Displaying items by tag: Plant

Nepal: Flooding has damaged the Huaxin Narayani Cement plant being built at Benighat Rorang Rural Municipality in Dhading. Rising water from the Malekhu River caused around US$90,000 damage to the construction site, according to the Himalayan Times newspaper. The deluge wrecked a storeroom and swept away five vehicles. Work on the US$137m project started earlier in 2019.

Ireland: Local environmental activists have accused the Irish Environmental Protection Agency (EPA) of ignoring European Union (EU) NO_x emission limits by granting an exemption to Irish Cement’s Limerick integrated plant. Limerick Against Pollution group alleges that the plant has been allowed a limit of 800mg/m3 despite a EU directive reducing the limit to 500mg/m³, according to the Limerick Post newspaper.

Philippines: Holcim Philippines has completed the upgrade to its integrated cement plant at Davao. The expansion involved the activation of a finish mill and installation of a new pipe for loading cement to the silos from the pier, eco-hoppers to improve dust emissions and an overhead crane. Cold commissioning started in April 2019 while full production began in late June 2019. The improvements add 0.7Mt/yr to the cement production of the plant.

The expansion of the Davao plant is part of the company’s on-going program to improve operations to better support the positive growth of Mindanao. In March 2019, the company launched in a new blended cement product, Solido. It also opened its first construction laboratory outside Metro Manila at Davao in 2018. Holcim Philippines will hold a ceremony in August 2019 to inaugurate the facilities with partners from the public and private sector.

Azerbaijan: Turkey’s Dal Teknik Makina is set to start work on an upgrade project at Akkord Cement’s integrated plant at Gazakh. It will increase the clinker production capacity to 3300t/day from 2500t/day. The supply of equipment is expected to be completed in six months and the shutdown period is planning to be five weeks. No value for the order has been disclosed.

The first phase of the upgrade project will be the retrofit of the raw mill unit. A static drying separator will be placed in front of the raw mill to dry clay and some of limestone. Equipment to be replaced in the raw mill unit include a dynamic separator, ball charge modification, all parts of separator cyclones and the raw mill fan. The raw mill grinding capacity will be upgraded by drying the raw materials and enhancing the separation efficiency.

The next phase will consist of replacing the raw mill/kiln bag filter and filter fan to reach the desired upgraded capacity. Finally, the pyro-processing system unit will be modified. In order to reach the target production capacity the equipment to be changed will be the first four stage cyclones with the modification of the calciner-TAD connection and new splash boxes will be installed.

Togo: Eric Goulignac, a regional director of HeidelbergCement based in West Africa, says that the company believes in the local market despite competition. He expressed confidence due to the quality of its products, according to Télégramme228. The building materials producer is currently finalising a call for tenders for a Euro25m upgrade to its operations, including a new mill, at Cimtogo’s cement grinding plant in Lomé and a photovoltaic (PV) solar energy plant.

The big announcement from LafargeHolcim this week was the launch of its Industry 4.0 plan known as ‘Plants of Tomorrow.’ The scheme hopes to use automation technologies and robotics, artificial intelligence, predictive maintenance and digital twin technologies across the company’s entire production process. Operational efficiency gains of 15 - 20% are promised.

There wasn’t much detail beyond the use of the Siggenthal integrated cement plant in Switzerland as the ‘lighthouse’ of the scheme, where around 30 proof-of-concept technology ideas will be tested. One technology it did flesh out a little was its long-running Technical Information System (TIS). This follows the work between Holcim and the power and automation product supplier ABB. LafargeHolcim says that over 80% of its plants around the world use the TIS to provide data transparency at plant, country, regional and global level. It added that some country operations have more than a decade of historic technical data available. This last point is pertinent as the data could potentially be used to support the training of any machine learning algorithms the company might want to invest in. The building materials company also mentioned its LH Maqer subsidiary. This startup incubator was launched at the end of 2018.

LafargeHolcim appears to be playing catch up here with Cemex, which has steadily been promoting its own Industry 4.0 developments in recent years. Emphasis on ‘promotion’ here as only yesterday, the day LafargeHolcim made its big reveal, Cemex happened to release information about a recent roundtable in France that it participated in on digitisation and productivity in the construction sector.

Notably in March 2019, the Mexican multinational struck a deal with Petuum to implement its Industrial AI Autopilot software products for autonomous cement plant operations at its plants around the world in March 2019. Readers can find out more about Petuum’s work with Cemex in the June 2019 issue of Global Cement Magazine. In late 2017 Cemex too set up a division, Cemex Ventures, to engage with startups, universities and other organisations. Cemex has also been building its digital customer integration platform Cemex Go since around the same time.

