Displaying items by tag: Plant

US: The Environmental Protection Agency (EPA) has awarded CalPortland’s Rillito cement plant in Arizona with its ninth consecutive Energy Star. Efforts towards energy intensity reduction at the plant included: replacing two preheater tower cyclones, installing 11km of new belting to a quarry belt conveyor, replacing the kiln baghouse fan and dust collector bags, increasing the plant’s focus on energy efficiency by expanding its energy team, conducting more frequent energy meetings and communicating energy efficiency best practices throughout the plant.

President and chief executive officer (CEO) Allen Hamblen said “CalPortland is pleased to accept the EPA’s Energy Star 2020 certification in recognition of our energy efficiency efforts at the Rillito plant. We continue to demonstrate our commitment to environmental stewardship and Energy Star while also reducing our energy costs through the hard work of our employees and our corporate energy management culture.”

Switzerland: Dürr is supplying a regenerative thermal oxidation system (RTO) to Jura Cement Fabriken integrated plant in Wildegg as the main stage in its air pollution control system. The upgrade is intended to enable the cement producer to comply with anticipated lower gas emission limits for carbon monoxide, hydrocarbons, and ammonia (NH₃). The supplier says its solution combines Dürr’s Ecopure RTO multiple-chamber principle with an optimisation of the existing process technology in the calciner. It is scheduled to start operation in 2022.

Jura Cement operates two integrated plants in Switzerland. It is part of the Switzerland-based Jura Materials Group, which has been part of the Ireland-based CRH since 2000.

Spain: Cementos Molins has dismantled kilns 3, 4 and 5 of the Sant Vicenç dels Horts cement plant in Catalonia. The company says that it will use 48,000t of waste material from the demolition process in cement production in kiln 6 at the plant. The material consists of 35,000t of concrete, 10,000t of scrap metal, 1450t of refractory material and 1500t of other waste.

The total investment cost of the dismantling work was Euro2m. The company said that the demolition of silos presented the most complex challenges of the 24-month process.

The plant mothballed lines 3, 4 and 5 upon the opening of line 6 in 2010.

Cuba: Corporacion Cementos Cubanos’ Siguaney plant produced over 90,000t in 2020. Centrovision News has reported that the plant produced 87,000t of grey cement and 3000t of white. It had planned to produce 10,000t of white cement, but still exceeded its cement target overall. Cost per tonne of cement was also lower than planned.

The company said that grinding operations were disrupted when the Cienfuegos cement plant delivered less clinker than expected. As a result, the Siguaney plant’s kiln produced 18,000t of additional clinker. It achieved this through the use of refractory bricks from another kiln. Disruptions to imports also caused the company to hire Cuban Lubicrants Company (Cubalub) to provide lubricants for the plant’s compressors.

The producer said that it foresees no increase in cement production in 2021. It will launch two new pozzolanic cements, PP-35 and PZ-25.

General manager Gonzalo Reina said "PP-35 and PZ-25 have similar benefits to other cements, but their constitution saves clinker, a raw material that generates the greatest cost and constitutes the greatest difficulty in maintaining stable production.”

UK: Cemex UK has announced plans for two new plastic packing production lines at Rugby cement plant. The company said that the lines will directly serve the plastic packing needs of packed cement production at the plant. The total investment cost of the installation will be Euro5.6m. Work will begin in early 2021 and be completed from June 2021. Cemex first entered the plastic packed cement market in 2011.

China: Huaxin Cement has ignited the kiln and started production at a new integrated 2.9Mt/yr cement plant near Huangshi City in Hubei Province. The company said that the plant will combine second-generation intelligent dry kilns, alternative fuel (AF) co-processing and a waste heat recovery (WHR) power plant, at a total investment cost of around US$465m. The group expressed its commitment to digital innovation and the promotion of Internet and industry. An artificial sand and gravel unit has also been started at the same site.

Cameroon: Aumund France has won a contract to supply three BWZ type bucket elevators with central chain, three BWG type belt bucket elevators and three Samson material feeders to Oyak Çimento’s upcoming plant near Kribi. When commissioned in September 2022, the plant will grind 100t/day of cement and 720t/day of calcined clay. ThyssenKrupp Industrial Solutions (France) is responsible for the overall design, supply and installation of equipment to the plant.

