Displaying items by tag: Plant

Vietnam: The People’s Committee of Hoa Binh Province authorised Xuan Khiem Group to begin building its Xuan Son cement plant earlier in July 2023. Việt Nam News has reported that the upcoming plant will commence operations in late 2024, and will have a capacity of 2.3Mt/yr.

Vietnam: Tan Quang Cement says that it fell short of its first-half 2023 cement production target by 80,000t at it 800,000t/yr Trang Da cement plant in Tuyen Quang. The plant will ‘presently’ enter a shutdown period for maintenance. Việt Nam News has reported that the producer attributed the shortfall in production to low demand, amid general national overcapacity.

Portugal: Cimpor Portugal has signed a contract with Germany-based KHD Humboldt Wedag (KHD) for an upgrade to production line 7 at its Alhandra cement plant. The project is intended to increase the production capacity at the plant to 3600t/day from 3000t/day and increase the line’s alternative fuels thermal substitution rate to over 80%. It will also be the first installation of KHD’s Pyrorotor alternative fuel combustion reactor in the country.

The scope of the engineering and supply contract comprises:

• New HKSK 224/335 preheater ID fan
• New downcomer duct
• New preheater with 8064/5-type HEM cyclones
• Pyroclon R calciner with Pyrotop mixing chamber. The Pyroclon R will utilize fine refuse-derived fuel (RDF) and natural gas
• 4m x 10m Pyrorotor alternative fuel combustion reactor
• Pyrobox coal firing system for process start-up and operation balancing
• Shortening of the existing kiln and installation of new kiln inlet chamber with bypass extraction
• New kiln drive station 2 (the existing girth gear and two pinions will be reused)
• New kiln hood and take-off of tertiary air from the cooler roof
• New main kiln burner designed to use more than 50% alternative fuels (but will also be capable of burning natural gas, as well as liquid fossil and alternative fuels)
• New Pyrofloor PFC²829AW cooler with a Pyrocrusher PRC 420-3ES clinker crusher.

KHD will also be supplying its KHD ProMax software product as part of the project.

Matthias Mersmann, chief technology officer at KHD, said “The decision by Cimpor Portugal to opt for KHD pyroprocessing equipment - and especially the Pyrorotor - underlines the leading market position of KHD, as well as the outstanding capability of KHD’s unique alternative fuel-processing solution.”

Project execution will be led by KHD Germany, with support from Humboldt Wedag India and the Turkish branch office of Humboldt Wedag. Commissioning of the upgraded production line is scheduled for 2025.

Norway: Capsol Technologies has been awarded a feasibility study for the CapsolEoP (end-of-pipe) carbon capture product at an unnamed cement plant in Northern Europe. The study is for a plant aiming to capture more than 1Mt/yr of CO₂. The award is Capsol Technologies’ first paid engineering study on a cement plant. The company says it is seeing an increasing amount of request and sales engineering work in the cement sector and it expects more engineering studies to be awarded going forward.

Jan Kielland, the chief executive officer of Capsol Technologies, said “The fact that the CapsolEoP carbon capture technology is easy to integrate without disrupting the operations of the host plant is an attractive value proposition to these types of facilities. In addition, the emission from a cement plant has a high concentration of CO₂ making it especially beneficial for the CapsolEoP technology relative to competing technologies, bringing down the cost per unit CO₂ captured.”

Norway-based Capsol Technologies is promoting a solvent/scrubbing-based approach to carbon capture using hot potassium carbonate (HPC). It was awarded a technology licensing agreement for the Stockholm Exergi BEECS (Bioenergy Carbon Capture and Storage) project in July 2022. It has also received orders for its CapsolGo carbon capture demonstration unit in Sweden and Germany.

France: Heidelberg Materials has announced plans for its CIRCO₂BETON concrete recycling project. It intends to build an industrial-scale selective separation unit at its Achères quarry near Paris. Here it will recycle demolished concrete by crushing it and separating it into its components: sand, aggregates, and recycled concrete paste (RCP). The recycled sand and aggregates will be reincorporated into new concrete.

