Displaying items by tag: Plant
UltraTech Cement to expand Maharashtra cement plant
18 September 2015India: Aditya Birla's UltraTech Cement has got the Environment Ministry's clearance to increase the capacity of its Awarpur plant in Maharasthra, which would entail an investment of US$37.7m.
The company plans to increase its clinker capacity to 4.5Mt/yr from 3.3Mt/yr and to increase its cement capacity from 4.48Mt/yr to 6Mt/yr.
"Based on the Expert Appraisal Committee (EAC) of the Union Environment Ministry recommendation, the Environment Ministry granted the final clearance subject to certain conditions. The EC was issued to the company on 11 September 2015," said a senior Environment Ministry official.
The company has been asked to comply with specific conditions like developing green belt over 33% of the total project area, installing air monitoring devices to monitor air emission and continuous stack monitoring of facilities to monitor gaseous emissions, among others. The company has also been asked to earmark at least 5% of the total cost of the project towards enterprise social commitment and prepare a detailed corporate social responsibility (CSR) plan for every five years for the existing expansion project.
UltraTech Cement has informed the Ministry that the proposed expansion will be carried out within the existing plant area. The additional power required for the proposed expansion will be 5.1MW.
Ecuador: Gebr. Pfeiffer Inc, a subsidiary of Germany's Gebr. Pfeiffer SE, was recently contracted to supply a complete grinding unit to replace aging ball mills at the Hormicreto clinker plant in Ecuador.
The new grinding unit helps reduce energy consumption and improves the overall grinding efficiency, allowing the plant to increase production from a single mill. Gebr. Pfeiffer supplied the following components of the new grinding station:
• MPS 2500 BC swing mill with 'Lift and Swing' technology;
• SLS 2250 BC classifier;
• Bucket elevator;
• Reject conveyor belt;
• Chutes and divert chutes;
• Reject silo;
• Weigh feeder;
• Dedusting unit;
• Metal detector;
• Separator;
• Rotary locks;
• Bag filter;
• Mill fan;
• Ducting, expansion joints and dampers;
• HML 1250 Pfeiffer hot gas generator;
• MCC, control and instrumentation;
• Related engineering services.
Delivery of the grinding unit is expected to be complete by December 2015.
Westbury cement plant chimney to be demolished
15 September 2015UK: The Westbury cement plant in Wiltshire County, which was constructed in the early 1960s and mothballed in 2009, is now set to be partly demolished. In a bid to attract investors, non-operational parts of the site, including the 122m-high chimney, will be cleared. The structure will be brought down with a series of controlled explosions, according to site owner Tarmac, now part of CRH.
Earlier in September 2015, Tarmac said that it had submitted a prior notice to Wiltshire Council to demolish part of the complex. At present, the site is an 'attraction to trespassers' and is 'a security and maintenance liability.' According to Tarmac management, the demolition will result in reduced trespass and a reduced need for maintenance.
Holcim Indonesia launches new cement plant in Tuban, East Java
15 September 2015Indonesia: PT Holcim Indonesia Tbk has launched its new US$800m, 3.4Mt/yr cement plant in Tuban, East Java.
Having started the construction five years ago, the plant is Holcim's first greenfield project in Indonesia. The plant will serve the East Java market and supply Sumatra and Kalimantan. With the new plant, Holcim Indonesia's cement production capacity has grown by 40% to 12.5Mt/yr.
"Currently, Holcim Indonesia is operating in an oversupply market and market slowdown. However, we believe that it is temporary as construction markets in developing countries are cyclical. The overall long-term macroeconomic fundamentals in Indonesia remain strong and the domestic economy will recover with the realisation of delayed infrastructure projects and housing," said Gary Schutz, CEO of Holcim Indonesia. "The new Tuban Plant completes our presence in Java as it will serves our markets better, ensures supplies and secures our position among the three biggest cement players in Indonesia."
China Resources Cement to pay US$237m for 40% stake in Yunnan Kunming Iron & Steel Building Materials
15 September 2015China: China Resources Holdings has agreed to pay US$237m for a 40% stake in Yunan Province-based cement producer Yunnan Kunming Iron & Steel Building Materials Group Co in a bid to lift production capacity, according to Dow Jones. Yunnan Kunming Iron & Steel Building Materials Group Co is currently a 100% owned unit of state-owned Kunming Iron & Steel Holding Co Ltd. China Resources plans to fund the investment via internal resources and bank borrowing, it said.
Arr Thit Man plans to double cement capacity in Mandalay
15 September 2015Myanmar: Local cement producer Arr Thit Man plans to double its cement production capacity from 5000t/day to 10,000t/day by 2016, according to senior officials. The company makes the Double Rhinos brand cement from its plant in Kyaukse, Mandalay. It claims to be the country's largest cement plant.
"We are a new brand, but we are focused on the quality of cement and fulfilling market demand," said the company's managing director. For the time being, Arr Thit Man plans to focus on meeting growing domestic demand rather than exports.
A number of other cement manufacturers are also looking to increase their local presence. Siam Cement Group is building a 1.8Mt/yr cement plant in Mon, which it expects to be operational in 2016. Several companies also import their cement to Myanmar.
ARM Cement’s clinker plant will boost margins
14 September 2015Kenya: Kenya's ARM Cement expects profitability to improve now that it produces its own clinker for its east African cement plants, according to managing director Pradeep Paunrana.
Reuters reported that ARM Cement posted a pre-tax loss of US$4.5m in the first six months of 2015, which the company blamed on unrealised foreign exchange losses associated with borrowing for its new clinker plant, a vital raw material for cement.
