Two of the mills will be MVR 5000 C-4 cement mills with the capacity to grind 360t/hr of clinker to a fineness of 3250 blaine. The other mill, an MVR 5000 R-4 raw meal mill, will grind 520t/hr of clinker to a fineness of 12% R90µm. The Chinese contractor Hefei Cement Research & Design Institute will install an SLS V high-efficiency classifier on each of the mills. The upgraded plant is scheduled for commissioning in mid-late 2022.
Gujarat Sidhee Cement restarts kiln at Sidheegram cement plant 23 September 2021
India: Gujarat Sidhee Cement has restarted the kiln at its Sidheegram cement plant in Gujarat. Reuters News has reported that full operations will commence at the plant on 25 September 2021. The producer shut down its kiln line for routine maintenance on 7 September 2021.
Fábrica Nacional de Cemento to increase clinker exports to Chile 23 September 2021
Bolivia: Fábrica Nacional de Cemento (FANCESA) has received an order for 8000t of clinker from Chile. The Correo del Sur newspaper has reported that the company previously delivered 1000t of clinker to Chile-based Cbb’s grinding operations in the country. The producer says that it is in the process of securing a supply contract for 80,000t/yr of clinker with its Chilean customer.
UK: ZwickRoell UK and Ireland has begun the construction of its new headquarters in Worcester, Worcestershire. The facilities will consist of a customer experience centre, a suite of offices, meeting and seminar rooms and a comprehensively equipped demonstration laboratory. Managing director Benno Sadowski said “We are very happy to be establishing a new facility in the Worcester Six Business Park, with its excellent strategic location in the UK.” He added “With our experience of more than 160 years in the materials testing equipment business, we are always investigating ways in which we can better support our customers with our advanced technology testing solutions in addition to creating relationships which embody our brand, vision and values.”
Texas Commission on Environment Quality discards crystalline silica limits for ready-mix concrete plants 23 September 2021
US: The Texas Commission on Environment Quality has discarded legal limits on crystalline silica in ready-mix concrete plants’ dust emissions. Commissioner Bobby Janecka said "I am pretty comfortable moving forward and finalising the proposed revision of the standard permit to bring us back to the point we departed from in 2012." He added that the commission had confirmed the decision with analysis from before the previous rule change, which he attributed to a ‘clerical error.’
Update on carbon capture in cement, September 2021 22 September 2021
It’s been a good week for carbon capture in cement production with new projects announced in France and Poland.
The first one is a carbon capture and utilisation (CCU) collaboration between Vicat and Hynamics, a subsidiary of energy-provider Groupe EDF. The Hynovi project will see an integrated unit for capturing CO2 and producing methanol installed at Vicat’s Montalieu-Vercieu cement plant in 2025. It aims to capture 40% of the CO2 from the kiln exhaust stack at the plant by using an oxy-fuel method and installing a 330MW electrolyser to split water into oxygen and hydrogen for different parts of the process. The CO2 will then be combined with hydrogen to produce methanol with potential markets in transport, chemicals and construction. The setup is planning to manufacture over 0.2Mt/yr of methanol or about a quarter of France’s national requirement. The project was put forward under a call for proposals by the Important Projects of Common European Interest (IPCEI) program. Pre-notification of its participation in the program has been received from the French government and it is currently being evaluated by the European Commission. Vicat’s decision to choose its Montalieu-Vercieu plant for this project is also interesting since it started using a CO2ntainer system supplied by UK-based Carbon8 Systems there on an industrial scale in November 2020. This system uses captured CO2 from the plant’s flue gas emissions to carbonate cement-plant dust and produce aggregate.
The second new project is a pilot carbon capture and storage (CCS) pilot by HeidelbergCement at its Górażdże cement plant in Poland. This project is part of the wider Project ACCSESS, a consortium led by Sintef Energi in Norway that aims to cut carbon capture, utilisation and storage (CCUS) costs and to link CO2-emitters from mainland Europe to storage fields in the North Sea. The cement plant part in Poland will test an enzyme-based capture method using waste heat at the plant. Another part of the project will look at how the captured CO2 can then be transported to the Northern Lights storage facility in Norway including the regulatory aspects of cross-border CO2 transport. ACCSESS started in May 2021 and is scheduled to end in April 2025. It has a budget of around Euro18m with Euro15m contributed by the European Union (EU) Horizon 2020 fund.
