Displaying items by tag: Ecocem

Ireland: Ecocem Ireland has appointed Micheál McKittrick as its Managing Director for Ireland and the UK. His role involves the management of all aspects of the Irish and UK operations. McKittrick is a Chartered Engineer and graduate of Trinity College Dublin. He previously worked in several senior roles with Atkins Consulting Engineers.

US: Orcem Americas, a subsidiary of Ireland’s Ecocem, has been refused planning permission to build a slag cement plant in Vallejo, California. The cement producer was hoping to build a US$50m grinding plant but it faced opposition from local residents on environmental grounds, according to the Irish Times. The issues for the planners was an anticipated increase in the number of trucks on local roads and pollution from the plant. Orcem Americas can now appeal the decision to Vallejo’s City Council if it chooses.

France: Ecocem France has ordered a Loesche type LM 46.2+2 CS mill for a slag cement grinding plant that it is building in Dunkirk. It follows a previous order by Ecocem of a LM 46.2+2 CS mill for the dry grinding of ground granulated blast furnace slag (GGBFS) at its plant at Fos-sur-Mer.

The LM 46.2+2 CS for the plant in Dunkirk is designed for the grinding of cement clinker and granulated blast furnace slag at a capacity of 105t/hr GGBFS. The gearbox will have a capacity of 3150kW.

All the mechanical equipment for the grinding plant starting from mill feed to the product discharge into the product silos is included in the Loesche scope of supply. The Loma heater type LF 28-L will be a full-inlined type designed to burn natural gas as well as blast furnace gas. The burner supplied by Loesche will be the MSBZ type, complete with fitting rack and local switch cabinet.

The lead-time for the main components of the mill and for the additional units included in the scope of supply is 6 to 13 months. The commissioning of the vertical roller mill is planned for the middle of 2017.

Ecocem’s grinding plant will be installed close to Arcelor steelworks for use of their granulated blast furnace slag. This LM 46.2+2 CS will be the seventh Loesche vertical roller mill installation for slag and cement grinding in France.

Once again Ecocem has shone the torch this week for a rare thing within Europe these days: a growing cement company. Its latest project is an import terminal in Sweden, as part of a deal with Bolidan, which launched on 22 September 2016. This supports an arrangement to supply cement for the Boliden Garpenberg mine. The agreement also includes supply for the Boliden Tara Mines in Ireland.

This follows the announcement to build a new slag grinding plant in Dunkirk, France in early September 2016 and the opening of a new terminal in Runcorn, UK earlier in the year. The 1.4Mt/yr Dunkirk plant is a joint-venture with the steelmaker ArcelorMittal, intended to target markets in north of France and in the UK. Once complete it will join Ecocem’s growing collection of grinding units in Ireland, France and the Netherlands. The slag-cement producer operates a 0.35Mt/yr plant at Dublin, a 0.7Mt/yr plant at Fos in the south of France and a 0.35Mt/yr plant at Moerdijk under its subsidiary Orcem Netherlands.

The focus on the UK makes sense given that Ecocem said that it had made commitments to sell more product in the UK in its first year than its total domestic sales in 2016. This followed the situation where, prior to entering the British market, Ecocem had to stop taking orders in the short term due to demand. If this is actually the case then it is unsurprising to note that Ecocem is also building a second UK terminal at Sheerness at the mouth of the River Thames near to London. As an aside, Francis Flower bought the Scunthorpe ground granulated blast furnace slag (GGBS) plant from Hanson Cement in mid-2015 after the local market regulator requested the sale.

As Charlie Zeynel, ZAG International, says in an interview to be published in the October 2016 issues of Global Cement Magazine, that supplementary cementitous materials, including slags, in cement blends has grown worldwide, particularly in Europe and Japan, where GGBS cement represents around 25% and 30% of cement sales respectively. Zeynel goes on to say that GGBS usage is set to rise in other parts of the world, particularly the US, but this helps to explain the market Ecocem is operating in within northern Europe.

Ecocem seems well aware of the potential for slag cements in the US because it is attempting to build a Euro45m grinding plant Vallejo, California under its Orcem Americas subsidiary. The process has so far been dogged by planning problems at the proposed site as well as organised local opposition, which does not want a new industrial plant in the neighbourhood and issues such as the increased traffic it would bring. The irony here is that Ecocem bills itself as an environmentally friendly cement producer. Yet even environmentally-friendly cement needs to be manufactured and taken to site.

