Displaying items by tag: Plant

Turkmenistan: Turkmencement’s integrated Lebap plant has increased its production of cement to 0.47Mt in the first half of 2022. This is an improvement over the 0.45Mt level reported in the same period in 2021, according to Jeyhun News. The plant was originally built in 2013. A new production line at the site was reportedly ordered from Germany-based Thyssenkrupp Industrial Solutions in mid-2021.

Algeria: Groupe des Ciments d'Algérie (GICA) has obtained a certificate of conformity with European standards (CE) for three types of cement. The certification should allow the company to export more products to Europe, according to the Expression newspaper. It applies to its Gica Moudhad and Gica Béton products. The move follows similar certification of products with the Association Française de Normalisation (AFNOR) from the company’s Aïn El Kebira plant in July 2021. At the same time the Minister of Industry said it was helping the group with its export strategy.

In 2021 GICA exported 2.25Mt of cement to countries including the Ivory Coast, Gambia, Ghana, Mauritania, Senegal , Cameroon, Benin,  Guinea, Brazil, Peru, the Dominican Republic, Haiti and a number of European countries.

Greece: Titan Cement Group has successfully started a pilot CO₂ capture demonstration project at its Kamari plant. As part of the RECODE2020 project it said it had reached a CO₂ purity above 99% during initial operation by using ionic liquids as the CO₂ adsorbents. The captured CO₂ is then intended to be utilised by converting it to nanocalcite and additives that can reused in cement production in different ways. The cement producer is also running the CARMOF project at the plant.

France: Despite a 12% year-on-year increase in consolidated sales to Euro1.75bn from Euro1.56bn, Vicat recorded a net income drop of 17% to Euro77.8m from Euro93.5m in the first half of 2022. The group attributed the decline to increased global energy costs and to non-recurring industrial costs in France, India and the US. These costs included investments in exceptional maintenance at its Montalieu cement plant in France and a debottlenecking capacity expansion at its Kalburgi, India, cement plant. Geopolitical events also impacted the profitability of the producer’s business in Mali. Group cement sales rose by 17% year-on-year to Euro1.1bn.

Chair and chief executive officer Guy Sidos said “The basis for comparison in the first six months of 2022 was unfavourably high given the sales and profitability levels achieved in the same period of the previous year.”

Congratulations are due to the National Cement Company of Alabama and Vicat for the inauguration of the new production line at the Ragland cement plant in Alabama. The event took place on 21 July 2022.

The US$300m project was originally announced in late 2019. It then took two years to build with construction starting in January 2020. Key features include a raw vertical grinding mill, a new roller mill, a five stage preheater tower, an automatic clay storage system, a 78m tall homogenisation silo, an alternative fuels storage area for tyre-derived fuel, sawdust and wood chips, a laboratory and a new control room. The new kiln was previously reported to have a clinker production capacity of 5000t/day and it will add up to 2Mt/yr of cement production capacity to the plant. ThyssenKrupp signed up as the principal equipment supplier in 2019 and H&M was the main contractor. The production line is expected to reduce energy consumption by one third. Further change is scheduled with a switch to production of Portland limestone cement (PLC) from Ordinary Portland cement (OPC) by the start of 2023.

Vicat has repeatedly noted its affection for the plant as it was the first cement plant the group purchased outside of France, back in 1974. Indeed, Vicat’s group chair and chief executive officer Guy Sidos personally managed the Ragland plant in 2001. However, rather more prosaic reasons may also have been behind the decision to expand Ragland. According to United States Geological Survey (USGS) data, Alabama, Kentucky and Tennessee’s cement shipments grew by nearly 5% year-on-year to 7.1Mt in 2019 from 6.8Mt in 2018. Shipments are up by 3% year-on-year to 2.5Mt in the first four months of 2022 and the three states were the fifth largest region in the US for cement shipments in April 2022. A shortage of cement was also reported in Alabama in April 2022.

The other big US-based cement plant expansion is Lehigh Hanson’s US$600m upgrade to its Mitchell plant in Indiana. It also celebrated a milestone this week with a ‘topping out’ ceremony to mark the placement of the final section of steel for the stack. Another recent achievement here was the completion of a 169,000t storage dome supplied by Dome Technologies. The supplier says that the 67m diameter and 48m tall dome is the second largest clinker storage facility in Europe and North America, after one it previous built in Romania in 2008.

The Mitchell K4 project was announced in mid-2018 and then ground breaking began in late 2019. However, the start of the coronavirus pandemic delayed construction in early 2020 before it restarted in September 2020. The revised commissioning date was then moved back about half a year to early 2023. The key part of this project is that it will replace the plant’s three current kilns with just one. The new production line will increase the site’s production capacity, reduce energy usage and decrease CO₂ emissions per tonne of cement. It was reported by local press back in 2018 that the project would increase the plant’s cement production capacity to 2.8Mt/yr. The project has been linked to supplier KHD with CCC Group as the contractor.

It’s fascinating to see two major new upgrades to cement plants emerging in a mature market like the US and during an unprecedented event like the emergence of coronavirus. No doubt compelling tales will emerge of how both teams coped with managing nine-figure capital expansion projects as a global public health emergency unfolded. The US market has been on a roll in recent years, despite all the uncertainty in the world, and so far it doesn’t seem to be slowing down. With luck both of the projects feature above have timed their opening right.

Mexico: State police have intervened during a confrontation between rival groups for control of Cruz Azul’s Tula cement plant in Hidalgo. A group of workers, allegedly numbering 1000 people, aligned to the faction that controls the majority of Cruz Azul’s cement plants travelled to the site in Jasso by bus and taxi on the evening of 26 July 2022, according to La Jornada newspaper. Another group defending the plant reportedly blocked local roads and used sticks, pipes and stones to repel the assault. The police managed to deter most of the convoy travelling to the plant. However, eight deaths occurred when some of the attackers made it through.

The Tula cement plant is the sole remaining Cruz Azul unit still controlled by former company director Guillermo ‘Billy’ Álvarez and his associates. The rest of the company is under the command of Cruz Azul’s directors José Antonio Marín and Víctor Manuel Velázquez.

Poland: PGE Group is ordering a feasibility study for a planned new cement production facility in Bełchatów county. Polish News Bulletin has reported that the plant will take advantage of locally available fly ash from coal-fired power plants.

India: Visaka Industries commissioned its Udumalpet cement panel plant in Tamil Nadu’s Tirpur district on 20 July 2022. Capital Market News has reported that the plant has a capacity of 10,000t/yr.

El Salvador: Holcim El Salvador has officially inaugurated an upgrade to its Maya cement plant. The company has invested US$11.6m towards increasing clinker production capacity by 0.45Mt/yr at the unit. Total cement production capacity of the plant has increased to 1.9Mt/yr from 1.2Mt/yr previously. The Maya cement plant previously reduced production levels significantly in 2008 in response to the global financial crisis at the same time. Oliver Osswald, Region Head of Holcim LATAM, attended the inauguration. The event was also used to launch Holcim’s new corporate branding in the region.

US: Lehigh Hanson’s Lehigh Cement plant in Union Bridge, Maryland plans to fully switch from Ordinary Portland Cement (OPC) to Portland limestone cement (PLC) production by January 2023. It will manufacture its EcoCemPLC product. The company says that the Union Bridge plant is currently the company’s largest cement plant in North America.

The decision to move to PLC follows similar changes at the company’s Mason City plant in Iowa and three cement plants in Indiana. Lehigh Hanson produced over 2Mt of PLC in 2021 and it says it is set to double this figure in 2022.