Displaying items by tag: Plant

Australia: Adbri has entered into an agreement to obtain a new limestone carrier for its South Australian cement operations, to replace its MV Accolade II vessel currently in operation there. Specifically, the new carrier will supply raw materials for the Birkenhead cement plant. It is 100% battery electric capable. Adbri has hired marine transport company CSL to supply and operate the vessel. The contract will last until 2043, with the option for two five-year extensions.

Adbri chief executive officer Mark Irwin said “The new vessel will support Adbri to increase cement volumes at Birkenhead, while also supporting the production of lower carbon products such as EvoCem cement, which uses limestone as a clinker substitute.” He continued “The new vessel is expected to start operations with a hybrid system, where electric power will replace about 25% of its diesel fuel. This is expected to reduce Scope 1 emissions by about 40% compared to the current emission intensity seen in the Accolade II operation. By 2031, we aim to achieve 100% electric power capability, further reducing Scope 1 emissions to less than 10% of the current emission intensity seen in the Accolade II operation. This milestone is a crucial step forward in our on-going net zero emission journey.”

Canada: A provincial offences court has fined Heidelberg Materials Canada US$142,000 for ‘failing to take every precaution reasonable in circumstances under which three contractors were injured at its Picton cement plant. The workers were reportedly injured in a flash fire while replacing the plant’s jet air blower, after company engineers mistakenly overrode digital signals on both open valves between the gas supply and the area where the repair was taking place.

China: China Resources Building Materials Technology (CRBMT) subsidiary Tianyang Cement has concluded a ‘full-process intelligent cement plant’ pilot at its 2.81Mt/yr Baise cement plant in Guangxi Province. Tianyang Cement said that the pilot entailed an upgrade that has more than doubled Baise cement plant’s production volumes and reduced its CO₂ emissions per tonne of cement by 24%. Tianyang Cement says that automation has reduced the plant’s unplanned shutdowns by 56% and improved product quality.

India: Shree Cement inaugurated its new 4.2Mt/yr Nawalgarh cement plant in Rajasthan on 14 December 2023. The plant boasts an 11,500t/day kiln, which is among the largest in India, according to the company. Following the inauguration, Shree Cement’s installed production capacity now stands at 53.4Mt/yr.

Managing director Neeraj Akhoury said “In our pursuit to become an 80Mt/yr company by 2028, we are excited to announce commissioning the kiln in our new integrated facility at Nawalgarh, Rajasthan. This facility is well suited to cater to the high consumption cement markets of National Capital Region, Punjab and Haryana, besides strengthening the company’s customer servicing capability in Rajasthan.”

India: UltraTech Cement has signed a memorandum of understanding (MoU) with the government of Bihar for the investment of US$120m in the state.

Press Trust of India News has reported that the Bihar government has asked the government of India to grant the state special status in order to advance its industrial development.

Sinoma International Engineering revealed this week that it has signed a Euro218m contract to supply a new clinker production line for Holcim Belgium. The scope of the deal covers building the new line from limestone unloading via train to clinker transportation and storage. Provisional acceptance and first clinker are stipulated to occur within about four years, by late 2027. Holcim Belgium operates the Obourg Plant, its only integrated unit in the country, and the unit has been preparing to build a new line as part of its Go4Zero project.

Two main points compete for one’s attention with the project at the Obourg Plant. Firstly, this may be the first time a large Europe-based cement producer has publicly contracted a China-based supplier to build a new production line. Secondly, the new line is part of a process to first replace two wet kilns at the site with a dry kiln. This is part of a grand plan at the site to add oxyfuel technology to the plant and then start capturing most of the CO₂ emitted for sequestration in the North Sea.

On the first point, China-based Sinoma International Engineering reported to the Shanghai Stock Exchange in early December 2023 that it had signed a contract for the project. Holcim Belgium has not said that it has appointed the subsidiary of CNBM but this is not unusual. Buyers are at liberty to name suppliers, or not as may be the case. Holcim has been talking about the Go4Zero project for several years though, so appointing a lead contractor is not surprising.

Yet, some cement companies in Europe have previously been circumspect about revealing the use of China-based suppliers. Lafarge France, for example, did not appear to publicly name the involvement of Sinoma International Engineering and its subsidiaries on the construction of a new line at its Martres-Tolosane cement plant between 2019 and 2022, although Lafarge Poland did say in 2020 that it had contracted China Triumph International Engineering for an upgrade to its Małogoszcz cement plant. No doubt there have been other plant projects in Europe from China-based suppliers that Global Cement Weekly is unaware of. It is also worth considering that just because a lead contractor on a plant project is from a particular country it doesn’t mean that the equipment and other sub-contractors necessarily are. And, of course, to add to the confusion, some Europe-based equipment suppliers are owned by companies based in China.

This leads to the second point. Holcim Belgium’s eventual goal is to set up a full-scale carbon capture, transportation and sequestration (CCUS) operation at Obourg using oxyfuel technology by the end of the 2020s. Spending over Euro200m on building a new (but conventional) production line is not trivial but it is being presented as one step towards creating a cement plant for the net zero age. To this end Holcim Belgium has been less shy in naming its partners for the second phase of the project: Air Liquide; Fluxys; and TotalEnergies. This may be due to the collaborative nature of this phase though and the need to apply for European Union (EU) funding to support it. In July 2023 Holcim disclosed that the EU Innovation Fund had allocated grants for three of its projects including the one at Obourg.

