Displaying items by tag: Plant

Russia: Eurocement has received nine new Volvo FM 8x4 heavy-duty dump trucks for its Kavkazcement and Maltsovsky Portland Cement plants. The vehicles have a capacity of 32t and include Volvo’s CareTrack telematics system. The cement producer hopes to increase the volumes of limestone it transports from each plant’s quarries by 15%. It has spent Euro1.3m on the new trucks.

Kyrgyzstan: Kant Cement has upgraded its packing equipment at its integrated plant. Russia’s Vselug supplied a Turbo K8 filling machine and Germany’s Berg provided compressors, according to Cement and its Applications magazine. The company plans to sell at 60% of its products in 25kg and 50kg following the upgrade.

The plant has also been installing general upgrades at the site, including a new combination burner from Austria’s Unitherm Cemcon in 2018. It is also planning to upgrade an electrical distribution substation by the end of 2019 to reduce interuptions to production.

Germany/US: HeidelbergCement has purchased Giant Resource Recovery’s 1.2Mt/yr integrated Keystone cement plant in Bath, Pennsylvania for US$151m. HeidelbergCement CEO Bernd Scheifele has called the cement plant, which has 90 years’ experience as a supplier to the Pennsylvania, New York and New Jersey markets, ‘an excellent strategic addition’ to the company’s North American market presence.

Dalmia Cement threw down the gauntlet this week with the announcement of a large-scale carbon capture unit (CCU) at one of its plants in Tamil Nadu, India. An agreement has been signed with UK-based Carbon Clean Solutions Limited (CCSL) to use its technology in building a 0.5Mt/yr CCU. The partnership will explore how CO₂ from the plant can be used, including direct sales to other industries and using the CO₂ as a precursor in manufacturing chemicals. No exact completion date or budget has been disclosed.

The move is a serious declaration of intent from the Indian cement producer towards its aim of becoming carbon neutral by 2040. Dalmia has been pushing its sustainability ‘journey’ for several years now hitting targets such as reaching 6Mt of alternative raw materials usage in its 2018 financial year and reaching a clinker factor of 63% at the same time. In an article in the November 2018 issue of Global Cement Magazine it said it had achieved CO₂ emissions of 526kg/t from its cement production compared to 578kg/t from other Indian members of the Cement Sustainability Initiative (CSI). In its eastern operations it had gone further to reach 400kg/t.

Using CCU is the next step to this progression but Dalmia’s approach is not without its caveats. Firstly, despite the size of the proposed project it is still being described as a ‘large-scale demonstration.’ Secondly, the destination of all that captured CO₂, as mentioned above, is still being considered. CCSL uses a post-combustion capture method that captures flue gas CO₂ and then combines the use of a proprietary solvent with a heat integration step. Where the capture CO₂ goes is vital because if it can’t be sold or utilised in some other way then it needs to be stored, putting up the price. Technology provider CCSL reckons that its CDRMax process has a CO₂ capture price tag of US$40/t but it is unclear whether this includes utilisation sales of CO₂ or not.

The process is along similar lines to the Skyonic SkyMine (see Global Cement Magazine, May 2015) CCU that was completed in 2015 at the Capitol Cement plant in San Antonio, Texas in the US. However, that post-combustion capture project was aiming for 75,000t/yr of CO₂. Dalmia and CCSL’s attempt is six times greater.

Meanwhile, Cembureau, the European cement association, joined a group of industrial organisations in lobbying the European Union (EU) on the Horizon Europe programme. It wants the budget to be raised to at least Euro120m with at least 60% to be dedicated to the ‘Global Challenges and European Industrial Competitiveness’ pillar. This is relevant in a discussion on industrial CO₂ emissions reduction because the scheme has been supporting various European cement industry projects, including HeidelbergCement’s work with the Low Emissions Intensity Lime And Cement (LEILAC) consortium and Calix at its Lixhe plant in Belgium and its pilots in Norway. As these projects and others reach industrial scale testing they need this money.

