Displaying items by tag: Upgrade

Asia: France-based Fives says it has commissioned a Pillard Novaflam Evolution burner for an unnamed cement plant in East Asia. Due to the travel restrictions linked to the coronavirus pandemic, the commissioning was carried out remotely with the cooperation of the customer. A 143MW coal and petcoke burner with oil as a start-up fuel was supplied as a replacement for an old burner. The aim of this replacement was to increase the kiln capacity to 9000t/day without impacting its NO_x emissions whilst maintaining a good clinker quality despite a high sulphur content in the petcoke. The installation is now in production and an intervention is planned in the coming weeks to further optimise the operation.

Austria: Germany-based Claudius Peters has supplied a conveyor and silos for Schretter & Cie’s integrated Vils Cement plant in Tirol. In the first part of the project Claudius Peters Projects delivered an aeroslide conveying system from the cement mill to the existing silos, including silo bottom aeration systems. For the second part, it built a silo group consisting of three 3500m³ units with expansion chamber technology equipped with truck loading facilities. Each of the silos can be operated at a loading capacity of 250t/hr by a mobile loader with a travelling range of 10m.

Oman: Oman Cement plans to upgrade its 4.2Mt/yr Rusayl cement plant. Reuters News has reported that the producers’ plans consist of a 25% capacity expansion of Line 3 of the plant to 5000t/day from 4000t/day and the construction of a new 10,000t/day Line 4. Lines 1 and 2 will subsequently shut down. Thus, the upgrade will increase the plant’s nominal clinker capacity to 15,000t/day from 8700t/day.

US: Italy-based Bedeschi has been awarded a new order for the supply of two BED RNSH 1800/6 type apron feeders for Lehigh Cement’s integrated Mitchell plant in Indiana. The new feeders will be able to process up to 1300t/hr of crushed limestone and they will be placed in the primary and secondary crushing area to replace the old existing machines. They feature super duty design with CAT type chains and a Bedeschi super duty belt. As part of the installation Bedeschi has used a three dimensional survey to define the exact room availability in the existing plant. The new feeders will join three others at the plant that were already ordered as part of an upgrade programme for clay crushing and additive dosing. No value for the order has been disclosed.

Lehigh Cement, a subsidiary of Germany-based HeidelbergCement, resumed work on its US$600m upgrade project at the Mitchell plant in February 2021. Work on the upgrade was suspended in early 2020.

UK: Mannok has commissioned a Euro2.1m bagging system supplied by Germany-based Haver & Boecker. The order included a Roto-Packer Adams 10 spout bag filling system and a new automatic film reel changer, designed to run at 1200 bags/hr. Installation took place in the second quarter of 2021 and the new bagging unit is now in production. The upgrade now gives Mannok the capacity to pack around 50t/hr of cement in weatherproof bags.

Chief executive officer Liam McCaffrey said, “This is a major investment in our Cement operations which completes the second phase of our investment in our weatherproof bagging line, upgrading it from a single to a double bagging line with a significant increase in output capacity. Our initial investment to bring our weatherproof polyethylene bags to the market was in response to demand from Great Britain-based merchants and we later introduced the bags to the Irish market, where the response was equally positive.”

The cement producer operates an integrated plant at Derrylin, Fermanagh in Northern Ireland. It previously installed a weatherproof bagging line in 2018 that allows it to extend its range of bagged cements.

India: The total new waste heat recovery (WHR) unit capacity of cement producers is expected to reach 175MW in the two years ending on 31 March 2022. Rating agency ICRA has valued the total investment in new WHR units over the period as up to US$230m, according to the Press Trust of India. A market report by ICRA reports that power generation using WHR costs around US$0.02/kWh compared to US$0.7/kWh from a captive coal power plant. Cement companies that replace 25% of total power capacity with WHR can potentially save around 15% from existing power costs.

India: Dalmia Cement has signed three memoranda of understanding with the state government of Jharkhand. The memoranda provide that the Dalmia Bharat subsidiary will invest US$104m in expanding its cement operations in the state. The producer’s plans consist of a US$68.5m upgrade and capacity expansion to its Bokaro cement grinding plant. The project will increase the existing production line’s capacity to 3.7Mt/yr and add a new grinding line, bringing the total plant’s capacity to 6.3Mt/yr. In addition the cement producer will spend US$34m towards building a solar power plant and the remainder will be spent on setting up a waste management facility.

Belgium: Holcim Belgium is hosting a public meeting as a preliminary step towards applying for a permit to install a new kiln line at its Obourg cement plant in Mons. The line is intended to replace the existing kiln line as it reaches the end of its operational life. The subsidiary of Switzerland-based Holcim has called the proposed project Go4Zero. The new kiln will be designed to concentrate CO₂ emissions to allow for capture and recovery. Limestone for the plant will be extracted from a quarry at Tournaisis and transported to the plant by railway.

Austria: Baumit has invested Euro5.6m in a new waste heat recovery (WHR) system at its Wopfing cement plant in Lower Austria. The producer claims that the installation will enable it to make energy savings of almost 20GWh/yr, corresponding to the energy consumption of 1000 households.

Commercial director Georg Bursik said “We have been using the waste heat for drying systems in the plant for decades. Thanks to this investment, the use of waste heat can be further increased – saving 4000t/yr of CO₂.

Spain: Construction work has started on 6.2MW solar plant that will supply electricity to Cementos Cosmos’ Toral de los Vados integrated plant in León. Commissioning is scheduled by February 2022. The photovoltaic plant will include over 11,400 solar panels in an area of around 10 hectares. It will meet 15% of the plant’s electricity demands. Spain-based solar specialist EIDF (Energía, Innovación y Desarrollo Fotovoltaico) is supplying the unit at a previously reported cost of Euro4m.