Displaying items by tag: Upgrade

Mexico: GCC has signed an engineering, procurement and construction (EPC) contract with ThyssenKrupp Polysius for an upgrade to its integrated Samalayuca plant to increase clinker production capacity, raise the usage of alternative fuels and reduce emissions. The project includes the engineering, supply and modification of the preheater, including cyclones, and an extension to the calciner, with the installation of a Prepol SC-S type system to increase the utilisation of alternative fuels. The work also includes fitting a Polytrack type clinker cooler and the installation of a bypass system. The project will begin in 2022 with operations scheduled to start in the second quarter of 2023.

Australia: Boral plans to install chlorine bypass technology at its Berrima cement plant in New South Wales. The Illawara Mercury newspaper has reported that the installation will help the plant to double its alternative fuel (AF) substitution rate to 100%. This is one of the ways in which the producer aims to reduce its Scope One and Two emissions by 46% between 2020 and 2030.

In mid-February 2022, Boral acquired new land at the site of its Dunmore quarry, also in New South Wales.

India: Ambuja Cement plans to invest US$469m in a 7Mt/yr expansion to its total grinding capacity. BusinessLine Online News has reported that the new capacity will consist of a new grinding plant at Barh, Bihar, and expansions to the company’s Farakka and Sankrail grinding plants in West Bengal. The company says that the new grinding capacity will become crucial after it completes its planned 3.2Mt/yr clinker capacity expansion to its Bhatapara cement plant in Chhattisgarh.

Russia: Eurocement has completed a Euro3.3m maintenance project on the kiln at its Mordovcement plant in Chamzinsky District. The wet-process kiln was reconstructed as part of a large-scale modernisation program. Work conducted included replacement casing bandages, roller supports, the kiln chain curtain and the welding of cracks along the kiln shell. The project included a major relining of refractory material with magnesia bricks produced by the Magnezit Group and aluminosilicate refractory bricks produced by BKO. Maintenance work was also carried out on the plant’s FLSmidth Cross-Bar cooler.

Italy: Cementir’s revenue grew by 11% year-on-year to Euro1.36bn in 2021 from Euro1.22bn in 2020. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 17.9% to Euro311m from Euro264m. Sales volumes of cement and concrete increased by 4.1% to 11.2Mt and 14.8% to 5.01Mm3 respectively.

“2021 marked for Cementir the year of the historic record of revenues and EBITDA despite the uncertainties related to the pandemic crisis, the substantial increase in energy costs, materials and services and the devaluation of the Turkish lira,” said Francesco Caltagirone Jr, chair and chief executive officer of Cementir.

The group also reviewed and approved the three-year Group Industrial Plan update for the period 2022 - 2024 and the 2022 budget. It has a target of reduce CO₂ emissions (scope 1) by 30% in 2030 compared to 1990 levels. It is also planning to invest Euro116m in the 2022 – 2025 to meet this goal and others. Some of this will go towards building a new production line at its integrated Gaurain cement plant in Belgium, where the work is intended to raise the unit’s alternative fuels substitution rate to 80% from 40%. The group noted that this project has been delayed to 2022 due to the coronavirus pandemic. Changes at other cement plants include switching to natural gas and biogas as well as energy efficiency projects. It is also said it was planning to ‘significantly’ increase the production of its FUTURECEM calcined clay cement and related sustainable products.

US: Ash Grove Cement has re-opened its Port Manatee terminal in Florida following the installation of a new Kovako type ship unloader supplied by FLSmidth. The machine was custom built for Ash Grove by the Denmark-based company to meet its specific needs. The cement producer says it is the largest mobile pneumatic ship unloader built, has twin 800hp blowers, 37m suction arm and can offload a dry bulk vessel at a high rate while maintaining maximum efficiency and minimising environmental impact by eliminating dust emissions.

A ribbon-cutting ceremony to celebrate the event was held on 7 February 2022 as a shipment of fly ash was processed at the site. This maiden shipment completes the Phase 1 transformation project at Port Manatee, which began in early 2021. The project is intended to improve the subsidiary of CRH’s capacity to import cement, slag and fly ash for customers in Florida and South Georgia. It is also planning to use the terminal’s existing silo capacity to complement the capabilities of Ash Grove’s cement plants in Sumterville and Branford.

Nigeria: President Muhammadu Buhari inaugurated BUA Group’s new 3.0Mt/yr Line 4 at its Sokoto plant in northern Nigeria on 27 January 2022. The plant is the largest private sector employer of labour in the north-western part of Nigeria.

At the inauguration, the President expressed delight that the Federal Government policies on economic diversification, job creation and creating an enabling environment for businesses to thrive were working. He pledged to continue his administration’s support for ‘serious investors’ to set up businesses that will take advantage of huge reserves of resources in different parts of the country.

The President thanked the Founder of BUA Cement, Abdul Samad Rabiu and the BUA team for the ‘great work they are doing’ in supporting the government's economic diversification and job creation agenda.

Speaking personally, President Buhari added that, as the head of Sokoto State in 1985, he had also inaugurated Line 2 at the same plant, saying, "Today, almost 37 years later, to commission the fourth line is a very special day for me personally. As you all know, one of the key economic pillars of our administration has been to create an enabling environment for businesses to thrive. This is necessary for job creation and indeed, for our economy and national security.”

Mexico/US: GCC plans to invest US$500m over the next three years to the end of 2024 on increasing its production capacity and strengthening its logistics and distribution network in North America. New projects in development include the expansion of a cement plant, debottlenecking at the integrated Samalayuca plant in Mexico, the construction of two new terminals and other projects to improve the company’s operational efficiency and its social and environmental strategy. The cement producer reported strong sales in 2021 and it expects even better results in 2022 and 2023, particularly in the US, due to the effect of the US infrastructure bill.

Notably GCC reported that both the kilns at its Odessa plant in Texas were running at full capacity in 2021 and an additional kiln at a plant in Chihuahua, Mexico was complimenting supply to the US state. High demand was also recorded in Montana.

Czech Republic: Ceskomoravsky Cement is planning a Euro12m upgrade of its integrated Radotín plant. The work will include installing a new vertical grinding mill and other environmental measures, according to the Czech Information Agency. The subsidiary of Germany-based HeidelbergCement will choose suppliers and apply for building permits by early 2023, ahead of construction in mid-2023 and potential operation in 2025.

India: Ramco Cements plans to commission a new 2.5Mt/yr clinker production line at its new plant near Kurnool, Andhra Pradesh in February 2022. A 1Mt/yr grinding unit, 12MW waste heat recovery system and 18MW captive power unit at the plant are expected to be commissioned in the 2022 – 2023 financial year, which starts in April 2022.

The cement producer also intends to commission at upgrade to its Nagar cement plant in the 2023 – 2024 financial year. The US$63m project includes installing a new 300t/day kiln at the plant in Tamil Nadu.