Displaying items by tag: Plant

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.

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

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.”

Nigeria: Finland-based Wärtsilä has secured a contract to supply a 70MW dual-fuel power plant for the upcoming 3Mt/yr Line 4 of its Sokoto cement plant. The power plant is scheduled for commissioning alongside the line before 2023. BUA Cement previously ordered a dual fuel plant for the Sokoto cement plant’s Line 3, which is also scheduled for commissioning alongside that line, in November 2021.

Chair Abdul Samad Rabiu said “BUA Cement is happy and pleased with the progress that Wartsila made with the construction of the power plant we initially purchased for our BUA Cement Sokoto Line 3. We believe Wärtsilä will bring the same level of efficiency, technical expertise and professionalism to bear in ensuring that this new power plant for the 3Mt/yr BUA Cement Sokoto Line 4 will be completed on schedule by the end of 2022 as we look towards bringing BUA’s total capacity in its Sokoto plant to 8Mt/yr by early 2023 and across all its plants to 17Mt/yr by the same time.”

Libya: Ahmed Abuhisa, the Minister of Industry and Minerals, has met with a delegation of officials from Chinese companies working in the mining and cement industry. The Chinese delegates reportedly expressed their desire to build cement plants in several regions within the country, according to the Libya Herald newspaper. General investment work was also discussed. The minister has referred the companies to the National Mining Corporation to determine investment priorities and follow up on the meeting.

Pakistan: The government of Punjab has granted no-objection certificates (NOCs) for 22 new cement plants. Pakistan Press International News has reported that 10 plants are currently under construction in the state.

Companhia Siderúrgica Nacional (CSN) Cimentos was confirmed this week as the agreed buyer for Holcim’s Brazilian cement business for US$1.03bn. The deal includes five integrated cement plants, four grinding plants and 19 ready-mix concrete facilities. CSN is now poised to become Brazil’s third-largest cement producer by production capacity after Votorantim and InterCement. Or second place if you believe CSN’s cheeky claims about a competitor’s idle capacity!

Figure 1: Map of cement plants included in CSN Cimentos’ deal to buy LafargeHolcim Brazil assets. Source: CSN Investor Relations website.

CSN originally started out in steel production and this remains the major part of its operations to the present day. In 2020 it reported revenue of US$5.74bn. Around 55% of this came from its steel business, 42% from mining, 5% in logistics and only 3% came from its cement segment. CSN’s path in the cement sector started in 2009 when it started grinding blast furnace slag and clinker at its Presidente Vargas Plant at Volta Redonda in Rio de Janeiro state. It then started clinker production in 2011 at its integrated Arcos plant in Minas Gerais. Not a lot happened for the next decade, publicly at least, as the country faced an economic downturn and national cement sales sunk to a low in 2017. From around 2019, CSN Cimentos then started talking about a number of new proposed plant projects elsewhere in Brazil, dependent on market growth and an anticipated initial public offering (IPO). These included plants at Ceará, Sergipe, Pará and Paraná and expansion to the existing units in the south-east. Then CSN Cimentos agreed to buy Cimento Elizabeth for US$220m in July 2021.

It is worth noting that the Holcim acquisition is subject to approval by the local competition authority. For example, the Cimento Elizabeth plant and Holcim’s Caaporã plant are both in Paraíba state and within about 30km of each other. If approved, this would give CSN Cimentos two of the four integrated plants in the state, with the other two operated by Votorantim and InterCement respectively. CSN also stands to pick up four integrated plants in Minas Gerais from Holcim to add to the one it holds at present. Although this would seem to be of less concern due to the high number of plants in the state.

Holcim has made a point of saying that its divestment in Brazil is part of its strategy to refocus on sustainable building solutions with the proceeds going towards its Solutions & Products business following the Firestone acquisition that completed in early 2021. It has also stated previously that it wants to concentrate on core markets with long term prospects. In this context a major steelmaker like CSN diversifying into cement is a contrast. Both industries are high CO₂ emitters so CSN is hardly moving away from carbon-intensive sectors. Yet the two have operational, economic and sustainability synergies through the use of slag in cement production. This puts CSN Cimentos in company with Votorantim in Brazil and JSW Cement in India, two other steel manufacturers that also produce cement. Whatever else happens at the 26th United Nations Climate Change conference (COP26) in November 2021, it seems unlikely that global demand for steel or cement is likely to be significantly reduced. CSN Cimentos is now going to resume its IPO of shares to raise funds for the Holcim acquisition.

Acquisitions are all about timing. The CSN Cimentos-Holcim deal follows the purchase of CRH Brazil by Buzzi Unicem’s Companhia Nacional de Cimento (CNC) joint-venture earlier in 2021. As mentioned above, the cement market in Brazil has been doing well since it started recovering in 2018. The coronavirus pandemic barely slowed this down due to weak lockdown measures compared to other countries. The current run of sales growth may be tapering off based on the latest National Cement Industry Association (SNIC) figures for August 2021. Rolling annual totals on a monthly basis had been growing since mid-2019 but this started to slow in May 2021. Annual sales will be up in 2021 based on the figures so far this year but after that, who knows? A CSN investors’ day document in December 2020 predicted, as one would expect, steady cement consumption growth in Brazil until at least 2025, based on correlated forecast growth in the general economy. Yet fears of inflation, rising prices and political uncertainty ahead of the next general election in late 2022 may undermine this. InterCement, for example, cancelled a proposed IPO in July 2021 due to low valuations amid investor uncertainty. CSN Cimentos may encounter similar issues with its own planned IPO or face over-leveraging itself when it picks up the tab for LafargeHolcim Brazil. Either way, CSN decided to take the risk on its path to becoming Brazil’s third largest cement producer.

India: Shree Cement is planning to launch three projects with a total value of US$646m. The Press Trust of India newspaper has reported that US$476m-worth of the sum will go towards establishing a new 3.8Mt/yr integrated cement plant at Nawalgarh in Rajasthan’s Jhunjhunu district. The producer will invest a further US$102m in establishing a grinding plant in Purulia district, West Bengal, to take advantage of ‘favourable’ demand. Lastly, it will invest US$68m in installing solar power plants at ‘various’ cement plants across India.

Shree Cement said “The company has committed to maximising the use of clean energy in its operations. Setting up of the above solar power plants will enhance the proportion of clean energy usage in the total energy consumption of the company.”

Egypt: Suez Cement is planning to invest US$20m on an 18MW waste heat recovery unit at its integrated Helwan plant. The subsidiary of Germany-based HeidelbergCement started the project in mid-2021 and expects to complete it by the end of 2022. It is currently negotiating with suppliers and hopes to appoint one soon with construction scheduled for 2022.

US: LafargeHolcim US says that the integrated 2Mt/yr Midlothian plant in Texas will become the first cement plant in the country to fully convert to Portland Limestone Cement (PLC) production. The unit will switch to producing the company’s OneCem product, a blended cement manufactured with up to 15% of finely ground limestone. The move is intended to help LafargeHolcim US and its customers meet sustainable construction goals and lower carbon emissions.

“This is an important, but not unique, step for us. We were the first to produce OneCem, a PLC product, in one of the fastest-growing metro areas in the country, and fuel our industry’s step towards a zero carbon future,” said Patrick Cleary, senior vice president of sales, LafargeHolcim US Cement.

The company is promoting OneCem as an alternative to Ordinary Portland Cement in terms of concrete workability, set time, durability and strength development. It can be incorporated into a broad spectrum of applications that will support foundational structures. The product is available in the Western and Southern regions of the US and the company plans to ‘rapidly’ expand production.