For reference, a number of other full-scale oxyfuel projects have been announced in Europe including in Germany at Heidelberg Materials' Geseke cement plant, Holcim Deutschland's Lägerdorf plant in Germany and Schwenk Zement’s Mergelstetten plant. Another one is planned for Heidelberg Materials’ CBR's Antoing cement plant in Belgium. Most of these are planned for the late 2020s or with pilots sooner. The key bit of information to consider here is that adding oxyfuel technology to a cement kiln (or building one with it to start with) makes it easier to capture CO₂ from the flue gas as it is more concentrated. However, the technology is newer and less-tested than many post-combustion carbon capture methods. Hence, the world’s first full-scale CCUS unit at a cement plant, at Brevik in Norway, will use a post combustion method.

All of this begs the question about where the value will lie in building cement plants for the age of net zero? The planned work at Holcim Belgium’s Obourg Plant pretty much summarises this quandary. Building a cement production line is expensive but the cost of disposing of CO₂ may become the single-biggest driver of whether a plant is profitable or not if governments are serious about reaching net zero. To that end today’s announcement from the 2023 United Nations Climate Change Conference (COP28) calling on the parties to “transition away from fossil fuels to reach net zero” is another sign of the increasing effects of the so-called ‘carbon agenda’ upon the cement sector. In which case the companies that can supply equipment to take care of the CO₂ emissions start becoming more important and discussions over who supplies the rest of the kit less so. Naturally, some cement equipment suppliers are already pivoting towards this approach. Others may find different solutions. Whether this works or not is a question for the future. In the mean-time, building new plants is looking increasingly collaborative.

Poland: The European Commission has granted Lafarge Polska, Air Liquide Polska and energy provider Orlen Euro2.54m in funding for their construction of a 3Mt/yr CO₂ terminal in Gdansk, Pomeranian Voivodeship. The terminal will transmit captured CO₂ from local industrial sites, including 1Mt/yr from Lafarge Polska’s Kujawy w Blelawach cement plant in Kuyavian-Pomeranian Voivodeship, for sequestration below the North Sea. ISB News has reported that the partners will use the European Union funding to complete plans, including front-end engineering design, for the terminal.

US: France-based Hoffmann Green Cement Technologies has signed an exclusive licensing agreement with a partner in the US to build and operate ‘several’ new units to produce its clinkerless cement in Florida. Business Wire News has reported that the units will employ the same model as Hoffmann Green France Cement Technologies’ existing H2 unit in France.

Hoffmann Green Cement Technologies co-founders Julien Blanchard and David Hoffmann said "Following on from the contract signed with Shurfah in Saudi Arabia a few weeks ago, we are delighted to continue our international expansion with the announcement of this future site in the United States. This agreement with a Florida-based partner demonstrates the appeal, beyond our borders, of our clinker-free cement and our vertical production model. We are proud to be working alongside our partner to decarbonise the construction sector in a state as strategic as Florida, the third most populous state in the US.”

Germany/UAE: Holcim has claimed two sustainability awards at the COP28 climate conference for its work on the Carbon2Business carbon capture project at its Lägerdorf cement plant in Germany. Holcim won a COP28 Presidency’s Energy Transition Changemaker award and the Outstanding Project award for Germany at the COP28 Mission Innovation Net-Zero Industries Awards. The COP28 Presidency Energy Transition Changemaker initiative fosters deployment of scalable innovations to accelerate decarbonisation. Holcim was among 39 winners across four different industries. Meanwhile, the Mission Innovation Net-Zero Industries Awards are the first global competition in recognition of projects that have revolutionised industries, disrupted the status quo and set new benchmarks for decarbonisation in energy intensive sectors.

Holcim’s chief sustainability officer Nollaig Forrest said “It's great to close COP28 with two awards for our Carbon2business project in Lägerdorf. This is just one of our six carbon capture, storage and utilisation projects in Europe enabling us to produce at least 8Mt/yr of fully net zero cement by 2030.” Forrest added “These awards recognise companies for their collaboration and innovation, and at COP28 Holcim continued to create momentum with our partners across the building value chain to accelerate decarbonisation.”

UK: Holcim subsidiary Aggregate Industries has commenced its construction of a cement blending plant and import hub on the River Thames at the Port of Tilbury in Essex. The facility also includes units for the production of reduced-CO₂ cement components, including ground granulated blast furnace slag (GGBFS) and construction demolition waste (CDW)-based materials. The Tilbury site has five loading heads and will help Aggregate Industries to maintain its continuous supply of conventional, reduced-CO₂ and circular cementitious materials to London and South East England.

Chief executive officer Dragan Maksimovic said “This important investment will further strengthen our position in the market, allowing us to drive our sustainability ambitions and lead the way in low carbon and circular building materials. The London and South East construction market has major regional projects on the horizon, and we are primed and ready to meet the region’s rising demand for sustainable solutions.”

Steve Curley, managing director cement, added “Our ECOPlanet range of green cement was recently added to our green offering. By investing in this impressive facility within the Port of Tilbury, we will truly boost our sustainable offering and be more agile and efficient in the way we manufacture, transport and supply our products across this region.”