Displaying items by tag: Slag

Ecuador: Union Andina de Cementos (UNACEM) has been recognised as an eco-efficient company by the Ministry for the Environment. The certification is given to companies that have demonstrated environmentally friendly production. Unacem submitted four case studies to qualify for the certification, according to La Hora. These included examples of using slag to produce clinker and co-processing alternative fuels like palm kernel shell and waste oils.

Tata Steel put up its UK business for sale last week. The Indian multinational declared that enough was enough having reported losses of over Euro2.5bn in the territory over five years. Non-UK readers may well wonder what the fuss is about. UK crude steel production comprised 10.9Mt in 2015 or about 0.7% of global production according to World Steel Association data according to World Steel Association data. By contrast the country produced 9.3Mt of cement in 2014 or about 0.2% of world production according to CEMBUREAU data according to CEMBUREAU data.

The UK’s flailing steel industry is worth discussing here for two reasons. Firstly, any decline in the local iron and steel industry will have implications for the supplementary cementitious materials (SCM) market as slag levels vary. Secondly, the cement industry in Europe may have lessons for a fellow heavy industry facing capacity rationalisation.

UK ground granulated blastfurnace slag (GGBS) production levels are low compared to total world supply. However, the UK Competition Commission certainly took note of the GGBS market in 2014. It was worried by LafargeTarmac’s and Hanson’s prominence in both the local GGBS supply chain and local cement production. At that time it ordered the HeidelbergCement subsidiary Hanson to sell one of its slag grinding plants to increase competition in the supply chain for GGBS. A GGBS plant in Scunthorpe was eventually sold to Francis Flowers in July 2015.

The general point here is that a Tata sale of its UK operations could have ramifications for the UK GGBS sector as existing deals are renegotiated following the shakeup. It would be even worse for the local slag market if any of the plants closed. No doubt the Competition Commission would also want to have its say to maintain some sort of competition in an already concentrated market. The UK cement market has been the bright spot in the multinational cement producers’ European regions in 2015. However, construction growth is starting to slow again with hints that the looming European Referendum in June 2016 may be having a negative effect. Uncertainty over GGBS supplies is not helpful in this atmosphere.

A wider lesson for other national cement industries looking in is that if Chinese steel continues flood the world market it will also hit the cement industry. Tata’s woes have been squarely blamed on China dumping its steel on the world market. Various jurisdictions promote the use of SCM cements and concrete for their low-carbon and sustainability properties. If local or existing GGBS supplies are hit then the cement industries may be penalised while the lawmakers and competition bodies play catch-up.

The wider point about heavy industry reducing its production capacity is one that the European cement industry will be well used to. Spain, for example, has seen its cement production drop from 55Mt in 2007 to 15Mt in 2014 according to Oficemen data. Alongside this, demand for cement has dropped to levels not seen since the 1960s. The European response has been to shut plants, sell assets and to merge companies.

The big question following the 2008 recession is whether ‘this’ is the new normal for mature construction markets. Eight years later global interest rates are still lagging and China’s economy is slowing down. All of the European infrastructure was built long ago meaning that steel and cement will only be required to maintain it. Luckily it looks likely that demand for SCMs should stay buoyant as industries are encouraged to decarbonise. The problem though is where the slag comes from. Oversupply in the short term in areas like Europe might be great for cement producers but as the iron and steel industries readjust to market reality there might be a hangover in store.

India: Kiran Global Chems has launched Geocement, an environmentally-friendly branded cement. The company claims that the product is stronger than Ordinary Portland Cement and that it does not require water for mixing or curing, according to local media.

Geocement is made from Geopowder and Geobinder, other products also made by Kiran Global Chems. Geopowder uses industrial by-products such as fly ash, rice husk ash, slag, activated clay and alumina. At construction sites it can be mixed with the company's proprietary Geobinder liquid and aggregates to make concrete. The company claims that Geocement does not require water curing and attains maximum strength within seven hours. Kiran Global Chems has also launched Geocrete, a Geocement concrete made with its powder and binder for various industrial applications.

"We have started distributing this to the bulk customers, such as builders and now we are launching the brand for retail. We are planning to sell it through e-commerce," said M S Jain, chairman of Kiran Global Chems. The price of Geocement will be slightly higher than normal cement, but it promises lower finished building cost and less construction time and labour. The company intends to target southern Indian states in 2016.

Kiran Global is also preparing a US$29m expansion programme to set up 12 Geobinder units, 12 Geopowder plants, two precast concrete units and four grinding units across the country. The expansion, is intended to cut logistics cost, will result in 4Mt of capacity with a potential turnover of up to US$300m by the 2018 – 2019 financial year. The company has an in-house research and development centre, accredited by the Union Ministry of Science and Technology, and has been conducting geopolymer research in collaboration with leading research institutes.

India: JSW Cement has ordered eight 90t/hr roller press slag grinding units from KHD Humboldt Wedag India Private Ltd (India) and KHD Humboldt Wedag GmbH (Germany) for its plants in India.