India: The government of India has granted licences to JSW Cement subsidiary Shiva Cement for the expansion of its cement plants in the state. The New Indian Express newspaper has reported that the company has received approval for an integrated capacity expansion of 1.1Mt/yr and a clinker capacity expansion of 1.3Mt/yr.

The state government approved a total of US$730m-worth of planned investments in various industries on 6 January 2020.

One of the last news stories we covered before the Christmas break was that Lafarge Poland had selected China-based Nanjing Kisen International Engineering as the general contractor for a Euro100m-plus upgrade to its Małogoszcz cement plant. This appears to be the first major European cement plant upgrade project to be publicly run by a Chinese contractor. There may be other European projects in the sector run by Chinese companies ‘on the down-low.’

If it is the first then this is a significant milestone for the growth of the Chinese industry. It is a noteworthy first for Nanjing Kisen in the European Union. Europe is the home, after all, of a number of locally-based contractors and companies that can build or upgrade cement plants including FLSmidth, Fives, ThyssenKrupp, IKN and others. Indeed, all of the work on this project might actually be conducted by local companies, selected by the general contractor. For example, Lafarge Poland says that the general contractor will select a subcontractor on the Polish market.

It’s easy to fall into jingoistic nostalgia but should we really be surprised that China can competitively build cement plants given the ferocious growth of its own industry over the last few decades? Arguments by Western critics against growing Chinese dominance in industry have tended to home in on excuses why they might be ‘cheating’ such as intellectual property theft, unfair state aid or the use of low-cost infrastructure loans to countries along its Belt and Road Initiative. That last one carries some irony given that not so long ago discussions about developing world debt were framed in the context of the Cold War and the oil crisis in the 1970s. Western countries were seen as the bogeymen depending on one’s political outlook. With this in mind, the Financial Times recently reported on data released in December 2020 that suggested that China might be heading into its own overseas debt crisis. The takeaway message here is that attempting to apply China’s whopping infrastructure boom elsewhere might not work so well without the same level of control. Exporting production overcapacity abroad may simply turn out to be something like a giant Ponzi scheme! For the cement industry this may mean a pause or wind-down in the number of new plants backed by Chinese money, often with Chinese contractors tied in, and that the rise of Chinese engineering firms might not seem as unassailable as all that after all.

This leads into another noteworthy story that we also published before Christmas on China’s latest proposal to further reduce production capacity at home. The Ministry of Industry and Information Technology (MIIT) wants to tighten the ratio of production capacity that has to be closed before new capacity can be built from 1.25:1 to 1.5:1. The kicker is that the new rules also include a clause intended to restrict the use of so-called ‘zombie’ capacity in the swapping process by limiting eligibility to productions lines that have been operated for two or more consecutive years since 2013. These rules seem targeted at the present day but they could potentially push Chinese cement production capacity per capita to rates more similar to those found in developed economies elsewhere (i.e. halve existing Chinese production capacity). Many of the country’s kilns were built in the early 2000s and the average lifespan of a clinker kiln is 50 years. This suggests that the ministry is thinking seriously about culling capacity by the administration’s carbon neutrality target of 2060.

Chinese penetration in the European cement plant market is more of an after-thought given the pace of projects in Asia and Africa over the last decade and the maturity of the sector. It can also be misleading given that some very-European-sounding engineering companies are actually owned by Chinese concerns. Yet no doubt local contractors and suppliers would like to keep any business they can. On the other hand, more market share may be found in Europe over the coming decades from retrofitting CO₂ mitigating equipment or building the anticipated hydrogen revolution once the regulatory and financial framework starts to favour it. Or maybe shifts to service and/or machine intelligence-style packages are the way forward. Nanjing Kisen may be the first Chinese company to upgrade a European cement plant but the market focus may quickly move on. Time will tell.

Answers by email for when readers think the first cement plant or production line in the US will be built by a Chinese company.

Happy New Year from Global Cement

Morocco: Bab Sahara Company is building a new cement plant in Guelmim, Guelmim-Oued Noun. Le Desk has reported that the company is a joint venture between three private investors, including Tarfaya City Council Chair Abdelhay Hartoun. An environmental impact study for the project was started in late December 2020 by the Ministry of the Interior.