HeidelbergCement also says that the second stage of its LEILAC (Low Emissions Intensity Lime And Cement) project at the Hannover cement plant is part of ACCSESS, with both testing of the larger-scale Calix technology to capture CO2 and the connected transport logistics and bureaucracy to actually get it to below the North Sea. That last point about Calix is timely given that US-based Carbon Direct purchased a 7% stake in Calix in mid-September 2021 for around US$18m. Whilst on the topic of carbon capture and HeidelbergCement don’t forget that the group’s first full-scale carbon capture unit at Norcem’s Brevik cement plant, using Aker Solution’s amine solvent capture technology, is scheduled for commissioning in September 2024. Another carbon capture unit is planned for Cementa’s Slite plant in 2030 but the proposed capture method has not been announced.
Other recent developments in carbon capture at cement plants include Aalborg Portland Cement’s plan to capture and store CO2 as part of the Project Greensand consortium. The overall plan here is to explore the technical and commercial feasibility of sequestering CO2 in depleted oil and gas reservoirs in the Danish North Sea, starting with the Nini West Field. The project is still securing funding though, with an Energy Technology Development and Demonstration Program application to the Danish government pending. However, the Danish Parliament decided in December 2021 to set aside a special funding pool to support a CO2 storage pilot project so this initiative seems to be making progress. If the application is successful, the consortium wants to start work by the end 2021 and then proceed with an offshore injection pilot from late 2022. How and when Aalborg Portland Cement fits in is mostly unknown but a 0.45Mt/yr capture unit at its Rørdal cement plant is tentatively planned for 2027. There’s also no information on the capture method although Aker Carbon Capture is also part of the Project Greensand consortium. Finally, also in September 2021, Chart Industries subsidiary Sustainable Energy Solutions announced that it had selected FLSmidth to help adapt and commercialise its Cryogenic Carbon Capture carbon capture and storage (CCS) system for the global cement industry.
All of this tells the cynics in the audience that a large international climate change meeting is coming up very soon. Most cement companies will likely want some good news to show off when the 2021 United Nations Climate Change Conference (COP26) dominates the media agenda in November 2021. Other observations to point out include that none of the projects above are full-scale industrial carbon capture installations, most of them are consortiums of one sort of another and that they are all subsidised or want to be. While hydrogen and CO2 networks get built this seems inevitable. Yet, we’re not at the stage where cement companies just order carbon capture units from a supplier, like they might a new clinker cooler or silo, without the need for long lists of partners. When this changes then carbon capture looks set to flourish.
On a final note, the UK is currently experiencing a shortage of commercially-used CO2. The reasons for this have nothing to do with the cement industry. Yet consider the constant doom-and-gloom about record global CO2 emissions and the sheer amount of effort going into reducing this by the projects mentioned above and others. Life has a sense of humour at times.
For a view on the CO2 sequestration permitting process in the US look out for the an article by Ralph E Davis Associates, in the forthcoming October 2021 issue of Global Cement Magazine
Li Qunfeng appointed as general manager of Anhui Conch 22 September 2021
China: Anhui Conch has appointed Li Qunfeng as its general manager. He succeeds Wu Bin who has resigned from the post but who intends to remain working as the company’s executive director. Li Qunfeng is a trained engineer who has worked for the company since 1994. Notably, he first worked for subsidiary Anhui Tongling Conch Cement in a number of production roles before attaining more senior postings within the group.
Philip Mathew appointed as deputy head of Dangote Cement 22 September 2021
Nigeria: Dangote Cement has appointed Philip Mathew as its deputy group managing director and chief executive officer with effect from 15 September 2021.
Following his training at the Indian Institute of Technology in Madras, Matthew has worked for cement companies since the mid-1980s when he started out as a process engineer for ACC. He later worked for Lafarge in a number of roles and countries, eventually becoming its Director - Performance and Progress for Asia based in Kuala Lumpur in the early 2010s. He held the post of Chief Manufacturing Officer for ACC in India from 2016 to 2019 before becoming LafargeHolcim’s Head of Cement Excellence Manufacturing for the Asia-Pacific region subsequently.
Poland: Lafarge Poland has laid the foundation stone for the Euro100m new kiln line at its Małogoszcz cement plant. The replacement of the three existing kilns and installation of an alternative fuel (AF) line aims to reduce the plant’s CO2 emissions by 20% and its energy consumption by 33%. The company, a subsidiary of Switzerland-based Holcim, aims to make the cement plant into one of the European Union’s most modern. China National Building Material (CNBM) subsidiary Nanjing Kisen International Engineering will carry out the work, which is scheduled for completion in early 2023.
Project director Krzysztof Byczyński said “One of the three kilns has already been demolished and in its place a new kiln will be built with the necessary installations. Preparatory works for the construction of a new kiln are currently underway.”