Displaying items by tag: Upgrade

Asia Cement unveiled a selective catalytic reduction (SCR) unit at its Jecheon plant this week. The Korea Cement Association (KCA), government representatives and staff from other cement companies were present at a demonstration. The US$25m project has been supported by the Ministry of Industry and Trade. It was originally announced in late 2023, has been running on a pilot basis for two months, and is expected to start full operation shortly. The cement sector in South Korea will be subject to tighter emissions controls in mid-2027 and further SCR installations are expected.

Earlier in 2025 the KCA estimated that installing SCR units on all 35 active clinker production lines in the country would cost around US$675m with an additional annual running costs. One point to note here is that one of the local sector’s commonly used alternative fuels (AF), waste synthetic resin, impedes the SCR process. Subsequently, it has to be run at higher temperature, which increases running costs.

The local cement industry has faced a mixed response to its uptake of AF in recent years. One strand of this has been a movement against so-called ‘trash cement.’ This culminated in the Ministry of Climate, Energy and Environment amending the Waste Management Act in November 2025 to make it mandatory for cement products to disclose on the packaging the means to check which ‘waste’ materials were used in their manufacture. This appears to include both supplementary cementitious materials (SCM) and AF. The government is now intending to make it possible for citizens to check the type of cement used in newly-constructed buildings. The KCA reported that the share of blended cements (i.e. those made with SCMs) was 15% in 2024. The rate had gradually decreased over the last decade from 19% in 2015. South Korean cement producers had a AF co-processing rate of 35% in 2021. The main fuels being used in this way were waste synthetic resin, waste tires and waste rubber, with the first being used the most.

Graph 1: Cement sales in South Korea, 2019 - 2025. Source: Korea Cement Association.

Meanwhile, cement producers in South Korea have turned to exports in 2025 in response to poor construction levels and growing input costs. The KCA revealed this week to local press that exports are expected to grow by 52% year-on-year to 4.5Mt in 2025 from 3Mt in 2024. Local shipments, however, are anticipated to fall by 16.5% to 36.5Mt from 42.9Mt. Producers have focused their export strategies towards South America and Africa in response to competition in the export market in South-East Asia from China and Vietnam, producers. For example, Halla Cement started targeting Cameroon and Guinea in 2025 following previous favourite destinations such as Peru and Chile. Exports are still lower than they were in the mid-2010s. In 2015, for example, the country exported 7.3Mt of cement and clinker. However, the share of the share of exports to total sales is at its highest level for at least a decade.

The necessity of running kilns at certain levels rather than simply idling them has also emerged in recent reporting. The reason given was to “...maintain a minimum allocation of carbon emission allowances.” The detail is lacking but this may sound familiar to readers familiar with the European Union (EU) Emissions Trading Scheme (ETS). Following the financial crash in 2008, for example, an over-allocation of carbon credits enabled some producers to make money despite falling demand for cement. This is not to say that the same thing is happening in South Korea. Merely, that any ETS can potentially face structural issues in a declining market.

The South Korean cement market is facing tough times, with the KCA further anticipating a decline of 1.3% in 2026. Environmental regulations such as the new emissions controls are further putting up costs. One peculiarity of the local market is the scrutiny that the easiest routes to decarbonisation, SCAs and AFs, are facing. Giving the public the tools to check this kind of information is admirable. Yet it creates extra hurdles for a sector trying to decarbonise at the same time as a construction market construction. Good luck!

The Global CemFuels Asia Conference will take place on 2 - 3 February 2026 in Bangkok

Türkiye: The European Bank for Reconstruction and Development (EBRD) is providing a €50m loan to cement producer Çimsa to support its decarbonisation efforts. According to the EBRD, the financing will fund a calcium aluminate cement (CAC) kiln and decarbonisation upgrades for existing grey and white cement kilns at Çimsa’s Mersin plant. CAC production has a ‘significantly’ lower carbon footprint than traditional grey cement, according to the producer.

The EBRD said that the project aligns with Türkiye’s Industrial Decarbonisation Investment Platform, the world’s largest industrial decarbonisation programme, which provides policy guidance and low-carbon pathways for hard-to-abate sectors, including cement.

Erdem Yasar, EBRD Deputy Head for Türkiye, said that the partnership supports both Çimsa’s competitiveness and broader industry sustainability.

North Korea: State-owned Komusan Cement has successfully deployed alternative raw materials derived from quarry overburden in cement production at its Komusan cement plant in Hamgyŏng Province. State-run Korean News has reported that the producer presented the resulting products at a provincial building materials exhibition.

The Komusan cement plant reportedly had ‘decades-worth’ of overburden in stockpiles, but previously lacked the equipment to properly process it.

This week we covered Capitol Aggregates’ order of an alternative fuels (AF) system from ATS Walter USA. The story is notable because it is an AF project for a cement plant in the US. Thermal substitution rates (TSR) of AF in the US have typically been lower than in the European Union (EU), but this could be changing.

