Displaying items by tag: Plant

Croatia: Nexe Group has ordered a suite of software products from US-based Rockwell Automation to digitise production processes, reduce energy usage and increase production. It will use the FactoryTalk Analytics Pavilion8 software together with performance-management dashboards based on the ThingWorx IIoT platform, part of the FactoryTalk InnovationSuite, supplied by PTC

The software architecture to be deployed at Nexe was formulated by data science teams from Rockwell Automation and subsidiary Kalypso. The Pavilion8 model predictive control (MPC) product sits on top of automation systems and continuously assesses current and predicted operational data. It then compares this data to desired results, and drives new control targets to reduce process variability, improve performance and boost efficiency.

Danijel Koren, plant manager at Nexe’s integrated cement plant at Našice said “This is a push forward on this important journey for the whole group. We are looking to link all systems together and put operational data in the hands of people who can make a difference. Early results point to real success in terms of savings and efficiency; indeed, we are predicting a payback period of less than a year.”

Romania: Holcim Romania has committed to an investment of over Euro25m to increase the production capacity of its cement plant in Campulung by approximately 20%. This would represent an expansion from 0.76Mt/yr to 0.9Mt/yr, according to the Argeşul newspaper. The company says that the investment will address both the existing need for more cement in the domestic construction market. It will also enhance the sustainability of the plant’s operation, streamline logistics and reduce the volume of CO2 emissions from the long-distance transport of building materials constructions.

India: Orient Cement has commissioned a waste heat recovery (WHR) plant at its Chittapur cement plant in Karnataka. Reuters has reported that the producer plans to subsequently scale up the WHR plant in a second construction phase.

Uzbekistan: China Energy International Group Samarkand Cement has installed a 3Mt/yr kiln at its upcoming Samarkand cement plant. Local press has reported that the kiln is the largest at a cement plant in Uzbekistan. The Samarkand plant will cost US$313m to build. Parent company China Energy and the government of Uzbekistan previously indicated that construction would conclude in 2024. The plant will produce ordinary Portland cement (OPC) of the local designations M-400 and M-500. It will use coal as fuel in its cement production and directly employ 500 people.

US: Buzzi Unicem USA’s Maryneal cement plant in Texas hit a production record of 1.03Mt of clinker and 1.18Mt of cement in 2022. The figures were more than 4% over the year’s budgeted figures. The plant says it achieved the result through consistent communication and a positive culture. Managers at the unit also shared updated production figures at daily meetings, kept all employees actively engaged and created an encouraging atmosphere. The plant has set new goals for 2023.

Antonio Corea Cruz, Operations Manager at the plant, said, “We’ve implemented strategies to keep reliable assets which allow the team members to work on continuous improvement. This affects the efficiency and productivity of all aspects of the plant.”

US: The Portland Cement Association (PCA) has announced the winners of its 2023 Safety Innovation and Chairman's Safety Performance Awards.

The Safety Innovation Award Program recognises companies that have developed innovative practices, projects and programs that improve safety at cement plants in the US. Entries are judged in five areas: innovation, ease of use and ease of construction, effectiveness and risk prevention. The recipients were:

• Distribution: Continental Cement, Continental Port Allen Terminal, Chesterfield, Missouri
• Quarry: CalPortland Company, CalPortland Oro Grande Plant, Oro Grande, California
• Pyroprocessing: GCC of America, GCC Tijeras Plant, Tijeras, New Mexio
• General Facility: Mitsubishi Cement Corporation, Mitsubishi Cushenbury Plant, Lucerne Valley, California

The Chairman’s Safety Performance Awards are given to member cement plants that did not have a reportable injury or illness during the year. Fifteen plants achieved this in 2023, which represented more than 10% of all active cement facilities in the US and its territories. The recipients were:

