Displaying items by tag: Dome

US: Holcim has completed a major expansion of its cement holding facility in North Fremont, allowing the plant to meet ‘growing’ market demands in the Omaha region. The US$20m project includes additional rail capacity, a new 50,000t cement dome, an extra silo and a blender for product mixing.

According to the company, the facility now employs seven staff members, up from three, and fulfils the Nebraska Department of Transportation's blended cement requirements using natural pozzolan to create a lower-carbon product.

Holcim's head of US Corporate Communications, Lynn Safranek, said "The availability of extra cement storage and the addition of rail capacity means fewer trips to transport cement from Holcim’s plant in Ste. Genevieve, Missouri, and more reliance on train transportation, which is more efficient than other land-based alternatives.”

US: Holcim US has announced plans for a 25MW solar power plant to serve 75% of the electricity needs of its Alpena cement plant in Michigan. The company says that the installation at the Alpena plant will be the largest in the US Midwest Region. Holcim US chose NorthStar Clean Energy to build the array, which it says will eliminate 25,000t/yr of CO₂ emissions.

Other planned projects at the Alpena cement plant include an upgrade to the plant's dock in order to accommodate larger vessels and reduce the number of trips in its Great Lakes transport operations.

Holcim US' senior vice president, manufacturing, Michael Nixon said “As Holcim is showing in Alpena, the path to net-zero carbon emissions requires a blend of proactive solutions. Whether it’s using alternative fuels or implementing renewable energy from solar power, we are committed to reducing our reliance on fossil fuels — a goal that will benefit the environment as a whole and the Alpena community we have called home for more than 115 years.”

US: Continental Cement will hold a ribbon-cutting ceremony for the new 114,000t-capacity cement storage dome at its Davenport cement plant in Iowa on 20 March 2023. The dome will replace existing winter storage facilities at the plant, resulting in a safer and more efficient operation, according to the subsidiary of Summit Materials.

The company’s president, David Loomes, said "The investment by Summit Materials of US$30m in the largest cement storage dome in North America represents a strong vote of confidence in Continental Cement and a commitment to sustained operations and investment in the State of Iowa."

Continental Cement plans to invest an additional US$32m in an expansion to its Green America Recycling programme, whereby it expects to achieve an alternative fuel (AF) substitution rate of 55%.

US: Titan America has successfully converted its cement operations to 100% Portland limestone cement (PLC) production. As part of its transition, the producer established two new 70,000t storage domes to serve its key markets.

President and CEO Bill Zarkalis said "I would like to thank all members of the Titan America team who are able and energised to provide the highest performing products to our customers, and do so with our 2030 goals for a sustainable future at top of mind. Our conversion to 100% Type IL PLC production and our expanded investments to deliver lower carbon products and solutions to customers showcase the progress we have made and our commitment to accelerate our contribution to addressing climate change."

Australia: Fremantle Ports has broken ground on its construction of a new US$35.1m cement terminal at Kwinana Bulk Terminal in Western Australia. Business News Western Australia has reported that contractor COVA-Haywards will build a 40,000t-capacity clinker storage dome at the site. The terminal will supply BGC and Cockburn Cement's local grinding operations. Commissioning is scheduled for 2024.

State development minister Roger Cook said"It will significantly improve our capability to move clinker faster, more safely and with very significant environmental benefits, and provide the capacity for the port facility to accommodate future trade growth. It's a great example of planning assets to integrate the state-owned port with adjacent private facilities, with benefits for all."

Congratulations are due to the National Cement Company of Alabama and Vicat for the inauguration of the new production line at the Ragland cement plant in Alabama. The event took place on 21 July 2022.

The US$300m project was originally announced in late 2019. It then took two years to build with construction starting in January 2020. Key features include a raw vertical grinding mill, a new roller mill, a five stage preheater tower, an automatic clay storage system, a 78m tall homogenisation silo, an alternative fuels storage area for tyre-derived fuel, sawdust and wood chips, a laboratory and a new control room. The new kiln was previously reported to have a clinker production capacity of 5000t/day and it will add up to 2Mt/yr of cement production capacity to the plant. ThyssenKrupp signed up as the principal equipment supplier in 2019 and H&M was the main contractor. The production line is expected to reduce energy consumption by one third. Further change is scheduled with a switch to production of Portland limestone cement (PLC) from Ordinary Portland cement (OPC) by the start of 2023.

Vicat has repeatedly noted its affection for the plant as it was the first cement plant the group purchased outside of France, back in 1974. Indeed, Vicat’s group chair and chief executive officer Guy Sidos personally managed the Ragland plant in 2001. However, rather more prosaic reasons may also have been behind the decision to expand Ragland. According to United States Geological Survey (USGS) data, Alabama, Kentucky and Tennessee’s cement shipments grew by nearly 5% year-on-year to 7.1Mt in 2019 from 6.8Mt in 2018. Shipments are up by 3% year-on-year to 2.5Mt in the first four months of 2022 and the three states were the fifth largest region in the US for cement shipments in April 2022. A shortage of cement was also reported in Alabama in April 2022.

The other big US-based cement plant expansion is Lehigh Hanson’s US$600m upgrade to its Mitchell plant in Indiana. It also celebrated a milestone this week with a ‘topping out’ ceremony to mark the placement of the final section of steel for the stack. Another recent achievement here was the completion of a 169,000t storage dome supplied by Dome Technologies. The supplier says that the 67m diameter and 48m tall dome is the second largest clinker storage facility in Europe and North America, after one it previous built in Romania in 2008.

The Mitchell K4 project was announced in mid-2018 and then ground breaking began in late 2019. However, the start of the coronavirus pandemic delayed construction in early 2020 before it restarted in September 2020. The revised commissioning date was then moved back about half a year to early 2023. The key part of this project is that it will replace the plant’s three current kilns with just one. The new production line will increase the site’s production capacity, reduce energy usage and decrease CO₂ emissions per tonne of cement. It was reported by local press back in 2018 that the project would increase the plant’s cement production capacity to 2.8Mt/yr. The project has been linked to supplier KHD with CCC Group as the contractor.

It’s fascinating to see two major new upgrades to cement plants emerging in a mature market like the US and during an unprecedented event like the emergence of coronavirus. No doubt compelling tales will emerge of how both teams coped with managing nine-figure capital expansion projects as a global public health emergency unfolded. The US market has been on a roll in recent years, despite all the uncertainty in the world, and so far it doesn’t seem to be slowing down. With luck both of the projects feature above have timed their opening right.

New Zealand: Two cement ship unloaders, a ship unloader and two conveyor belt systems purchased by Holcim are being shipped to New Zealand from the Netherlands on a heavy lift ship called the Happy Dragon.

One of the cement ship unloaders along with a ship unloader, which have a combined weight of 240t, will arrive in Timaru in early November 2015 and will be used by Holcim at its new dome at the Timaru Port. The other unloader and conveyor belts are bound for Holcim's Auckland dome.

Holcim's Capital Projects Manager Ken Cowie said that Holcim was excited to have the cargo in transit in the North Atlantic. "This signals the arrival on site of all the major equipment for the terminal and brings us closer to commissioning the operations later this year."

The cement ship unloaders were built by Van Aalst Bulk Handling in Hazerswoude. The largest of them is 33m long, 15.5m wide and 18m high. A logistics company brought the unloaders 20km east of Rotterdam, where they were placed on a pontoon by a floating crane and floated down to be loaded onto a ship.