The order was confirmed publicly at the end of September 2025. The subsidiary of ATS Group will supply a solid AF metering and conveying system to the integrated plant in San Antonio, Texas. The system will include a moving floor receiving station, chain belt conveyors, a screen and a separator, dosing equipment, an air-supported belt conveyor and an injection system. ATS Walter says that, by the end of 2026, it will have supplied four AF projects in North America. As an aside, Capitol Aggregates also mentioned in the press release that it “...views sustainability as essential to long-term success.” This sentiment is backed up by the fact that the plant built an early commercial carbon capture unit in the 2010s!

Data from the American Cement Association (ACA) revealed that the AF TSR in the US reached 16% in 2023 from 14.6% in 2022. This compares to a 58% rate in the EU in 2022. It is also worth noting that, in the US the share of gas in the cement industry energy mix rose from 25% to 31%. The ACA attributed this change to a falling price of gas. It added that the coal and petroleum share of the fuel mix fell to its lowest level since 1974. The point here is that the energy mix used by cement plants changes over time regardless of sustainability trends.

Research by LEK Consulting estimated that 60 of the 87 cement plants in the US had a TSR of below 20% in 2023. 39 of these were believed to have a TSR of under 5%. It summarised that hazardous waste and tyre-derived fuels have tended to predominate in the US compared to refuse-derived fuel (RDF) in the EU and elsewhere. LEK went on to say that its research suggested that a quarter of cement plants in the US were likely to install an AF feeding system in 2024 or 2025. This is likely to be the highest rate of AF uptake in the US cement sector to date.

The ACA reckons in its sustainability roadmap that with the right policies and regulations the country’s AF TSR could reach as high as 50%. Its policy suggestions include: reduce permitting barriers to use of so-called non-hazardous secondary materials (NHSM) fuels in industrial manufacturing; treating waste-to-industrial energy as valid recycling use; building robust recycling infrastructure and markets that incentivise the use of non-recycled material streams as industrial AF; community education and support for use of low carbon AF; and increasing the use of NHSMs to divert these materials from landfills. This can be mostly summarised as supporting the uptake of RDF through better permitting and building up the infrastructure and markets for it. LEK also identified the same issue. It called for the adoption of landfill reduction targets or zero-landfill policies by commercial and industrial waste generators. However, LEK believes that, even if this were done, current sources of high-quality RDF in the US would not be able to increase the TSR to even 20%.

News from Capitol Aggregates and others about AF projects in the US are encouraging. If LEK’s research is indicative then a step change in the TSR in the country’s cement sector is already underway. The beauty of AF usage is that it can both potentially cut fuel costs and reduce CO₂ emissions. It won’t be easy as new supply chains for refuse byproducts are built and utilised. Yet, as the ACA is advocating, it is possible and worthwhile.

The 1st CemFuels Asia Conference will take place in Bangkok in February 2026 and the 19th Global CemFuels Conference will take place in September 2026 in Geneva

Saudi Arabia: Northern Region Cement Company (NRCC) has announced the signing of a contract for the construction of a US$8.7m, 20MW solar power plant in Turaif City. The plant will be supplied by Sinoma Overseas Development. The company says that the contract is in line with Saudi Vision 2030 and the company’s strategy to increase the use of renewable energy. Construction will take place over 10 months, with operations expected to begin in late 2026.

Sinoma Overseas Development will carry out the full scope of engineering design, procurement, supply and delivery during the contract duration time, in addition to civil construction, installation and commissioning.

Jamaica: Caribbean Cement Company has exported 3000t of cement to Curaçao, following the completion of its US$41.8m debottlenecking project at the Rockfort plant in June 2025. The upgrade expanded production capacity, allowing the company to sustain ‘record output’ of cement and clinker, according to Our Today news.

Managing director Jorge Martinez said the shipment demonstrated the company’s ability to serve both domestic and regional markets. “What you are witnessing is a company that not only fully resources the local market but also has the strengthened capacity to export. Our first commitment is to Jamaica, and now that we can consistently meet domestic demand, we are complementing the local market with exports, leveraging the surplus from our expanded capacity,” he said.

The cargo was loaded onto the MV Suzie Q on 22 September 2025. Curaçao’s construction sector is reportedly growing on the back of tourism-led economic activity, with demand rising for real estate, roads, public spaces and utilities. Caribbean Cement said that it plans to expand its export presence across the Caribbean Basin.

Spain: IKN is progressing with its satellite replacement project at Grupo Cementos Portland Valderrivas’ Fábrica Els Monjos plant. The project includes the replacement of a cooler with an IKN grate cooler, with a new cooler building, burner and a complete vent air dedusting system. On pier two, IKN is fitting a new shell section and replacing the equipment on the pier, including a new base frame, rollers with bearings and CFU.

The company reported two major milestones: the new kiln section, including the tyre, was successfully lifted into place as one piece, shortening installation time; and the pre-assembly and positioning of the cooler, which was moved into its final position.

There have been a few burner and related stories to note in the cement industry news this week. Firstly, Canada-based PyroGenesis announced that it had signed a deal with an unnamed-European cement company to supply a plasma torch system for a ‘calcination furnace.’ Around the same time UBE Mitsubishi Cement (MUCC) revealed that it had successfully tested natural gas co-firing at MUCC’s Kyushu Plant using a newly developed burner.

