Displaying items by tag: California

Charah Solutions has been steadily building up its fly ash distribution business in recent years with an eye on the supplementary cementitious materials (SCM) market. This week it opened the third of its new series of SCM grinding plants, at Oxnard in California, US. The unit sticks out because it is focusing on grinding natural pozzolans. The plant will receive natural pozzolan by truck and rail and then use Charah’s patented grinding technology to produce pozzolan marketed under its MultiPozz brand. The previous plants in this series mentioned natural pozzolans but this is the first to promote it explicitly.

The change is potentially telling because global demand for granulated blast furnace slag (GBFS) outstrips supply. Both performance benefits and environmental regulations are pushing this. It’s a similar situation for fly ash, also driven by trends to close coal-fired power stations in some countries. As Charles Zeynel of SCM trading firm ZAG International explained in the March 2019 issue of Global Cement Magazine, “...volcanic pozzolans are a potential SCM of the future. This is gaining traction, but it’s slow progress at the moment. This will be the answer for some users in some locations.”

The problem though is that natural pozzolans are down the list of preferred SCMs for their chemical properties after silica fume, GBFS and fly ash. The first is expensive but the latter two were traditionally cheap and easy to obtain if a cement or concrete producer had access to a source or a distribution network. Natural pozzolans are very much subject to variations in availability.

It’s no surprise then that Charah is promoting natural pozzolans in a Californian plant given that state’s environmental stance. It’s unclear where Charah is sourcing their pozzolan from but they are not the only company thinking about this in the US. Sunrise Resources, for example, is working on the environmental permits for a natural pozzolan mine near Tonopah in Nevada. As it described in its company presentation, California and Nevada are the most affected states in the fly ash supply crisis because they are, “...at the end of the line when it comes to rail deliveries from power stations in central and eastern USA.” It also estimated that California used 0.9Mt of pozzolan in its cement production of which about 90% is fly ash. The state produced 9.6Mt in 2015. Other companies are also mining and distributing natural pozzolans in the US as the website for the National Pozzolan Association (NPA) lists. Although, if this line-up is comprehensive, then the field is still fairly select. Most of these companies are based in the west of the country.

One last thing to consider is that various groups are tackling a potential future lack of SCMs for the cement industry by making their own pozzolanic materials through the use of calcined clay. These groups include the Swiss-government backed LC3 project and Cementir’s Futurecem products. Using clay should bypass the supply issues with natural pozzolans but the cost of calcining it requires at the very least an investment to get started.

As concrete enthusiasts often point out, a variant of pozzolanic concrete was used by the Romans to build many of their iconic structures, some of which survive to the present day. To give the last word to the NPA, “What is old is new again: natural pozzolan is back!” If environmental trends continue and steel and coal plants continue to be shut then it might just be right.

US: Charah Solutions plans to open a grinding plant to make supplementary cementitious materials (SCM) from natural pozzolan at Oxnard in California. The unit will be accessible by truck and railway. It will sell pozzolan and other materials to concrete product manufacturers throughout south California.

The Oxnard plant will be operated in partnership with Diversified Minerals, a supplier and manufacturer of standard and custom blend cement and concrete products. It will receive natural pozzolan by truck and rail and then grind pozzolan marketed under the brand MultiPozz pozzolan. MultiPozz pozzolan will be distributed throughout Charah Solutions’ MultiSource materials network of more than 40 nationwide in the US with international sourcing and distribution.

“Fly ash is becoming more difficult to source in California, which is forcing the construction industry to look for viable alternatives. Natural pozzolan and other SCMs that meet ASTM specifications are generating very high interest. With Charah Solutions’ resources and DMI’s strategic partnership with the only active pozzolan mine in Southern California, we are both the closest and the first to bring these products to market,” said Jim Price, chief executive officer (CEO) of Diversified Minerals.

US: Trabits Group and Brookhaven National Laboratory have been selected to present joint research papers at two scientific geothermal forums on the self-repair ability of the FlexCem Lightweight Variable Density well cement product. The first presentation will be at the September 2019 meeting of the Geothermal Resources Council (GRC), which will be held in Palm Springs, California, US. The second presentation will be at the World Geothermal Congress (WGC), which will be held in Reykjavik, Iceland in April 2020.

