Displaying items by tag: Upgrade

Australia: Boral has launched upgraded ‘carbon-reducing’ technology at its Berrima Cement Works in the Southern Highlands region of New South Wales (NSW). The upgraded facility features a new chlorine bypass, which reduces the build-up of chlorides and other alternative fuel byproducts. This will reportedly enable alternative fuel usage to reach 60% over the next three years at the site, doubling its current substitution rate of 30%.

US: Zanini Renk has received a repeat order from St. Marys Cement for four additional gearboxes at its Charlevoix, Michigan plant. In 2016, St. Marys Cement's Charlevoix plant began a US$130m upgrade to expand the plant's infrastructure. The project scope included adding a new finish mill, an additional kiln and a new coal grinding system. The 2016 upgrade at St. Marys Cement expanded the Charlevoix plant’s cement capacity from 1.4Mt/yr to 2Mt/yr.

The initial order for a Zanini Renk gearbox was for installation in its vertical roller mill. Zanini Renk completed the gearbox installation in 2022. The first new gearbox has been in operation since January 2023 and the other two new gearboxes will be delivered at the end of November 2024. Installation is expected to be completed by March 2025 and by April 2025.

US: Eagle Materials has awarded thyssenkrupp Polysius a contract for the modernisation and expansion of its Laramie, Wyoming cement plant. The modernisation project will result in an expansion of the plant's manufacturing capacity to approximately 1.1Mt/yr of cement. The project also includes the installation of an alternative fuel substitution system. The modernisation of the cement plant is expected to deliver benefits such as cost reductions, achieved with lower-cost alternative fuels and natural gas, simplified maintenance and improved operational efficiencies. The production expansion from the new finish mill will supplement the grinding capacity of the existing plant, which already operates with an integrated polysius booster mill. The polytrack ECO cooler will facilitate heat recovery and clinker cooling while improving process reliability. The project, which has received primary regulatory approvals, is slated to commence immediately [in November 2024], with construction scheduled for completion by the second half of 2026.

Belgium: Holcim has selected the joint venture between BESIX and DENYS as the main contractor for the civil works of the upgrade at its Obour, Mons, plant. The GO4ZERO project will produce nearly 2.3Mt/yr of carbon-neutral cementitious materials by 2029. In a separate contract, BESIX’s subsidiary Franki Foundations is handling the deep foundations. Work began in August 2024 and will conclude in February 2025.

Fiji: Fijian Holdings (FHL) plans to construct a new cement plant within the next two to three years in Lami, replacing the current facility which began operations in 1962. According to CEO Jaoji Koroi, the existing plant, operated by subsidiary Pacific Cement, has faced issues with machine breakdowns, which have affected production and profitability. In 2023, damaged machine parts forced the plant to close down for two months. The proposed new plant reportedly aims to produce more ‘environmentally-friendly’ products. The announcement follows a year where Pacific Cement saw reduced sales due to price controls and outdated equipment.

North Macedonia: Titan Usje will invest €20m over the next three years to modernise its operations, focusing on digitalisation and new technologies. Since 2019, the company has invested over €6m in digitisation and artificial intelligence solutions. The system is being rolled out across all Titan plants and is designed to maximise production efficiency, reduce energy use by over 10% and improve product quality, while cutting CO₂ emissions.

Kenya: East African Portland Cement (EAPC) has contracted a technical audit from Denmark-based FLSmidth Cement with a value of just under US$70m. EAPC’s acting managing director Mohamed Osman said the findings would guide a pending plant upgrade, to be funded by some of the proceeds from the land sale, according to the Star newspaper. It hopes to double capacity at the unit by the late 2020s without incurring debt. The cement producer is also considering its options to use alternative fuels such as macadamia husks and other agricultural biomass. The 10-week audit process is expected to end in early December 2024.

Osman said “We have tapped FLSmidth to undertake a comprehensive technical audit of the plant, which will assess how to maximise the capacity and inform the design and cost of a new one,'' Osman said. “The audit by FLSmidth will also look at the reserves of raw materials that it has and inform whether it needs to acquire more land that has adequate reserves.”

Italy: Cementir Holding has blamed a fall in earnings in the first nine months of 2024 on “lower results achieved in all geographical areas except Egypt.” It added that sales had fallen due to a decrease in volumes in some places and negative currency effects in Türkiye and Egypt. The group’s revenue fell by 5% year-on-year to €1.24bn in the first nine months of 2024, from €1.30bn in the same period in 2023. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) dropped by 9% to €296m from €326m. Sales volumes of cement and clinker remained stable at 7.98Mt. It noted that volumes increases were reported in Türkiye and, to a lesser extent, in Malaysia and the US. However, volumes of ready-mixed concrete rose by 5% to 3.33Mm³ from 3.18Mm³.

Francesco Caltagirone Jr, chair and CEO, said “The results for the first nine months of 2024 are in line with our expectations and, after several quarters of contraction, signs of a market turnaround in some geographies are emerging in the third quarter of 2024. We are strengthening our competitive position through initiatives such as: the investment on Kiln 4 in Belgium, the restart of the second line in Egypt, the acquisition in concrete in Nordic & Baltic, a new limestone quarry in Malaysia, and the repurchase of a large part of the minority interest in our Egyptian subsidiary, to prepare ourselves for any upcoming market opportunities”.

Tanzania/Kenya: Amsons Group will build a US$320m cement plant in northern Tanzania's Tanga area with a production capacity of 5,000t/day, Bloomberg reports. The company also plans to implement a major upgrade at the recently acquired Mbeya Cement in Tanzania, including a new grinding mill, according to Capital News Kenya. Additionally, Amsons plans to invest US$400m in Holcim’s Kenyan subsidiary Bamburi Cement, contingent on its successful US$180m bid.

Edha Nahdi, managing director at Amsons Group, said "Thanks to the support of the Tanzanian and Kenyan governments, our regional expansion plans are now firmly on course. We plan to be one of the largest cement manufacturers in Kenya and Tanzania by 2030."

Philippines: Cemex Philippines has extended Aboitiz Construction’s contract to provide technical services for the commissioning of the upcoming Line 4 of its Antipolo City cement plant in Rizal. The Manila Times newspaper has reported that the new date on which the contract will conclude is in December 2024.

Aboitiz Construction chief operating officer Ramez Sidhom said "Our recent partnership with Cemex Philippines demonstrates our commitment to execution excellence and affirms our ability to provide reliable maintenance solutions while prioritising safety and quality of work.”