To misquote Kermit the Frog: it’s not easy selling green cement. However, Ecocem’s progress in Europe is encouraging both in the UK and the wider area. Roll on the opening of the Sheerness terminal.

Find out more about Ecocem's operations here: www.ecocem.fr/en/

Ireland/Sweden: Ecocem has arranged a deal with Boliden to supply mines in Ireland and Sweden. The two mines concerned by this deal are Boliden Tara Mines in Ireland and Boliden Garpenberg in Sweden. The agreements are initially for three years with options for extensions.

Ecocem have entered into an agreement with the Port of Gavle, the nearest Port to the Boliden Garpenberg mine. The Port of Gavle has built an import terminal to unload ships, and transfer the Ecocem product to trucks destined for the mine. The new facility will accommodate approximately 8000t. Ecocem’s cement will be pumped into the mine to backfill voids created by excavation.

“Ecocem Ireland are very proud to be associated with one of Europe’s oldest and biggest mining companies. Boliden’s environmental performance and ambitions are very much in line with our own and we feel that these contracts represent a strong vote of confidence on the consistency of performance and service that Ecocem deliver,” said Conor O’Riain, the managing director of Ecocem Ireland.

France/Ireland: According to the Irish Independent newspaper, Irish cement company Ecocem has invested Euro30m into a new production facility in Dunkirk in the north of France as part of joint venture with the world's largest steel company. The investment is split 30% to 70% in favour of Ecocem and will increase the Irish firm's capacity from 1.4Mt of high performance, low carbon cement to around 2Mt. Ecocem said the main target markets for the plant will be the north of France and the UK.

ArcelorMittal, the company that is investing with Ecocem, is the world's largest steel firm. The investment is a strategic partnership as Ecocem uses a by-product of the manufacture of iron and steel - Granulated blast furnace slag - to make cement.

The news follows recent builds by the company with the Peel Ports Group. The pair built an import terminal in Runcorn on the Manchester Ship Canal and will look to add to it with another two, one in Runcorn and another in Sheerness in England.
Ecocem's continued expansion in the UK is a response to growing demand from the market. The firm has experienced an increase in exports from the UK as a result of a bustling cement market and a shortage of the type of cement Ecocem produces.

Speaking at the time of its UK investment, Ecocem managing director Conor O'Riain said the firm is looking long-term at the market. "We've invested in state-of- the-art equipment to demonstrate to the market that we're here for the long term, and I'm delighted to say that the response from the market has been phenomenal. We've made commitments to sell more in the UK in our first year than our total domestic sales in 2016," he said. Prior to entering the British market Ecocem had already received orders for 200,000t of product for its first year and stopped taking any further offers in the short term.

Ecocem is also trying to make its first move into the US. The company is looking to build a Euro45m grinding mill near San Francisco but has some hurdles to its intentions from its planning applications.

The firm has continued to grow its reputation as a low-carbon cement producer and last month the firm picked up the Green Product Award 2016 for its superfine product.

UK/Ireland: Ecocem is to open a new terminal at Runcorn to increase its exports of slag cement to the UK. A second terminal in the south east of the UK will be opened later in 2016, according to the Irish Times. It has invested Euro5m towards building both terminals. The ground granulated blastfurnace slag (GGBS) producer is targeting the UK market due to demand for cement coupled with changes in the coal and steel industries.

The company says it has received orders for 200,000t of slag cement in its first year and that it is not taking any further orders. Opening its second terminal in the UK is anticipated to give it access to 80% of the UK market. Ecocem produces slag cement at three grinding plants in Dublin in Ireland, Moerdijk in the Netherlands and at Fos in France.

US: Irish cement maker Ecocem's US subsidiary, Orcem Americas, has been accused of attempting to influence the planning process in Vallejo, California, where it wants to build a US$50m grinding mill. The mill would be the group's first venture in the US. However, the town's residents are objecting to the proposal on environmental grounds.

The company recently found itself at the centre of a row over its involvement with an unofficial economic committee of Vallejo's city council that some local politicians and campaigners say could potentially breach California law.

Orcem is represented on the Mare Island Straits Economic Development Committee, which is made up of local council members, state officials and private sector interests. Its involvement in the committee, alongside the city's Deputy Mayor, Jess Malgapo, at a time when it was seeking permission to build its facility at a sensitive site in Vallejo, sparked anger among the project's opponents. Some of them have claimed that its activities have potentially breached the Brown Act, a California law that guarantees the public's right to attend and take part in meetings of local councils and legislative bodies. However, the councillors involved, including Malgapo, deny the act was breached, saying that the committee was established to aid the city's economic development and not to pass legislation.