• Argos USA, Atlanta, Georgia
• Argos USA, Newberry, Florida
• Argos Puerto Rico Corp, Dorado, Puerto Rico
• Ash Grove Cement Company (CRH), Durkee, Oregon
• Ash Grove Cement Company (CRH), Midlothian, Texas
• Buzzi Unicem USA, Chattanooga, Tennessee
• Buzzi Unicem USA, Maryneal, Texas
• CalPortland Company, Rillito, Arizona
• GCC of America, Odessa, Texas
• Heidelberg Materials, Bellingham, Washington
• Martin Marietta Materials, New Braunfels, Texas
• Martin Marietta Materials, Midlothian, Texas
• Martin Marietta Materials, Tehachapi, California
• National Cement Company of California, Kern, California
• St Marys Cement (Votorantim), Detroit, Michigan

Taiwan Cement has just commissioned a 107MWh energy storage project at its Yingde plant in Guangdong province, China. Subsidiary NHOA Energy worked on the installation and has been promoting it this week. The battery storage works in conjunction with a 42MW waste heat recovery (WHR) unit, a 8MWp solar photovoltaic unit and a proprietary energy management system. It is expected to store about 46,000MWh/yr of electricity and save just under US$3m/yr in electricity costs.

NHOA Energy, formerly known as Engie EPS before Taiwan Cement bought a majority stake in it, claims it is one of the largest industrial microgrids in the world. We can’t verify this for sure, but it is definitely large. For comparison, the 750MW Vistra Moss Landing Energy Storage Facility in California often gets cited as the largest such facility in the world. This is run by a power company, as are many other large battery energy storage systems. In its annual report for 2022 Taiwan Cement said it was planning to using NHOA’s technology to build seven other large-scale energy storage projects at sites in Taiwan including its integrated Suao, Ho-Ping and Hualien cement plants.

The aim here appears to be supplying renewable electricity to the national grid in Taiwan. Taiwan Cement is diversifying away from cement production, with an aim to derive over 50% of its revenues from other activities besides cement by 2025. In 2022 cement and concrete represented 68% of its sales, while its electricity and energy division, including power supply and rechargeable lithium-ion batteries, represented 29%. The company is also not using its own batteries at the Yingde plant. Instead it is using lithium iron phosphate batteries supplied by Ningde Times. This is worth noting, as the cement producer’s batteries are used in vehicles.

Global Cement regularly reports news stories on cement plants that are building photovoltaic solar power arrays. However, so far at least, energy storage projects at scale have been rarer. One earlier example of an energy storage system loosely associated with a cement plant includes the now decommissioned Tehachapi Energy Storage Project that was situated next to the Tehachapi cement plant in California. That project tested using lithium ion batteries to improve grid performance and integrate intermittent generation from nearby wind farms. It is also worth noting that Sumitomo Osaka Cement’s sister company Sumitomo Electric is one of the world’s larger manufacturers of flow batteries, although no installation at a cement plant appears to have happened yet. In simple terms, flow batteries are an alternative to lithium ion batteries that don’t store as much energy but last longer.

More recently, Lucky Cement in Pakistan started commercial operation of a 34MW solar power plant with a 5.59MWh energy storage unit at its Pezu plant in Khyber Pakhtunkhwa in late 2022. Reon Energy provided the equipment including a lithium-ion based battery approach to the storage. Then, in March 2023, Holcim US said that it was working with TotalEnergies to build solar power capacity and a battery energy storage unit at the Florence cement plant in Colorado. TotalEnergies will install, maintain and operate a 33MW DC ground-mounted solar array and a 38.5MWh battery energy storage system at the site. Operation of the renewable energy system is expected to start in 2025.

Away from electrical batteries, the other approach to energy storage at cement plants that has received attention recently from several quite different companies has been thermal batteries. The two prominent groups using them at different scales are Rondo Energy and Synhelion. The former company has developed its Heat Battery technology, which uses refractory bricks to absorb intermittent renewable energy and then supply the energy back as a steady stream of hot gas for use in a cement plant mill, dryer, calciner or kiln. Both Siam Cement Group (SCG) and Titan Cement have invested in Rondo Energy. In July 2023 SCG and Rondo Energy said that they were planning to expand the production capacity of a heat battery storage unit at a SCG plant to 90GWh/yr. Synhelion, meanwhile, has been working with Cemex on using concentrated solar power to manufacture clinker. It achieved this on an ‘industrially viable scale’ in August 2023. It has since been reported that the companies are working on building a small scale industrial plant at Móstoles near Madrid by 2026. Crucially for this discussion though, the process also uses a thermal energy storage unit filled with ceramic refractory material to allow thermal energy to be released at night, and thus ensure continuous operation.

