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Displaying items by tag: Quarry
Autonomous haulage in the cement sector
10 November 2021Volvo Autonomous Solutions and Holcim Switzerland announced this week that they are testing and developing the use of autonomous electric haulers in a limestone quarry. It’s a two-part project, as being able to run electric dump trucks will help Holcim to meet its sustainability goals by switching to renewable energy supplies. Automating the control of the trucks then lets Holcim work towards its digitisation targets as part of its ‘Plants of Tomorrow’ initiative. Holcim Switzerland has also been running a drone programme at the plant (see GCW520) and has been using a few electric concrete mixer trucks since early 2021.
The use of autonomous haulage systems (AHS) in quarries by the cement industry seems to mark the start of something new. As far as Global Cement Weekly can tell, the Volvo Autonomous Solutions - Holcim Switzerland project is the first one in the cement sector that has been announced publicly. Most of the examples of AHS to date have been for heavy mining applications such as iron ore, copper, oil sands and coal. Automation in limestone and aggregate extraction has been slower. One recent example in the aggregate sector was announced in late 2020 when Norway-based technology company Steer said it had signed a contract with Romarheim to supply three autonomous dump trucks for use in a stone quarry. Previously Steer has used its vehicles to clear unexploded ordinance for the Norwegian army.
AHS have been around commercially since the mid-2000s when Komatsu tested and then deployed one at a copper mine run by Codelco in Chile. By September 2021 Komatsu said it had commissioned over 400 trucks with its autonomous system and that these had hauled over 4Bnt of materials. For its part Caterpillar says it started its first automated vehicle research program in 1985 and was even testing a pair of Cat 773 dump trucks in the 1990s. However, it then took a pause before resuming after 2000 and starting its commercial projects in the 2010s. In April 2020 it hit 2Bnt of hauled materials by AHS using its MineStar Command product. Hitachi, Liebherr and Belaz have also been working on their own AHS products in conjunction with third party technology providers and these were developed later in the 2010s. Most of these products are complimentary control systems that have been added to existing models or can be added to new ones. Autonomous vehicle company ASI is the other big name in the field with its Mobius product. Unlike the other systems, this is purely a retrofit product. ASI does not make its own vehicles. Komatsu and Caterpillar have also developed retrofit kits for their systems.
Most of the products above look mostly like normal trucks with the addition of extra kit. Volvo and Scania have also been working on AHS but their products have been taking it further by removing the cab entirely. Scania launched its AXL product in September 2019. Volvo launched its Volvo Autonomous Solutions subsidiary in 2020 and its Tara system electric dump truck the same year. Volvo had previously planned to run a pilot for its Tara truck with Harsco Environmental carrying slag at the Ovako Steelworks in Hofors, Sweden. Unfortunately the pilot was disrupted by the start of the coronavirus pandemic shortly after it started.
It’s early days yet with the use of autonomous vehicles in the quarries of the cement and aggregates sectors. Obvious advantages are additional operational hours, better worker safety and reduced costs. As ever with automation, cutting out human jobs would be one disadvantage for the current workers at least. There is also the possibility that an experienced human driver using efficiency software tools might be better than a fully AHS. A challenge in the field is developing open standards or methods to allow autonomous machines to communicate or work with both products by the same manufacturer and its rivals, as well as with conventional human-driven ones. Another challenge is for the mining and quarrying industry to determine how flexible it wants its heavy vehicles to be. One thought to end with this that an autonomous vehicle with a cab and a steering wheel can still be driven by a human. The cab-less vehicles being tested by Volvo and Scania would be rather less useful if they get into a situation where the software can’t cope. Lots to consider.
If readers are aware of other examples AHS in the cement industry, please let us know at This email address is being protected from spambots. You need JavaScript enabled to view it.
Cementos Polpaico plans Cerro Blanco cement plant upgrade
08 November 2021Chile: Cementos Polpaico has submitted an environmental impact study for a US$60m upgrade of its Cerro Blanco cement plant in Tiltil, near Santiago. Business News America has reported that the proposed work consists of the installation of a new precalciner, an expansion to its four limestone quarries and the establishment of a new filtered tailings deposit and 3000t cement silo.
The producer hopes to launch the project in January 2023 in order to commission the upgraded plant before 2026.