US: Irish cement maker Ecocem's proposed manufacturing plant in San Francisco Bay faces a potential planning setback after receiving almost 500 submissions challenging its environmental impact report.

Ecocem is seeking permission for a US$50m grinding plant in Vallejo, close to San Francisco, in the group's first venture in the US, but the town's residents are objecting to the proposal on environmental grounds. According to local reports, some 400 - 500 people and organisations have questioned the company's assessment of the plant's likely impact on the environment, which could force Vallejo's council to delay a decision on planning permission until 2016. The council was hoping to have cleared all planning hurdles by December 2015, but local sources have said that the volume of questions posed during a 60-day public consultation period means the deadline could be pushed back to March 2016.

California law requires Ecocem's subsidiary, Orcem Americas, which is directly responsible for the project, to answer the questions before preparing a final environmental impact report. The city's Architectural Heritage and Landmarks Commission will have to decide whether the buildings that would be knocked to make way for the plant are historic, which is likely to happen in December 2015. The proposal will then have to pass both the Vallejo Planning Commission and then get the support of a majority of councillors before it can get the go ahead.

According to local activist Peter Brooks, a group of citizens recently began a petition to remove four council members said to favour Ecocem's project. He also said that influential US environmental group, the Sierra Club, wrote to the city's authorities expressing concerns about the plans.

Ecocem wants to build the plant on the site of an old flour mill in the city's harbour. It would grind furnace slag from iron smelting that is then used as a component in cement. The process cuts greenhouse gas emissions from normal cement manufacture by 90%.

Encouraging news from Egypt with the announcement that Lafarge Ecocem has taken on two refuse-derived fuels (RDF) contracts in Suez and Qalyubeya. The RDF plants will have production capacities of 42,000t/yr and 280,000t/yr respectively, after upgrades are built.

The move follows a deal Lafarge struck with Orascom in March 2015 to develop a waste management framework of municipal and agricultural waste. The plan is to achieve an average fuel substitution rate of 25% by the end of 2015. Around the same time Ecocem also signed a cooperation agreement with the German Development Cooperation (GIZ) and the Qalyubeya Governorate to upgrade a recycling plant in Qalyubeya to produce RDF. Part of the deal was intended to reinvest some of the revenue from RDF sales back into the region's waste collection infrastructure.

These production levels compare to SITA UK's new RDF plants in the UK, which has a more mature RDF market. There, the newly opened Malpass Farm plant is planned to produce 200,000t/yr and the Tilbury plant will have an output capacity of 500,000t/yr when it opens. However, the Malpass Farm plant mainly feeds one cement plant, the 1.3Mt/yr Cemex Rugby plant with a mean substitution rate of 61% in 2013. By contrast, Lafarge Cement Egypt runs the massive 10.6Mt/yr El Sokhna plant.

Co-processing at El Sokhna by Lafarge is of particular interest given the links with Egypt's unofficial household waste collectors, the Zabbaleen. Lafarge Egypt recruited and trained 140 Zabbaleen to gather waste material for RDF production. The strategy enabled Lafarge to gather continuous supplies of RDF and strengthen local stakeholder relations, as Lafarge's 2013 sustainability report puts it. Lafarge Egypt's substitution rate was 2.2% in 2012 with significant improvements made since then. The current target of 25% for the end of 2015 shows how much progress Lafarge has made.

Hisham Sherif of the Egyptian Company for Solid Waste Recycling (Ecaru) placed Egypt's municipal solid waste level at 20Mt/yr at a presentation given at the Global CemFuels Conference earlier in 2015. From this 4Mt/yr of RDF could be produced. Together with biomass derived fuel (BDF) Sherif reckoned that the country's cement plants could reach substitution rates of 30 – 40%. Problems though with increasing RDF rates in Egypt include legal complexities, institutional issues, poor services and monitoring and centralised planning with little regard for the country's unofficial waste pickers, such as the Zabaleen.

Lafarge Ecocem appears to be tackling each of these problems in turn as the deals with Orascom and the Qalyubeya Governorate show. However, spare a thought for Egypt's unofficial waste sector workers who are likely to lose their livelihoods as waste management becomes more formalised and personnel rates per tonne of waste collected tumble.

For more information on the Zabaleen, check out the documentary made about them in 2009, called 'Garbage Dreams'.