Displaying items by tag: Upgrade

Argentina: Germany’s KHD has been awarded a contract by Holcim Argentina for the upgrade project of a clinker production line at its Malagueño cement plant near Córdoba. Holcim Argentina intends to recommission its mothballed 1650t/day production line, which originally was supplied by KHD Humboldt Wedag in the early 1980s. Commissioning for the updated line is planned for mid-2019.

KHD’s scope includes the engineering and supply of mechanical equipment for raw material preparation and clinker production as well as electrical equipment in order to modernise and recommission the currently mothballed production line no 1.

Core equipment for the project includes: tertiary raw material crusher with a capacity of 250t/hr; ball mill drive for existing ball mill and new feeding equipment for raw meal preparation; separator for raw material grinding plant; kiln feed dosing system; four-stage preheater; rotary kiln 4.4m x 64m and drive system; revamping of existing clinker cooler with ‘fourth generation’ walking floor grate; main bag house for kiln/mill and clinker cooler; and main process fans.

Jamaica: Caribbean Cement plans to raise the production of gypsum and limestone from its quarries. It intends to increase the size of its Halberstadt Gypsum Quarry to 200,000t/yr and build a new 800,000t/yr limestone quarry at Harbour Head, according to the Gleaner newspaper. Both quarries will be near to the cement producer’s plant at Rockfort in Kingston. The plan requires approval from the National Environment & Planning Agency.

Caribbean Cement says that the expansions to its quarrying operations are required to secure supply of these materials. It has not commented on the size of the investment required for the project. Its quarries are operated through a subsidiary, Jamaica Gypsum & Quarries.

India: France’s Vicat plans to spend Euro223m towards upgrading a cement plant and building a new one in India. Group chairman Guy Sidos signed two memoranda of understanding on a recent French business delegation to India, according to the Economic Times newspaper. Vicat’s local subsidiary, Kalburgi Cement, plans to spend Euro140 on an upgrade to its Karnataka cement plant. The upgrade will add 2.25Mt/yr of cement capacity and will be completed by the first quarter of 2023. It also plans to invest Euro60m towards building a new 1.75Mt/yr plant in the Vizianagaram district of Andhra Pradesh. The new plant is scheduled for completion in mid-2022. Once both projects are completed Kalburgi Cement will have a total cement production capacity of 6.75Mt/yr from two units.

India: NCL Industries has completed a production capacity upgrade project for both clinker and cement. Commercial operations for the upgrade started on 7 March 2018. The cement producer increased its clinker capacity to 2.6Mt/yr and cement capacity to 2.7Mt/yr in 2017. It operates an integrated cement plant at Simhapuri in Telangana and a cement grinding plant at Kondapalli in Andhra Pradesh. It sells cement under the Nagarjuna Cement brand.

Cuba: The government has allocated over US$26m to upgrade three of the country’s cement plants. Pavel Cansino Ávila, deputy director of the Cement Business Group, told the Cuban News Agency that the Santiago de Cuba plant, also known as the José Mercerón plant, will be replaced with a new plant. The new unit is scheduled to be built by 2021 and it will have a production capacity of 1.2Mt/yr. The Siguaney plant and the Nuevitas plant will also be upgraded in 2018.

In 2017 the six local cement plants were unable to meet a government order of 1.57Mt of cement. Failures occurred due to lack of maintenance budget for the plants, issues due to a lack of packaging materials and logistics issues with deliveries.

Rwanda: Cimerwa plans to upgrade its Bugarama cement plant in Rusizi District of Western Province. The project is intended to increase the plant’s production capacity and to target demand locally and abroad, in particular infrastructure development, according to the New Times newspaper. However, the subsidiary of PPC has not disclosed how much it is spending on the project. Upgrade work will start in March 2018 and end in April 2018.

At present the 0.6Mt/yr plant has a 65% production utilisation rate. The company expects to reach full capacity in mid-2019, although it claimed in 2017 that it would be able to do this by mid-2018. In 2017 the company sold 0.38Mt of cement, with 10% exported to Democratic Republic of Congo and Burundi. The plant imports most of its coal from Malawi and Tanzania.

Russia: China CAMC Engineering is seeking international finance for an upgrade to the Zhiguli cement plant. The US$70m project was part of a wider US$175m contract with Eurocement signed in mid-2014 to upgrade three plants, according to Inside International Industrials. The building phase of the project is planned to last 36 months. The other plants in the project are the Pikalevo cement plant and the Savinski cement plant. China CAMC Engineering a subsidiary of China National Machinery Industry Corporation (Sinomach).

Russia: Eurocement Group plans to spend Euro31m on upgrade work at two cement plants in the Leningrad region. It will allocate Euro14m towards work at Pikalyovskiy Cement and Euro17m at Peterburgcement, according to the Delovoy Peterburg newspaper. New milling equipment with additional filter will be installed at Pikalyovskiy Cement, and one of the plant’s two mills will be closed. This will allow the enterprise to raise the output of premium cement, decrease its production cost, and reduce emissions. A gas-piston thermal power with a capacity of 24.9MW will be built at the Peterburgcement plant.

Turkey: Dal Teknik Makina has completed an upgrade project on Kiln Line 1 at Nuh Çimento in Kocaeli. Key features of the project included increasing the line’s production capacity, decreasing its energy requirements, making savings on power consumption and lowering the exit temperature of the clinker. The work has increased the plant’s production capacity to 3400t/day from 2800t/day. Other benefits of the update include decreasing the specific heat consumption of clinker to 740kcal/kg clinker from 870kcal/kg clinker, reducing electrical power consumption by 7kWh/t and increasing the raw mill capacity to 185t/hr from 160t/hr. The exit temperature of clinker was also reduced to 55^oC plus the ambient temperature.

This project involved the design, manufacturing and erection of the pre-heater tower cyclones group, kiln feed transport system, clinker cooler, kiln hood, removing of dust cyclone at tertiary air duct, cooler vent fan modification, main bag filter duct modification and kiln inlet seal and commissioning of the system.

The first part of the upgrade project was the modification of the pre-heater tower, which as a result reduced the pressure drop, improved heat transfer and separation efficiency, and heat consumption. The second part of the project was the retrofit of the grate cooler. The clinker cooler, kiln hood, cooler fans and cooler vent fan were replaced by Fons Technology International. In this part, kiln hood, cooler vent, exit pipe of waste heat recovery (WHR) unit and tertiary air duct were modified as well. The third part was to replace the horizontal duct of main bag filter inlet with an inclined one in order to avoid dust accumulation. The last step was the replacement of the pneumatic kiln feed by bucket elevator.

The project followed Dal Teknik Makina’s Filter-To-Filter Pyro-Process Concept.

France: Fives FCB has been awarded an engineering, equipment supply and supervision of works contract for the replacement of a kiln at the Lumbres cement plant. The work covers replacing the downstream shell of the 42.2m kiln, including the tyre. The project is part of the cement producer’s plan to adapt Kiln 5 at the site for the installation of a new clinker cooler.