FlexCem well cement was developed by Trabits Group following completion of a research grant from the Department of Energy Geothermal Technologies Office (GTO). It is a composite cement using Type I/II cement clinker and Ferrierite zeolite, interground in proprietary ratios.

US: CalPortland has been awarded a US$0.34m grant by the Mojave Desert Air Quality Management District (MDAQMD) as a partner in the replacement of a 1987 Trackmobile with a 2019 Rail King RK330 railcar mover at its Oro Grande cement plant in California. The new machine has been chosen to reduce its air emissions in accordance with the California Clean Air Act.

US: CalPortland has held the official opening of a rapid fill bulk cement loading station at the Oro Grande, California cement plant. The loading station is the final part of an upgrade project that originally started in 2008 when Riverside Cement owned the plant. This included two new cement loadout facilities, two distribution silos and a cement grinding mill. The upgrade cost US$58.5m.

“Our engineering staff and the Oro Grande operations team have developed a truck loadout system that is one of the fastest in the industry. The added rapid fill bulk loading stations will prevent long wait times for our customers by reducing the total number of trucks on each loading station, thereby further contributing to reduction of greenhouse gas emissions,” said Allen Hamblen, president and chief executive officer (CEO) of CalPortland.

France: Vicat’s sales have risen due to its acquisition of Ciplan in Brazil. Its sales rose by 4.7% year-on-year to Euro600m in the first quarter of 2019 from Euro573m in the same period in 2018. However, adjusted for the acquisition, its sales remain stable. The group’s cement sales revenue fell by 1.4% to Euro302m when similarly adjusted. Its concrete and aggregate sales rose by 6.6% to Euro225m.

“The rise in prices across all zones has resulted in stable consolidated sales at constant scope and perimeter, despite strong volume erosions in Turkey as a result of the 2018 lira devaluation and of the consequences of highly adverse weather conditions in California. The integration of Ciplan in Brazil is on track amid conditions that are stabilising after several years of major consumption falls,” said chairman and chief executive officer (CEO) Guy Sidos.

By region sales were strong in France, stable in the rest of Europe and Africa and poor in the Americas, Asia and Turkey. Poor weather in California dragged down sales in the US, competition was reported in India and an economic slowdown was reported in Turkey.

US: The Portland Cement Association (PCA) has announced the winners of the 2019 Energy and Environment (E&E) Awards. The awards recognised environmental and community relations projects that were completed in 2018 and were presented at the 3rd Annual Cement and Concrete Fly-In.

The CalPortland Mojave cement plant in California won the Energy Efficiency award for the installation of a new classifier system for its vertical roller mill that increased energy efficiency by reducing fan power requirements. The plant also installed a control system for the finish mill that will maximise performance and help reduce wear on equipment. The classifier installation reduced the finish mill energy intensity by 1.5 to 2.0kWh/t, and the control system reduced energy intensity by 13%. In 2018 22% of the electricity consumed by the plant came from on-site renewable wind energy generation. CalPortland has implemented significant energy efficiency measures and its energy management program has been recognised by the Environmental Protection Agency Energy Star program as the Energy Star Partner of the Year for 15 years in a row.

Roanoke Cement Company and Titan America’s Troutville plant in Virginia won the Environmental Performance award for being the first cement manufacturing plant in the US to receive ISO 50001 certification for energy management of all aspects of energy procurement, design and use. The plant reduced its total electrical consumption by 10% and fossil fuels use by more than 12%. The plant has also implemented an alternative fuels program as part of its certification for the True Zero Waste Program, administered by Green Business Certification and has received silver status achieving a 96% rate of waste divergence from landfills.

Lehigh Hanson’s Permanente cement plant at Cupertino in California won the Innovation award for the installation of a water treatment system reducing concentrations of metals, including selenium, to meet permit limits. Lehigh Hanson developed a treatment system that combined ultrafiltration and reverse osmosis (UF/RO) technology in conjunction with biological treatment technology to remove metals, including selenium and dissolved solids. This ensured applicable effluent limits were met while optimising treatment capacity and efficiency. This treatment system is the first of its kind in the cement industry ensuring that effluent limits are met while, at the same time, limiting the quantity of waste needed to be managed.

