Displaying items by tag: Upgrade

UK: GyroMetric Systems has signed an agreement to install digital monitoring equipment on a 11kV raw mill drive at Tarmac’s Tunstead cement plant in Derbyshire. Measured digital parameters will include dynamic torque across the coupling, radial displacement of the shaft (and therefore misalignment), and torsional vibrations of the drive system. The data will also provide information on the condition of the gearbox. GyroMetric Systems is controlled by Remote Monitored Systems. No value for the order has been disclosed.

US: Lehigh Hanson has started construction work on a US$600m upgrade to its Mitchell cement plant. The groundbreaking ceremony follows approval of an air permit by the Indiana Department of Environmental Management (IDEM) in July 2019, according to WBIW radio. The subsidiary of Germany’s HeidelbergCement is building a new production line to replace the existing three lines at the site. Start-up for the line is scheduled for the third quarter of 2022.

Russia: Sibirsky Cement has issued details of upgrade work at its Topkinsky Cement plant. Cement grinding mill No. 9 was upgraded with replacement housing and updated mill equipment. Minor overhauls have also been made on mills 1 and 2 including work on the gearbox. Restorative work has also been conducted on the rotary kilns 1, 4 and 5 and on all packaging lines.

Pakistan: Gharibwal Cement has blamed reduced exports due to tensions on the Pakistan-Indian border and rising input costs for a reduction in its sales. Its net sales fell by 3% year-on-year to US$72.3m in the year to 30 June 2019 from US$74.5m in the same period in 2018. Its cement dispatches fell by 11.4% to 1.68Mt from 1.89Mt. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) dropped by 6.5% to US$18.7m from US$20m.

The cement producer said that work on a new 0.15Mt clinker silo is in progress and this is expected to be completed by June 2020. It is also building a rainwater reservoir to capture precipitation for use in the production process. The company operates a 2.1Mt/yr integrated plant at Ismailwal in Punjab Province.

Philippines: Cemex Philippines has ordered a MVR type mill for cement raw material grinding from Germany’s Gebr. Pfeiffer for a plant in Antipolo. The order also includes a MPS mill to grind coal. Gebr. Pfeiffer said that the order was received through a Chinese general contractor. No value for the order or timescale was disclosed.

Saudi Arabia: Al Jouf Cement has signed a six-month technical contract with China’s Riga Company to convert its second production line to produce white cement. The contract was signed to coincide with the arrival of the project team that will handle the conversion. No value for the upgrade has been disclosed.

Kyrgyzstan: Kant Cement has upgraded its packing equipment at its integrated plant. Russia’s Vselug supplied a Turbo K8 filling machine and Germany’s Berg provided compressors, according to Cement and its Applications magazine. The company plans to sell at 60% of its products in 25kg and 50kg following the upgrade.

The plant has also been installing general upgrades at the site, including a new combination burner from Austria’s Unitherm Cemcon in 2018. It is also planning to upgrade an electrical distribution substation by the end of 2019 to reduce interuptions to production.

UK: Fuchs Lubricants is building a new Euro5.5m raw materials warehouse at its headquarters in Staffordshire. Work on the project started in August 2019 and it is due for completion in the second quarter of 2020. Once completed it will ‘significantly’ increased the amount of raw materials the business can store on-site.

The warehouse will have a capacity of approximately 4000 pallet spaces, with ability for automatic or manual storage place allocation. Two wire-guided driverless Very Narrow Aisle trucks will operate in the unit. Warehouse Control and Warehouse Management Systems will streamline the process, with benefits including goods receipt entry and booking, a paperless put away process, inventory support and batch traceability.

Egypt: Siemens has submitted an integrated survey of the digitalisation potential of various industries in four zones to the Ministry of Industry (MoI) with a view to improving the competitiveness of the country’s products. Daily News Egypt has reported that the Germany-based technology company has already signed contracts for the supply of digital efficiency solutions with El Ameria Cement and Lafarge Egypt. It is also negotiating with Misr Beni Suef for the installation of thermal emission measuring units at its 3.5Mt/yr integrated cement plant in Beni Suef, Maadi.

Dalmia Cement threw down the gauntlet this week with the announcement of a large-scale carbon capture unit (CCU) at one of its plants in Tamil Nadu, India. An agreement has been signed with UK-based Carbon Clean Solutions Limited (CCSL) to use its technology in building a 0.5Mt/yr CCU. The partnership will explore how CO₂ from the plant can be used, including direct sales to other industries and using the CO₂ as a precursor in manufacturing chemicals. No exact completion date or budget has been disclosed.

The move is a serious declaration of intent from the Indian cement producer towards its aim of becoming carbon neutral by 2040. Dalmia has been pushing its sustainability ‘journey’ for several years now hitting targets such as reaching 6Mt of alternative raw materials usage in its 2018 financial year and reaching a clinker factor of 63% at the same time. In an article in the November 2018 issue of Global Cement Magazine it said it had achieved CO₂ emissions of 526kg/t from its cement production compared to 578kg/t from other Indian members of the Cement Sustainability Initiative (CSI). In its eastern operations it had gone further to reach 400kg/t.

Using CCU is the next step to this progression but Dalmia’s approach is not without its caveats. Firstly, despite the size of the proposed project it is still being described as a ‘large-scale demonstration.’ Secondly, the destination of all that captured CO₂, as mentioned above, is still being considered. CCSL uses a post-combustion capture method that captures flue gas CO₂ and then combines the use of a proprietary solvent with a heat integration step. Where the capture CO₂ goes is vital because if it can’t be sold or utilised in some other way then it needs to be stored, putting up the price. Technology provider CCSL reckons that its CDRMax process has a CO₂ capture price tag of US$40/t but it is unclear whether this includes utilisation sales of CO₂ or not.

The process is along similar lines to the Skyonic SkyMine (see Global Cement Magazine, May 2015) CCU that was completed in 2015 at the Capitol Cement plant in San Antonio, Texas in the US. However, that post-combustion capture project was aiming for 75,000t/yr of CO₂. Dalmia and CCSL’s attempt is six times greater.

Meanwhile, Cembureau, the European cement association, joined a group of industrial organisations in lobbying the European Union (EU) on the Horizon Europe programme. It wants the budget to be raised to at least Euro120m with at least 60% to be dedicated to the ‘Global Challenges and European Industrial Competitiveness’ pillar. This is relevant in a discussion on industrial CO₂ emissions reduction because the scheme has been supporting various European cement industry projects, including HeidelbergCement’s work with the Low Emissions Intensity Lime And Cement (LEILAC) consortium and Calix at its Lixhe plant in Belgium and its pilots in Norway. As these projects and others reach industrial scale testing they need this money.

These recent developments provide hope for the future of the cement industry. Producers and their associations are engaging with the climate change agenda and taking action. Legislators and governments need to work with the cement sector to speed up this process and ensure that the industry is able to cut its CO₂ emissions while continuing to manufacture the materials necessary to build things. Projects like this latest from Dalmia Cement are overdue, but are very encouraging.