Displaying items by tag: Upgrade

US: Ash Grove Cement plans to build a new cement mill at its cement plant in Durkee, Oregon. The project is scheduled to be completed by the end of 2024. The upgrade is intended to allow the plant to manufacture low-carbon cement products.

Serge Schmidt, the president of Ash Grove Cement, said "The transition to low carbon cement production and reducing our environmental footprint is a top priority for Ash Grove Cement. We are always seeking new ways to improve our sustainability performance while providing high-quality cement solutions to our customers. This state-of-the-art finish mill at our Durkee plant will strengthen Ash Grove's position as a leader in low-carbon cement across the Western US."

Romania: Holcim Romania has committed to an investment of over Euro25m to increase the production capacity of its cement plant in Campulung by approximately 20%. This would represent an expansion from 0.76Mt/yr to 0.9Mt/yr, according to the Argeşul newspaper. The company says that the investment will address both the existing need for more cement in the domestic construction market. It will also enhance the sustainability of the plant’s operation, streamline logistics and reduce the volume of CO2 emissions from the long-distance transport of building materials constructions.

India: Orient Cement has commissioned a waste heat recovery (WHR) plant at its Chittapur cement plant in Karnataka. Reuters has reported that the producer plans to subsequently scale up the WHR plant in a second construction phase.

China: Taiwan Cement (TCC) commissioned a 107MWh energy storage project at its Yingde plant in Guangdong province in August 2023. Subsidiary NHOA Energy worked on the project that linked the battery storage capacity to a 42MW waste heat recovery (WHR) system and a 8MWp solar photovoltaic unit. It uses lithium iron phosphate batteries supplied by Ningde Times.

The company’s say that the project is one of the largest industrial microgrids in the world. It is intended to provide energy flexibility to the cement plant by using NHOA Energy’s proprietary energy management system to manage peaks in energy demand and acting as a backup for critical equipment to avoid damage caused by sudden blackouts.

The NHOA Energy storage project is expected to store about 46000MWh/yr of electricity and save just under US$3m/yr in electricity costs. The system will also support the Guangdong Provincial Government’s energy storage development policy and be eligible to associated subsidies of over US$350,000/yr.

Giuseppe Artizzu, the chief executive officer of NHOA Energy, said “NHOA Energy’s proprietary energy management system will optimise the generation and consumption profile of the industrial microgrid, while also supporting the regional grid towards its 100% green energy objective, taking the energy transition in the area one step forward in total accordance with NHOA Group’s and TCC’s shared mission of fostering a positive change for the future of our planet.”

Bangladesh/India: The completion of an upgrade project to Chhatak Cement’s plant has been thrown into doubt due to uncertainty about securing limestone from India. The plant still needs to build a new 17km ropeway conveyor and this has been delayed due to failure to obtain permission on the Indian side of the border, according to the Daily Star newspaper. It is also facing problems procuring limestone in India due to on-going legal proceedings on environmental grounds between exporters in Meghalaya and the government. The Supreme Court of India granted permission for exports in 2022 but the case is still pending. In addition, plans to install a gas line from Sylhet to the plant has not started yet either.

The state-owned cement producer is run by the Bangladesh Chemical Industries Corporation (BCIC). It originally announced in 2016 that it was spending over US$100m to build a new 1500t/day dry production line at the plant to replace an old wet production line. Although the old line originally had a production capacity of 233,000t/yr, it had fallen to around half of this. However, despite the construction of new silos and other equipment at the site, the unit has not been operational since early 2020. The new line was originally planned to start operation in 2020 but this was delayed until 2023. The BCIC has now proposed that completion of the project be extended to mid-2025.

India: The India Cements expects to commission the upgraded grinding unit at its Sankar Nagar cement plant in Tamil Nadu later in September 2023. Hindu BusinessLine News has reported that the producer is undertaking the upgrade in order to increase efficiency and lower the plant’s operating costs. The producer has hired US-based Boston Consulting Group to ascertain other possible improvements to three of its plants in Andhra Pradesh and Telangana. At its Chilamkur cement plant in Andhra Pradesh, it is installing a waste heat recovery (WHR) system, scheduled for delivery in early 2024. FLSmidth and ThyssenKrupp Industrial Solutions are both reportedly conducting ‘detailed studies’ for possible future projects for The India Cements.

The core of the Caribbean cement industry consists of the Dominican Republic (with 5.9Mt/yr in integrated capacity), Cuba (4.7Mt/yr) and Jamaica (3.5Mt/yr). Haiti and Trinidad & Tobago also command small, single integrated plants, while there are numerous grinding plants and cement terminals along the region’s extensive coastlines. The industry has been the subject of new commercial and capital expenditure-related announcements in the past fortnight. Regarding the Caribbean’s cement producers, these developments seem to lack a single clear direction.