The RCP will be transported to the Ranville cement plant in the Normandy region. There, a reactor for enforced carbonation will be installed to carbonate the RCP by exposing it to CO₂-containing exhaust gases from the kiln. The carbonated RCP acts as a carbon sink and will replace clinker in new low-carbon cement types. The project has the potential to reduce the CO₂ emissions of the Ranville cement plant by 20%.

CIRCO₂BETON is supported by the ‘Investment for the Future’ Program coordinated by the Ecological Transition Agency (ADEME). In addition, the Île-de-France region supports the selective separation plant at Achères through its zero-waste and circular economy plan. Subject to the funding, construction of both industrial pilots is scheduled to start in 2024 with production of RCP starting in 2025. The carbonation reactor is planned to be operational by 2026.

Nicola Kimm, the chief sustainability officer at Heidelberg Materials, said ”We are investing in a pioneering large-scale project based on innovative process technologies. Selective separation and CO₂ mineralisation are important levers to reduce the carbon footprint of our products. By closing the materials loop, we prove that concrete has the potential to be the most sustainable building product over its entire life cycle from production to recycling.”

Read more about RCP in the Decemeber 2022 issue of Global Cement Magazine

US: In 2022, Fortera began building a 15,000t/yr-capacity plant to produce its low-carbon cementitious material, Fortera Reactive Calcium Carbonate (RCC), at CalPortland's Redding cement plant in California. The commercial-scale plant will produce a reactive form of calcium carbonate using CO₂ from the kiln of the 600,000t/yr cement plant. Fortera's process converts 1t of limestone into 1t of Fortera RCC by capturing and mineralising CO₂ from the cement plant's kiln. Fortera cement production emits 60% less CO₂ than ordinary Portland cement (OPC). The 15,000t/yr plant will operate at 20 times the scale of previous pilot tests. The Redding Record newspaper has reported that 15 workers will be employed at the site.

Former Redding cement plant owner Lehigh Hanson formed an agreement with Fortera to collaborate on the low-carbon cement plant project in March 2021. The plant subsequently switched ownership to Martin Marietta Materials in October 2021, before CalPortland bought it in July 2022.

Spain: Cementos El Molino plans to invest Euro3.7m in an upgrade to energy infrastructure at its 450,000t Santa Eulalia grinding plant in Aragon. Alimarket Construction News has reported that the upgrade consists of a 12MW substation and a 2.4MW solar power plant. Euro2m-worth (54%) of investments will go towards construction of the subsystem and Euro1.7m (46%) towards the solar power plant. Cementos El Molino expects to carry out the investments before the end of 2023.

Pakistan: Dandot Cement says that its on-going upgrade to its Lahore cement plant reached 60% completion during the fourth quarter of the 2023 financial year, which ended on 30 June 2023. The project remains scheduled for completion in July 2023. Pakistan Company News has reported that the producer has taken delivery of new equipment, completed civil construction work, handed over the site to its engineering contractor, completed 75% of mechanical erection and conducted some tests. The producer awarded a new contract for installation of remaining portions of its control systems to an Uzbekistan-based contractor. Complete sections of the project include the plant's captive solar power plant.

Dandot Cement has made total investments worth US$12.3m in the project.

Zimbabwe: Khayah Cement (formerly Lafarge Cement Zimbabwe) commissioned a new vertical roller mill at its Manresa cement plant on 6 July 2023. The Chronicle newspaper has reported that the project constituted Phase 2 of Khayah Cement's expansion to the plant.

Austria: Rohrdorfer has bought 20 new railcars equipped with ÖBB Rail Cargo’s RockTainer SAND containers. The cars will transport limestone between the producer’s Ebensee quarry and its Gmunden cement plant. Each railcar consists of two RockTainer SAND containers mounted on an InnoWaggon carriage, with a maximum load of 134t. The new cars will increase the volume of despatches from the Ebensee quarry by 28% to 804t of limestone per train from 630t/train, enabling Rohrdorfer to transport 450,000t of limestone per operating season.