The examples above demonstrate that some cement companies are actively testing out storing energy at scale. Whilst this will not solve the cement sector’s process emissions, it does potentially start to make using renewable energy sources more reliable and reduce the variable costs of renewable power. Whether it catches on remains to be seen. Most of these kinds of projects have been run by power companies and that is where it may stay. It is instructive to note that Reon Energy was the only company to state that its battery-based energy storage system has a life-span of 8 - 12 years. Our current vision of a net-zero future points to high electrical usage but it may be shaped by how good the batteries are… from our phones to our cars to our cement plants.

For more information on Rondo Energy read the January 2023 issue of Global Cement Magazine

Uzbekistan: Hengyuan Cement has held a ground-breaking ceremony at the site of its up-coming cement plant in the Kattakurgan district of Samarkand. The plant, a joint-venture between Chinese and Uzbek partners, will have a capacity of 3Mt/yr and cost US$350m to construct. Cement will be sold in the local market and, according to developers, exported to as far afield as the European Union.

At the opening ceremony, the Hokim of Samarkand region Erkinjon Turdimov and Chinese partners noted that cooperation between Uzbekistan and China has been developing steadily in recent years. The project will lead to 600 new direct jobs. The long-awaited cement plant was first announced in 2018, but has repeatedly been delayed, particularly by the Covid-19 pandemic.

China: Taiwan Cement (TCC) commissioned a 107MWh energy storage project at its Yingde plant in Guangdong province in August 2023. Subsidiary NHOA Energy worked on the project that linked the battery storage capacity to a 42MW waste heat recovery (WHR) system and a 8MWp solar photovoltaic unit. It uses lithium iron phosphate batteries supplied by Ningde Times.

The company’s say that the project is one of the largest industrial microgrids in the world. It is intended to provide energy flexibility to the cement plant by using NHOA Energy’s proprietary energy management system to manage peaks in energy demand and acting as a backup for critical equipment to avoid damage caused by sudden blackouts.

The NHOA Energy storage project is expected to store about 46000MWh/yr of electricity and save just under US$3m/yr in electricity costs. The system will also support the Guangdong Provincial Government’s energy storage development policy and be eligible to associated subsidies of over US$350,000/yr.

Giuseppe Artizzu, the chief executive officer of NHOA Energy, said “NHOA Energy’s proprietary energy management system will optimise the generation and consumption profile of the industrial microgrid, while also supporting the regional grid towards its 100% green energy objective, taking the energy transition in the area one step forward in total accordance with NHOA Group’s and TCC’s shared mission of fostering a positive change for the future of our planet.”

Bangladesh/India: The completion of an upgrade project to Chhatak Cement’s plant has been thrown into doubt due to uncertainty about securing limestone from India. The plant still needs to build a new 17km ropeway conveyor and this has been delayed due to failure to obtain permission on the Indian side of the border, according to the Daily Star newspaper. It is also facing problems procuring limestone in India due to on-going legal proceedings on environmental grounds between exporters in Meghalaya and the government. The Supreme Court of India granted permission for exports in 2022 but the case is still pending. In addition, plans to install a gas line from Sylhet to the plant has not started yet either.

The state-owned cement producer is run by the Bangladesh Chemical Industries Corporation (BCIC). It originally announced in 2016 that it was spending over US$100m to build a new 1500t/day dry production line at the plant to replace an old wet production line. Although the old line originally had a production capacity of 233,000t/yr, it had fallen to around half of this. However, despite the construction of new silos and other equipment at the site, the unit has not been operational since early 2020. The new line was originally planned to start operation in 2020 but this was delayed until 2023. The BCIC has now proposed that completion of the project be extended to mid-2025.