Holcim Schweiz and Volvo Autonomous Solutions develop automated electrical dumpsters
05 November 2021Switzerland: Holcim Schweiz has partnered with Sweden-based Volvo Autonomous Solutions to test and develop automated electric dumpsters at its Gabenchopf quarry in the Siggenthal. The companies aim to develop a safe, efficient and sustainable dumpster for use in the cement industry.
CEO Simon Kronenberg said “We are very excited to be working with Volvo on this project. For us, this project means a further step towards realising our sustainability goals: in order to make a contribution to a sustainably built future, we continuously invest in measures to reduce our ecological footprint and look for solutions that are both innovative and sustainable."
Cementa preparing to ration supplies in December 2021
27 October 2021Sweden: Cementa says it is preparing to ration deliveries of cement in December 2021 due to uncertainty about whether it can renew the mining licence at its integrated Slite plant in Gotland beyond the end of October 2021. The subsidiary of Germany-based HeidelbergCement has warned customers that it is preparing to implement quotas of cement products from its two plants and five terminals on a week-by-week basis. The quotas will be based on what level of cement customers have ordered previously over the past 36 months. It will also take into account whether there have been significant volume changes during the period.
Cementa says it submitted its application for an emergency permit in late September 2021. It needs approval from the government by mid-November 2021 to avoid a potential cement shortage. However, any such approval may be subject to an appeal leading to further delays in mining.
Argentinean Mining Workers Association disrupts operations at Minerar’s Olavarría quarry
22 October 2021Argentina: Sit-in protesters from the Argentinean Mining Workers Association (AOMA) have blocked access to the hoppers of limestone crushers at Minerar’s Olavarría quarry, according to the Clarín newspaper. The quarry supplies limestone to Loma Negra’s La Amali cement plant.
The cement producer said “The biggest problem is that if they don't solve the problem, and stop the supply raw material, it will complicate cement production."
Poland: Cemex Poland has established a new 50kW solar power plant at its Pruszków ready-mix concrete production plant in Masovian Voivodeship. The company says that it is planning other investments to retrofit renewable energy systems into its operations across Poland.
Materials director Michał Grys said “Cemex is actively addressing the climate challenge by decarbonising our processes. The key to realising our ambitious goals is finding and implementing new low-emission products as well as more sustainable technologies and construction solutions.” He added “Photovoltaic farms are another investment by Cemex Poland in renewable energy sources. Currently, much of the electricity used in our aggregate quarries, cement plants and many concrete plants comes from renewable sources."
Australia: AdBri and Barro Group have signed an agreement to acquire Metro Quarry Group’s sand operations. The business consists oftwo quarries, the Lang Lang quarry and the Nyora quarry, in Victoria. The quarries command a total of 50Mt of sand reserves. AdBri will pay US$21.6m to the companies’ joint venture for the purpose of the acquisition and to supplement the business’ working capital. The partners expect to conclude the deal in November 2021.
Cemex España to acquire a quarry and three ready-mix concrete plants from Hanson Spain
05 October 2021Spain: Hanson Spain has agreed to sell its Madrid quarry and three ready-mix concrete plants in the Balearics to Cemex España. The buyer said that the investments promise a high return and are part of the strategic global strengthening of its vertically integrated positions near high-growth urban centres. It expects the deal to close in early 2022.
Europe, Middle East, Africa and Asia regional president Sergio Menéndez said “This acquisition will allow us to better serve our clients by integrating and complementing our portfolio to provide a comprehensive and sustainable offering in Cemex’s high-growth regions of Madrid and the Balearic Islands.” He added “This is another example of the efforts we make to optimise our portfolio and drive earnings before interest, taxation, depreciation and amortisation (EBITDA) growth through high-yield complementary investments."
Hanson has also sold its aggregates and ready-mix concrete assets in Asturias, Catalonia and Madrid to different buyers. Parent company HeidelbergCement had announced a review of its Spanish assets on 22 February 2021. Their total value was Euro300m.
Tarmac completes repairs on excavator at Dunbar quarry
24 September 2021UK: Tarmac has completed a seven-week repair job on its PC2000 backhaul excavator at its Dunbar, East Lothian, quarry. The East Lothian Courier newspaper has reported that the work consisted of a rebuild of all major components, including the 11t bucket, pins and bushes. The equipment has been in service since 2014. It will next require servicing in 2026. Marubeni Komatsu carried out the work.