Caribbean market leader Cemex revealed that it was considering selling up in the region’s largest market, the Dominican Republic, on 1 September 2023. Bloomberg cited unnamed sources stating that the Mexico-based cement giant hired financial services JPMorgan Chase to explore the possible divestment of local subsidiary Cemex Dominicana. Exactly one year had passed since Cemex completed its sale of Cemex Costa Rica and Cemex El Salvador to Guatemala-based Cementos Progreso for US$329m. Sources clued in on the latest development reportedly expect Cemex Dominicana to command a selling price three times greater than the Central American divestments combined.

Cemex has discussed its scattered disposal of global assets since 2019 as a strategic realignment towards its main markets, in particular those in North America and Europe. On this understanding, the Caribbean straddles an invisible line between Cemex’s strategic core in North America and Central America on its periphery.

Just to the north of the line lies Jamaica. There, Cemex subsidiary Caribbean Cement will expand its Rockfort cement plant by 30% to 1.3Mt/yr through a US$40m upgrade, scheduled for completion in early 2025. Late last week, Caribbean Cement told investors that the upgrade will equip the plant with new equipment, including a new dosing system. The producer expects this to help the Rockfort plant to further increase its alternative fuel (AF) substitution rate. It co-processed 5.6% AF in its kiln during the first half of 2023, more than double its first-half 2022 substitution rate of 2.7%. Caribbean Cement began exporting cement to Turks and Caicos on 16 September 2023, and plans to increase its shipments there and elsewhere. Managing director Yago Castro reassured Jamaicans that Caribbean Cement would also continue to help meet domestic demand.

Currently, Caribbean Cement and fellow Jamaican producer Cement Jamaica compete in the domestic market against imports, including some cement from Dominican Republic-based Domicem. This enters the country via Buying House Cement’s Montego Bay terminal. Montego Bay Cold Storage, an affiliate of Buying House Cement, shared plans for a second, US$8m cement terminal in the city earlier in 2023. The facility is expected to help meet growing demand from residential and hospitality sector construction.

More new production capacity is soon to come online in the form of a 1.23Mt/yr grinding plant in the Dominican Republic. Cemento PANAM will own and operate the plant, while Germany-based Gebr. Pfeiffer will supply a 3750 C-4 vertical roller mill via engineering, procurement and construction contractor CBMI Construction.

In a market where the nearest cement exporter is only a short sail over the horizon, producers have to compete fiercely for their market shares, even at home. Disputes over Caribbean Community member states’ rights to protect domestic cement production have gone as high as the Caribbean Court of Justice. It ended Barbados-based Rock Hard Cement’s hopes of resuming exports to Trinidad & Tobago last year.

The Caribbean’s cement producers will be acutely aware of Cementos Argos’ planned expansion of its north-facing Cartagena, Colombia, cement export facility, hot on the heels of a previous, US$42m expansion. The South American giant says that it is targeting the US, where it anticipates an upcoming construction boom. Caribbean countries present other possible markets for producers like Cementos Argos, yet their cement industries might equally emulate any successes it enjoys in the US. Like Argos in Colombia, Jamaica’s Caribbean Cement is part of a group with an existing presence in the US. Its on-going investments in the Rockfort plant signal a readiness to catch the trade winds rapidly picking up in the Caribbean.

UK: Cemcor has migrated its existing SAP asset management system over to IBM Maximo Application Suite (MAS). Cemcor says that IBM MAS offers a 360°, real-time view of its operations across multiple sites, enabling the company to resolve maintenance challenges, optimise its assets, increase the lifespan of essential equipment and remove inefficiencies. Peacock Engineering delivered the new system and will continue to provide support services with the platform.

Peacock Engineering’s chief operating officer Matt Deadman said “We’re thrilled to be working with Cemcor over the course of the next three years. We have already completed the first stage of our change programme with the successful delivery of its new enterprise asset management system. MAS is one of IBM’s sustainability software solutions. It will provide Cemcor with a clearer view of its assets, which include heavy plant and processing equipment, and help in mitigating the current challenges found in its maintenance programme.”

Germany: Engineering company GEA has installed a carbon capture pilot plant at the Phoenix Zementwerke cement plant in Beckum, North Rhine-Westphalia. The supplier will now conduct testing over ‘several’ months, but said that it is confident that the cement plant is suitable for an installation to capture over 90% of its CO₂ emissions. GEA’s carbon capture systems run on energy from waste heat recovery, with minimal to zero extra electrical input.

Phoenix Zementwerke managing director Marcel Gustav Krogbeumker said “We consider carbon capture a very exciting technology. Thanks to GEA's decades of experience in emissions control, I am very positive that together we can develop and implement a solution."

Jamaica: Caribbean Cement plans to launch an upgrade to expand its Rockfort cement plant’s capacity by 30% to 1.3Mt/yr in October 2023. The producer says that the expansion will cost US$40m and that the new capacity will come online in early 2025. The work will include enlargements of multiple kiln sections and the installation of a new coal dosing system, clinker cooler and clinker transport system.