Buzzi Unicem USA’s Greencastle cement plant in Indiana won the Land Stewardship award for opening a 4km smooth packed stone trail in conjunction with the not-for-profit People Pathways organisation as Phase 2 of the Putnam Nature Trail. Buzzi Unicem USA staff and People Pathways used heavy equipment for rough clearing and grading of the overgrown former railroad bed and improved and expanded the physical trail. These areas were then landscaped with trees, native prairie vegetation plugs, interpretive signage, benches, birdhouses and other features. Additional nature trail enhancements include placement of wildlife monitoring cameras along the trail, installation of nesting boxes and interpretive signage, and maintenance of the recently completed restoration of native flora installed in 2017 and 2018.

Cemex’s Lyons cement plant in Colorado won the Outreach award for volunteering work by its staff at the Rocky Mountain National Park in Boulder, Colorado, performing campground improvement activities at Glacier Basin Campground by moving rocks and fallen timber and clearing existing fire pits of ash deposits. The plant then introduced a new community outreach initiative by hosting a Manufacturing Day event, providing local students tours of the quarry and plant to increase youth interest in pursuing a vocation in skilled trades. Additionally, the plant teamed up with the Celestial Seasonings B Strong Ride for cancer care and research for an event aimed at increasing safety awareness while fundraising for two local organizations and their efforts to fight cancer.

US: CalPortland has commissioned a new cement grinding mill and distribution system at its Oro Grande cement plant in California. The US$58.5m project includes the construction of the finish ball mill and two new cement shipping lanes with two new distribution silos. It completes a partial plant modernisation program that was originally completed in 2008, prior to the acquisition of the facility by CalPortland. The Oro Grande cement plant was purchased from Martin Marietta Materials in mid-2015.

“The addition of this modern finish mill and efficient distribution system allows the plant to operate to the best in class standards as originally designed. It will help provide the industry with the additional supply required for necessary rehabilitation and rapidly developing infrastructure in California and Nevada,” said Steve Regis, Senior Vice President Corporate Services, CalPortland.

The project began in January 2018 and was constructed by general contractor ThyssenKrupp and sub-contractor TIC (The Industrial Company), in collaboration with CalPortland’s Engineering Services team.

The mill is a Polysius two compartment mill with production capability of around 180t/hr. It is equipped with motor, mill and separator technology as well as cement cooler design technology. The system also employs mechanical conveyance (bucket elevator) to convey finished product to the new silos, reducing its energy requirements. These additional systems are being added to the Oro Grande plant.

France: HGH Infrared Systems is expanding its brand name across its subsidiaries around the world. It says it is developing its brand image and communication strategy to suit its position as a global leader in the optronics market as its sales grow. Asia Infrared Systems, HGH’s subsidiary in Singapore, and Electro Optical Industries (EOI), will take on the HGH identity.

In 2016 HGH acquired EOI, a producer of electro optical test equipment based in Santa Barbara, California in the US. HGH’s and EOI’s products include SPYNEL thermal cameras, blackbody sources, integrating spheres, electro-optical test benches, NVD testing solutions and thermographic scanners. They cover the whole spectrum of light from visible to infrared radiation.

‘’By opting for a harmonised universal brand, we are strengthening our corporate culture and our shared commitment across our subsidiaries. This common identity is built upon quality care, customer service and innovation values, and opens door to a dynamic and highly promising future,’ said Thierry Campos, the chief executive officer (CEO) of HGH Infrared Systems.

US: Apparent cement consumption grew by 3% year-on-year to 100Mt in 2018 from 97.4Mt in 2017, according to estimates from the United States Geological Survey (USGS). Production of Ordinary Portland Cement and masonry cement rose by 2% to 87.8Mt from 86.1Mt. Imports of cement increased by 14% to 14Mt from 12.3Mt. Texas, California, Missouri, Florida, and Alabama were, in descending order of production, the five leading cement-producing states and accounted for nearly 50% of US production.

The USGS said that construction spending increased ‘modestly’ during the year, largely owing to somewhat higher spending in the residential and public construction sectors. The non-residential private building sector declined slightly. The leading cement-consuming states continued to be Texas, California, and Florida. Production of cement remained below capacity, in part reflecting both the technical and environmental issues in returning long-idle kilns to full production at some plants, and the availability of imported cement in coastal markets.