The PyroGenesis project is a potential game-changer for the sector because it alters the way cement production lines are heated. Roughly one third of CO₂ emissions associated with cement manufacture arise from the fossil fuels used to heat the kiln and the pre-calcination system. Cut out some of that and the specific CO₂ emissions of cement production drop. PyroGenesis’ approach uses electricity to generate high-temperature plasma. This then gives the cement plant the option of obtaining its electricity from renewable sources. PyroGenesis signed a memorandum of understanding with the power conversion division of GE Vernova in March 2025. This had the aim of targeting high temperature processes, such as cement production, with electric plasma torches. The current deal with a cement producer has been valued at US$871,000 with delivery to the client scheduled for the first quarter of 2026.

We don’t know who the mystery client might be. However, Heidelberg Materials reportedly operated a 300kW plasma-heated cement kiln at its Slite cement plant in February 2025 as part of the ELECTRA project. The producer said it had achieved 54 hours of continuous operation, with 60% CO₂ concentration in the flue gas. The aim was to reach 99%. It then said that it was planning to build a larger 1MWel furnace at its Skövde cement plant in 2026 with tests to continue in 2027. In an interview with Global Cement Magazine in May 2025, Heidelberg Materials said that it was using commercially supplied CO₂ as the ionising gas in the plasma generator but that it was considering using captured CO₂ from the production process in the future. It also mentioned issues from its trials such as the effective ‘flame’ being hotter than the conventional process but not as long. This increased the reactivity of the resulting clinker. Finally, Heidelberg Materials noted from a feasibility study that a 1Mt/yr cement plant would need around 170MW of plasma generation, but that typical plasma generators topped out at around 8MW. Hence, any full set-up would likely require multiple plasma generators. For more on non-combustion style kilns see GCW561.

UBE Mitsubishi Cement’s burner installation is more conventional but again it is concerned about sustainability. In this case the line has tested burning natural gas. The cement producer says it is the first such installation at a cement plant in Japan to do so commercially. The burner was jointly developed by UBE Mitsubishi Cement, Osaka Gas and Daigas Energy. Firstly, the plant will consider switching to natural gas. This will reduce the unit’s CO₂ emissions from fuel combustion. However, a later step being considered is to move on to e-methane. This is a synthetic methane made from CO₂ and hydrogen using renewable energy.

Finally, another recent story on this theme is the installation of a new satellite burner by Northern Ireland-based Mannok at its Derrylin cement plant in August 2025. This is Phase One of a two-part project to upgrade the pyro kiln system at the site. The cement company worked with FLSmidth on the €2.5m upgrade. The new burner has now allowed the plant to burn solid recovered fuel (SRF) by up to a 30% substitution rate in the kiln. This followed a project, also with FLSmidth, to install a FuelFlex Pyrolyzer in 2022. This is used to replace coal with SRF in the pre-calcination stage of cement production. Phase two will be an upgrade of the main burner to a new Jetflex burner. Once this part is completed, Mannok is aiming for an overall substitution rate of 65 - 70% on the whole pyro-processing system.

Burners at cement plants are replaced fairly commonly. However, the supplier companies don’t advertise every installation due to the commercial relationships with their clients and other factors. Hence the more interesting upgrades tend to get the publicity. Typically this means if a burner uses new technology, meets sustainability goals and so on, we find out about it. It’s a similar situation when a new heating technology such as plasma is trialled. Changing trends in fuel types for cement plants suggest different types of conventional burners. Some of this can be seen in the burner stories above with the trend moving towards ever higher rates of alternative fuels usage. Combustion in cement kilns is here to stay for the time being but plasma trials will be watched carefully.

The 18th Global CemFuels Conference & Exhibition on alternative fuels for cement and lime 2025 will take place in Milan on 17 - 18 September 2025

Ireland/UK: Mannok has completed Phase 1 of a two-phase upgrade to its pyroprocessing system with the installation of a new satellite burner in collaboration with FLSmidth. The €2.5m project enables the use of solid recovered fuel (SRF) as a replacement for coal, achieving up to 30% substitution and reducing CO₂ emissions by 23,000t/yr.

Phase 2 will involve upgrading the main burner to a Jetflex system, targeting 65–70% coal substitution across the kiln. Mannok produces about 1.4Mt/yr of cement for customers across the UK and Ireland.

India: Nuvoco Vistas will invest US$24m to expand its grinding capacity in eastern India by 4Mt/yr, according to local press. A new mill will be installed at the Arasmeta plant in Chhattisgarh, with upgrades, process improvements and debottlenecking at Jojobera (Jharkhand), Panagarh (West Bengal) and Odisha plants.

Phase one will add 1Mt/yr by the third quarter of the 2026 financial year, 2Mt/yr by the end of 2025, and 1Mt/yr by the 2027 financial year. The company said that the work at Jojobera, Panagarh and Odisha will be achieved with limited capital expenditure.

Following the acquisition of Vadraj Cements, Nuvoco Vista’s total capacity stands at 31Mt/yr, with eastern capacity set to rise by over 20% to 23Mt/yr within 18 months. Capacity utilisation was 78% as of March 2025.