These recent developments provide hope for the future of the cement industry. Producers and their associations are engaging with the climate change agenda and taking action. Legislators and governments need to work with the cement sector to speed up this process and ensure that the industry is able to cut its CO₂ emissions while continuing to manufacture the materials necessary to build things. Projects like this latest from Dalmia Cement are overdue, but are very encouraging.

India: Barathi Cement has commissioned a 10MW solar power station at its 5.0Mt/yr integrated Barathi Cement Plant. The Hindu Times has reported that the facility, which spans 16.6 hectares, will partially replace combustion-derived electricity sources at the plant.

Oman: Oman Cement has engaged the services of a leading consulting company for construction of its 1.8Mt/yr integrated cement plant in Duqm. The company announced the appointment of the consultancy firm to its US$212m project, which has been ongoing since December 2018, on 12 September 2019.

Italy: The 0.4Mt/yr integrated cement plant at Travesio, which has been out of operation since early 2016, has not been purchased by w+p Zement, a subsidiary of Weitersdorfer, the Austrian cement and construction materials group. Diego Franz, the mayor of Travesio, has expressed the hope that Buzzi Unicem will now oversee the decommissioning of the plant itself.

Iraq: Arab Swiss Engineering Company (ASEC) will cover operation and maintenance of KAR Group’s 1.9Mt/yr integrated Qarachogh cement plant in Erbil. In a press release, ASEC stated that it has already overseen recruitment and planning and implementation of personnel development programs. ASEC's chairman and managing director Khaled El-Sebaie said he was ‘thrilled’ at the completion of the plant's hand-over.

US: Grupo Cementos de Chihuahua’s 0.9Mt/yr integrated cement plant in Odessa, Texas, will run entirely on wind and solar power. Adpren has reported that the company engaged an unnamed energy provider on a 10-year power purchase agreement for the entirety of its electricity consumption, beginning in July 2022. This will cut 45,000t/yr of carbon dioxide (CO2) emissions and represents a saving of US$4.6m in energy costs over its period of effect, a saving of 22% annually compared to Grupo Cemento’s current bill.

The news from Mali this week is that a new cement grinding plant is in the works. Ciments et Matériaux du Mali plans to build a 0.5Mt/yr plant near Bamako. Work on the US$34m project is set to start in October 2019 although there has been no word on the equipment supplier. The project is a long-standing one from France’s Vicat.

A new plant is probably very welcome following the last six months in the local market. Prices spiked by a third in May 2019, leading local producer Diamond Cement Mali to arrange a press conference to defend itself. Director Ibrahima Dibo explained that the company had fixed its prices in conjunction with the government at its units at Astro and Dio Gare since 2012. Instead, he blamed importers and traders for the situation, as well as low import rates from Senegal and Ivory Coast. The company proposed that it tackle the situation by importing more cement from one of its plants in Takoradi in Ghana and then transporting it into Mali via Dakar in Senegal. Although it noted that it would need permission from the government to do this.

The country has also been targeted by Nigeria’s Dangote Cement for several years. Back in 2016 the Nigerian cement producer was considering building a 1.5Mt/yr grinding plant. It also wanted to build a second production line at its Pout plant near Dakar in Senegal to export clinker specifically to Mali. It has since scaled back its expansion plans as the Nigerian economy entered a recession but in its 2018 annual report it noted that it had exported 0.43Mt of cement from Senegal and that most of this had gone to Mali, with plans to further increase exports in 2019.

At present Mali has three main grinding plants. Two are run by Diamond Cement and the third by Ciments de l'Afrique (CIMAF). An integrated plant at Guinbané, Diéma in the Kayes region was announced in late 2016 when the government signed a memorandum of understanding with Gaia Equity, a private equity company. This project was going to be built by China’s Sinoma.

Figure 1: Distribution of cement prices in Africa and Location of Plants 2015. Source: World Bank / ECDPM.

The status of that last project is unknown since there has been little news on it since. However, Figure 1 above shows why a private equity firm might sense opportunity. It’s out of date as various countries have become self-sufficient and we’ve covered this plenty of times before but the graphic from the World Bank really brings home the message that moving cement overland is uneconomical. This is mirrored by the mounting price of cement in Mali earlier this year. Africa has been described as the last great cement frontier and Mali is on the frontline.