US: Essroc, part of Italcementi, has acquired the Holcim (US) slag cement grinding plant in Camden, New Jersey, according to MarketLine. As part of the transaction, Essroc will also obtain Holcim's cement terminal in Everett, Massachusetts, US. Upon completion of the transaction, Holcim's staff in Camden and Everett will join Essroc. The transaction is expected to be completed later in 2015. The acquisition will allow Essroc to strengthen its position in the sustainable building products market.

US: Essroc Italcementi Group has signed an agreement with Holcim to purchase its slag cement grinding facility in Camden, New Jeresy. As part of the transaction, Essroc will also obtain Holcim's cement terminal in Everett, Massachusetts. The acquisition will finalise when the pending Holcim and Lafarge merger completes later in 2015.

"The acquisition of the Camden slag grinding facility reiterates Essroc's commitment to the northeast market," said Francesco Carantani, Essroc's president and chief executive officer. "With the focus on sustainability and durability, there is a projected growth in the demand and usage of slag cement."

The Camden facility can produce upwards of 700,000t/yr of slag cement. Essroc currently produces slag cement at its Picton, Ontario, and San Juan, Puerto Rico, cement plants and at its slag grinding facility in Middlebranch, Ohio. With the addition of Camden, Essroc has a combined annual production capacity in excess of 1Mt/yr. Holcim's staff in Camden and Everett will join Essroc once the transaction completes.

China: Loesche GmbH has completed work on the largest slag mill in the world for Shanxi Taigang Stainless Steel Co (TISCO) in Taiyuan, China achieving a new record product rate of producing 255t/hr blast-furnace slag meal. The Loesche type LM 63.3+3 vertical mill for grinding granulated blastfurnace slag was originally ordered by the Taigang Group International Trade Co in September 2011. It started operation in March 2014.

At the TISCO steelworks the LM 63.3+3 has now been used for the pure grinding of granulated blast-furnace slag for the first time. The mill is driven by a motor with an output of 7400kW, the most powerful motor to have been installed so far by Loesche in a mill. The projected guarantee values of 255t/ hr granulated blast-furnace slag at a fineness of 4400 Blaine are reliably attained here. This is also ensured by the newly developed Loesche LDC classifier, used in the grinding plant and ideally customised to the Loesche mills.

The first Loesche LM 63.3+3 mill started production at Nallalingayapalli, India in 2009. It attains a peak value of 367t/hr ordinary portland cement at 3000 Blaine or 371t/hr portland pozzolana cement at 3400 Blaine.

Turkey: Gebr. Pfeiffer SE has received another order from Bolu Cimento Sanayii A.S., Turkey. In addition to the three MPS mills that Bolu Cimento ordered in December 2013 for the Kazan, Ankara Province plant, this order will see Gebr. Pfeiffer supply an MPS 4500 BC mill for the grinding of granulated blast furnace slag, which will be set up at Bolu Province plant. The mill will be identical to the cement mill that will be installed in Kazan.

The mill is designed to reach a throughput rate of 85t/hr of slag, ground to a product fineness of 4500 - 4750cm²/g. Gebr. Pfeiffer's scope will include the core components of the mill and classifier as well as the mill gearbox. The required drawings and parts lists for the local manufacture of housing and steel parts as well as documents for quality control will also be produced and supplied.

The delivery of the mill scheduled to start at the end of 2014 and will have been completed by early 2015.

UK: Britain's competition watchdog has asked HeidelbergCement to sell one of its three plants that produces ground granulated blast furnace slag in the UK. The Competition Commission said the move is intended to increase competition.

UK: The Competition Commission (CC) has demanded that Lafarge Tarmac sell one of its cement plants in the UK to create a fifth cement company in the country to increase competition in the market. The CC also intends to increase competition in the supply chain for ground granulated blast furnace slag (GGBS) by forcing Hanson to sell one of its GGBS production facilities. The CC is also introducing measures to limit the flow of information and data concerning cement production and price announcements.

"We believe that the entry of a new, independent cement producer is the only way to disturb the established structure and behaviour in this market which has persisted for a number of years and led to higher prices for customers," said CC Deputy Chairman and Chairman of the Inquiry Group, Professor Martin Cave.

The measures follow a two year investigation which found that both structure and the conduct in the cement sector restricts competition by aiding coordination between the three largest producers: Lafarge Tarmac, Cemex and Hanson. Competition problems also arose from the UK having only one domestic producer of GGBS in the UK (Hanson) with exclusive rights to use the output of Lafarge Tarmac, the single domestic producer of granulated blast furnace slag (GBS), which is the main raw material input into GGBS. The CC estimates that the lack of competition for both of these issues may have cost UK customers up to Euro60m/yr.

The final report follows the publication of the CC's provisional findings in May 2013 and an Addendum to the provisional findings and its provisional decision on remedies in October 2013.