One interpretation of Industry 4.0 is as a German-industrial approach to the so-called fourth or digital revolution pushed by Anglophone software companies. The idea of taking as much data from a production process, such as making cement, is enticing but the prospect of actually doing something useful with this tsunami of information is daunting. Typically algorithm techniques or predictive maintenance seem so far to focus on discrete parts of a process such as a finish grinding mill or final product logistics networks. Companies like Germany’s Inform focus on the latter for example and, incidentally, it celebrated its 50th anniversary this week.

If automated systems start making apparently nonsensical yet useful decisions across the whole raw materials, production and supply chains, then Industry 4.0 will reach its full potential. This moment, if it comes, will be analogous to the time IBM’s computer Deep Blue managed to beat chess grandmaster Garry Kasparov in the late 1990s. What’s more likely are automated systems that can perform consistently outside the human operator comfort zone edging up against hard physical process constraints.

Meanwhile, what will be interesting to watch here is whether LafargeHolcim will be able to leverage any advantage over Cemex by having more cement plants to pull data from. Before LafargeHolcim started selling off its south-east Asian subsidiaries it had more than three times as many cement plants as Cemex. If data really is more valuable than oil these days then starting late in the industrial digital arms race may not be as deleterious as one might first think.

India: The National Company Law Tribunal (NCLT) in Mumbai has approved Dalmia Bharat’s offer for debt-laden Murli Industries, subject to conditions intended to stop the company going into liquidation. The tribunal has given Dalmia Bharat until 12 July 2019 to decide if it wants to proceed, according to the Economic Times newspaper. The conditions include forcing the buyer to reinstate lapsed mining leases related to Murli Industries itself and removing clauses allowing Dalmia Bharat to modify or withdraw its plans at any stage. Dalmia Bharat bid around US$60m to buy Murli Industries’ 3Mt/yr cement plant in Maharashtra in late 2017.

Switzerland: LafargeHolcim has launched a four-year industrial automation plan called ‘Plants of Tomorrow.’ It includes Industry 4.0 concepts such as automation technologies and robotics, artificial intelligence, predictive maintenance and digital twin technologies for its entire production process. The plan is expected to show 15 – 20% operational efficiency gains. It also claims that the initiative is, “one of the largest roll-outs of Industry 4.0 technologies in the building materials industry.”

“Transforming the way we produce cement is one of the focus areas of our digitalisation strategy and the ‘Plants of Tomorrow’ initiative will turn Industry 4.0 into reality at our plants. These innovative solutions make cement production safer, more efficient and environmentally fit,” said Solomon Baumgartner Aviles, Global Head Cement Manufacturing.

The building materials company is presently working on more than 30 pilot projects covering all regions where the company is active. The company’s integrated cement plant at Siggenthal in Switzerland will be a trial site where the integration of all relevant modules will be tested.

One examples of where LafargeHolcim has started the plan include a partnership with Swiss start-up Flyability to use drones to increase the frequency of inspections at plants while simultaneously reducing cost and increasing safety for employees by inspecting confined spaces. The concept is being rolled out to several markets, including Switzerland, France, Germany, the UK, the US, Canada, India and Russia. It is also using a subsidiary, Maqer, to identify technology startups with promising technology. It aims to harness the potential of this through new partnership models with both manufacturing and software companies.

LafargeHolcim has already launched technology to track performance centrally and allocated resources to support the plant network in real time. More than 80% of LafargeHolcim’s cement plants are already connected to its Technical Information System that provides data transparency at plant, country, regional and global level. Some country operations have more than a decade of historic technical data available. Other systems allow the remote control of certain parts of the operations through online condition monitoring systems. Since its implementation in 2006, this system has saved over Euro70m and an additional 3Mt of cement sold through fewer breakdowns.

US: Lehigh Cement has received permission from the Indiana Department of Environmental Management for a US$600m upgrade to its integrated Mitchell plant. IDEM's Office of Air Quality granted a modification to the unit’s air permit in late June 2019 following a period of public comment, according to the Times-Mail newspaper. The subsidiary of Germany’s HeidelbergCement plans to increases the production capacity at the plant to 2.8Mt/yr from 0.8Mt/yr. Construction is scheduled to begin in 2020 and completion of the new plant is anticipated by the end of 2022. Once finished the upgrades will create 52 new jobs at the unit.

Egypt: El Nahda Cement has suspended production at its 1.7Mt/yr plant at Quena for six months. It has taken the decision due to lower sales and increased supply in the local market, according to Mist News. The local industry has reported production overcapacity in recent years. In mid-2018 the 13Mt/yr government/army-run El-Arish Cement plant at Beni Suef was fully opened