Paunrana said that the new 1.2Mt/yr clinker plant was operating at about 75% capacity since production began in April 2015. "What this essentially means is that our production cost has come down drastically because imported clinker is much more expensive, at least 70 or 80% more expensive than what we are producing locally," said Paunrana. "So we expect improvement in our margins both in Kenya and in Tanzania with the production of our own clinker." He added that ARM was also selling clinker to other companies in Tanzania, the Democratic Republic of Congo, Rwanda and Burundi.
ARM's operating margin was 13.4% in 2014 according to Thomson Reuters data, compared with an industry median of 15.5%. ARM's Tanzanian plant has 1.5Mt/yr of cement production capacity, while its Kenyan plant can produce 1Mt/yr and its plant in Rwanda can make 100,000t/yr.
Paunrana said that he expected an improved financial performance in the second half of 2015, citing the 9% rise in earnings before interest, tax, depreciation and amortisation (EBITDA) in the first half to US$18.4m. "The company is still very profitable, especially now that we have more clinker production and more volume growth," said Paunrana. He added that earnings in foreign exchange were rising and that ARM now had an advantage over some rivals. "We are keeping our margins steady and are now becoming a lot more competitive against those who import either clinker or finished cement."
Turkmenistan to build 220 facilities for US$18bn in 2016
14 September 2015Turkmenistan: The Republic of Turkmenistan plans to construct more than 220 facilities for US$18bn in 2016, according to president Gurbanguly Berdymukhammedov.
The construction will take place under a large investment development programme and will include a natural gas pipeline that will transverse Turkmenistan, Afghanistan, Pakistan and India and will ship 33Bnm3/yr of gas. The projects will also include a 1Mt/yr cement plant in Lebap, a gas-chemical complex designed to produce 467,000t/yr of polyethylene and polypropylene, a plant to produce 600t/yr of petrol from natural gas, as well new airports in the cities of Atamyrat and Garabogaz.
"Over the past few years, gross domestic product has been growing rapidly in Turkmenistan. During this past year, GDP growth hit 8.3%. Capital investments rose by 8.2% and the average monthly wages increased by 10%," said Berdymukhammedov.
From brownfield to leftfield: what happens to closed cement plants?
09 September 2015Plans for the former Shoreham cement plant on the south coast of England took an exciting turn towards the end of 2014. Zero carbon design firm Zedfactory announced its plans to regenerate the brownfield site into an eco-resort featuring holiday homes, performance space, affordable homes, a hotel and conference centre, a watersports venue, wildlife preserves and more. Or, ' hobbit homes' as the Daily Mail put it when it covered the story six months later.
This raises the question of what happens to cement plants when they close?
In the UK, where a housing shortage in certain areas collide with NIMBY (not in my back yard) attitudes and strict planning regulations, former industrial or brownfield sites are prime sites for new housing developments. Subsequently, old cement plants are attractive to builders to build houses. Two examples of current sites heading this way include the former Cemex plant in Barrington, Cambridgeshire and the former Lafarge Eastgate plant in County Durham. Both sites have gained planning permission and were still in the pre-building stage according to local press reports in mid-2015. Dylan Moore's website 'Cement Plants and Kilns in Britain and Ireland' provides a good resource on former plants in the UK and Ireland.
One of the jokes about classic UK science-fiction television series Dr Who was that during the 1970s it was either filmed on cheap studio sets or in quarries. Endless encounters with alien beings took place in cement plant quarries including Lafarge Northfleet (alien in spacesuits), Lafarge Aberthaw (tentacle faced aliens), Hanson Ketton (Arthurian knights who may in fact be aliens...) and many more. Indeed, one of the conditions of the proposed Lafarge Eastgate sale in March 2015 was that a television production company could continue to use the quarry to film an adaptation of Beowulf for five years!
On the more imaginative side of what to do with old plants, La Fabrica near Barcelona is a spectacular example. Architect Ricardo Bofill converted a 19th century plant into his firm's head office, La Fabrica, and his own personal residence. As Ricardo Bofill Taller de Arquitectura's website puts it, "Eight silos remained, which became offices, a models laboratory, archives, a library, a projections room and a gigantic space known as 'The Cathedral', used for exhibitions, concerts and a whole range of cultural functions linked to the professional activities of the architect." Architecturally the project refers to Catalan Civic Gothic style with surrealist elements.
This sense of entertainment from industrial architecture was continued by sculptor Bob Cassilly in St Louis, USA who decided to build Cementland. Cassilly purchased the former plant and slowly assembled his clinker-themed version of Disneyland. Unfortunately he died in 2001 following an accident with a bulldozer at the site before he finished.
More and more former cement plants will be seeking new purposes as Europe rationalises its cement industries and excess capacity is eliminated. China too faces similar issues as it consolidates its industry. Most will probably lie fallow before eventually being knocked down and then turned into something following the cheapest economic path forward. With luck though, some will follow the dreams of Zedfactory and people like Ricardo Bofill and Bob Cassilly.
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DG Khan releases further details of new Baluchistan cement plant
09 September 2015Pakistan: DG Khan Cement has signed a contract with Germany's Loesche GmbH to supply complete raw, cement and coal grinding mills for its greenfield cement plant in Lasbella, Baluchistan. The cement grinding mills will be provided by a German company, while Denmark's FLSmidth has been contracted for engineering and equipment, according to DG Khan Secretary Khalid Chohan. The new 9,000t/day plant will be completed with a cost of around US$300m within three years. DG Khan has already signed an agreement with K-Electric for the supply of 40MW of electricity.