Quarry manager Mark Grieve said “With the excavator playing an absolutely key role in our process, this was a major project for Tarmac Dunbar.”
Storm over Slite
08 September 2021Cementa’s prospects for continued mining limestone in Sweden beyond the end of October 2021 have been looking dubious recently. The subsidiary of Germany-based HeidelbergCement wants to carry on mining limestone at its quarries near its integrated Slite plant in Gotland after 31 October 2021 when its current permits expire. However, the Supreme Land and Environmental Court rejected its renewal application in July 2021 on the grounds that the impact of the quarries on groundwater had not been sufficiently investigated. Then the Supreme Court ruled that it had no basis for appeal at the end of August 2021. This leaves the cement producer hanging on for proposed government plans to make legislative changes to keep limestone mining ongoing for another eight months until mid-2022 and then for whatever scheme the legislators cook up next.
In July 2021 construction multinational Skanska publicly said that it was taking the situation ‘seriously’ because its concrete suppliers had warned it of the impending risk that they would potentially be unable to meet demand in the third quarter of 2022. At the same time the Swedish Construction Federation and related bodies noted that up to 175,000 jobs in construction could be adversely affected with a loss of investment of nearly Euro2bn/month due to the predicted cement shortage. In their view, increasing imports in the short term was unrealistic due to capacity constraints at ports and import terminals. Understandably, the Swedish government has been scrambling to keep the quarries open to protect cement supply and has been accused by both the local press and environmental bodies of circumventing legal norms in the process.
This is not a good situation to be in for either Cementa or anyone who might want to use cement locally in the near future. The cement producer operates both of Sweden’s integrated plants, at Slite and Skövde respectively, with Slite holding around 80% of the company’s production capacity. On its own, the Slite plant alone supplies 75% of the country’s cement, with about another 10 – 15% provided by importer Schwenk Zement. As a whole Cembureau data shows that the country’s market was just under 3Mt/yr in 2020 and stable despite the coronavirus pandemic. A small decline in the residential segment was reported, coupled with a ‘flat’ infrastructure segment, although increased demand from wind farm construction was noted. Cementa stopped production at a third local integrated plant, Degerhamn, in mid-2019 due to low profitability at the site and tightening environmental regulations.
Cementa and HeidelbergCement are putting up a fight by publishing lots of information on Cementa’s website about the permit application process and working towards both solutions in the short and longer term. In early September 2021 Nordkalk signed a deal with Cementa to supply it with limestone. However, as Thomas Lind, the head of cement for HeidelbergCement Northern Europe, pointed out in August 2021, the agreement won’t cover the entire shortfall, nor would it be ideal from logistical or environmental angles. On the opposing side, the Swedish Society for Nature Conservation has joined with the Supreme Land and Environmental Court in opposing the quarry permit renewal along with other environmental groups. Plus the government decision to force through a permit reprieve has also given ammunition to its political rivals.
The argument over Slite’s quarry sums up some of the challenges facing society over continued cement production in a world with ever-tougher environmental legislation. Cement plants are likely to face mounting opposition on environmental grounds but most governments will panic when facing the potential consequences of societies running out of essential building materials. There are many ways to avoid this scenario, such as far greater community and political involvement on the part of cement companies, recognition by governments of the importance of building materials, supporting the development and uptake of concrete made with less Ordinary Portland Cement or switching to higher ratios of other building materials and so on. Yet, without preparation, legislators elsewhere will also find themselves in similar positions to the one the Swedish government is in now.
Slite’s problems have arisen in part over a perceived direct threat to local drinking water, although Cementa says that this is absolutely not the case. Typically, cement plants in similar battles find themselves in opposition to local communities due to the immediate impacts of quarrying or production on water, or due to noise or dust. Yet the hidden consequence of clinker production is significant process CO2 emissions with resulting global climate change. The particular tragedy in Gotland is that HeidelbergCement is one of the more sustainable-minded cement companies, with investment to match. In June 2021 it announced ambitions to upgrade the Slite plant to become the world’s first carbon-neutral cement plant through bio-based fuel substitution and a carbon capture and storage unit by 2030. This may be eight years away but it is one of very few full scale cement plant carbon capture upgrades that have been promised worldwide.