Displaying items by tag: Upgrade
LafargeHolcim unveils Indian waste heat recovery plans
03 December 2020India: Switzerland-based LafargeHolcim plans to invest US$112m in implementing waste heat recovery (WHR) plants across six of its cement plants in India by the end of 2022. The group has estimated a net carbon dioxide (CO2) emissions reduction of 0.5Mt/yr as a result of the installations, towards its target of a 65% total reduction between 2018 and 2030.
Chief Sustainability Officer (CSO) Magali Anderson said, "On our net zero journey, we set ourselves an ambitious scope-two target. I am very excited to see India leading the way by investing US$112m in WHR. This major step forward builds on our procurement teams’ work in renewable energy."
When commissioned, the new plants will double the group’s WHR power generation capacity in India.
Cementos Cosmos plans 6.2MW solar power plant
03 December 2020Spain: Cementos Cosmos has partnered with France-based EDF energy to establish a 6.2MW solar power plant in Toral de los Vados, León, at a cost of Euro4m. The Diario de León newspaper has reported that the plant intends to use 9.0GWhr/yr of energy from the new unit. This will provide 15% of the electrical power requirements at the cement plant. The 14,000-panel project is scheduled for completion in mid-2021.
Pakistan: Pioneer Cement has begun power generation at its upgraded 24MW coal-fired power plant. Link News has reported that the plant previously had a power generation capacity of 12MW.
Update on France: November 2020
25 November 2020There were mixed feelings evoked by HeidelbergCement’s good news last week that its French subsidiary Ciments Calcia is to set to spend Euro400m on a modernisation project. Sadly, this came with the bad news that the integrated plants at Gargenville and Cruas will be downgraded into a grinding plant and a terminal respectively, and there will be a review of the company’s headquarters in Guerville. All of this will cut 160 jobs but create 20 new ones.
Make no mistake, this is serious money to invest. Euro300m alone will go towards an upgrade of the integrated Airvault cement plant in the former Poitou-Charentes administrative region. HeidelbergCement didn’t say it in its press release but French press reported that the pyroprocessing line at Airvault will be rebuilt starting in 2022 with commissioning scheduled for 2025. If correct then this certainly suits an investment on this scale for a single plant. Smaller investments in the region of Euro25 – 50m were also said be earmarked for the integrated plants at Bussac-Forêt, Beaucaire and Couvrot. These are serious commitments to HeidelbergCement’s production base in France.
Generally speaking, the French cement and construction market has done as well as expected for a country forced to implement two coronavirus lockdowns so far in 2020. Half-way through the year the major cement producers were reporting sales declines of around 10% year-on-year with business picking up again over the summer. Vicat, for example, reported a 9% fall in sales volumes in the first half followed by ‘solid business growth’ in June 2020. LafargeHolcim, CRH and HeidelbergCement all reported a similar situation for their local subsidiaries.
Looking at the wider construction industry, in October 2020 analyst company GlobalData stuck by its forecast of a contraction of construction output by 11.6% in France in 2020. It noted a 35.5% quarter-on-quarter rebound in the third quarter, although it reckoned output was still down by around 5% in the quarter year-on-year, using French National Institute of Statistics and Economic Studies (INSEE) data. With a second national lockdown initiated in late October 2020, it said that INSEE expected a contraction in the fourth quarter of 2020 even with construction sites being allowed to stay open. This follows a peak of cement production above 20Mt in the late 2000s before hitting a low of around 15.5Mt in 2015 and a gradual recovery since then, according to data from the French cement industry union (SFIC).
Ciments Calcia’s upgrade at Airvault is noteworthy for the whole of Europe because it is one of only a few new pyroprocessing line projects in the last decade. The last major one was the new 4000t/day line at HeidelbergCement’s Burglengenfeld plant in Germany that was commissioned in 2018. The trend since then has generally been one of integrated plants slowly closing as markets shrank following the 2008 financial crisis, international clinker levels boomed and environmental measures tightened. Dominik von Achten, chairman of the managing board of HeidelbergCement, addressed this last point directly with the announcement of the Airvault project when he said, “This is why we focus our initiatives on the main CO2-emitting plants in France.” The competitors to the larger established cement producers in France are certainly thinking about CO2. Alongside the general European trend of fewer new clinker production lines has been rise in France of the smaller cement producers with grinding and/or reduced-clinker factor models like Cem’In’Eu, Hoffmann Green Cement Technologies and Ecocem. Anyone spending Euro300m on a clinker kiln spewing out CO2 would do well to consider how much the CO2 price might be in fifty years time.
Lafarge Zementwerke appoints A TEC for Mannersdorf cement plant alternative fuels Flash Dryer installation
24 November 2020Austria: Loesche subsidiary A TEC has won a contract for the supply and installation of a Flash Dryer for alternative fuels (AFs) in the kiln line of Lafarge Zementwerke's 1.1Mt/yr Mannersdorf cement plant in Lower Austria. The supplier said that it will complete the project in early 2021.
The company said, “Reaching high thermal substitution rates (TSR) requires firing of alternative fuels at the kiln burner. To reach a stable sintering zone for the required clinker quality a high fuel quality (high LCV, small particle size) is needed, otherwise the clinker quality may suffer or the TSR can be limited. With the A TEC Flash Dryer various waste heat sources can be used (clinker cooler flue gas, bypass gas, preheater gas, etc.). The material is dosed to the hot gas flow in the flash dryer and transported with this gas flow, while the moisture is evaporated, to a cyclone and a subsequent filter where the fuel is separated from the gas flow and on-line fed to a kiln burner or a satellite burner. In addition to the drying the lifting effect of the gas can separate 3D impurities which contributes in a further increase of the fuel quality.”
Tokyo Cement plans 1Mt/yr expansion
20 November 2020Sri Lanka: Tokyo Cement Company (Lanka) has announced that it expects to sign an agreement to increase the production of OPC and other hydraulic cement products by 1Mt/yr. The investment will be made at its existing cement grinding plant in Trincomalee on the north east coast of Sri Lanka.
Tokyo Cement said that the project would cost approximately US$12m. Global Cement notes that this amount is fairly low for such a large increase in cement capacity and therefore may represent increases in cement handling capacity, rather than grinding capacity. Tokyo Cement said that it expects the project to be completed within 24 months.
Ciments Calcia to stop clinker production at two plants as part of Euro400m modernisation plan in France
19 November 2020France: HeidelbergCement’s subsidiary Ciments Calcia plans to stop clinker production at two plants as part of a Euro400m investment and reorganisation programme for several of its sites in France. Around Euro300m of this will be spent at the integrated Airvault cement plant. The company also intends to: convert its integrated Gargenville cement plant into a grinding plant and shut down its kiln systems and quarry operations; convert its integrated Cruas white cement plant into an automated cement terminal for the distribution of white cement; and adapt the organisation at its French headquarters at Guerville. The plan will cut 162 jobs and create 20 new ones.
“As part of our global business excellence initiative, we intend to further optimise effectiveness, processes and structures of our French sites,” said Dominik von Achten, chairman of the managing board of HeidelbergCement. “We want to considerably speed up the modernisation of our plants in order to enhance our performance in France, while ensuring alignment with the goals of the Paris agreement. This is why we focus our initiatives on the main CO2-emitting plants in France.”
Dyckerhoff reopens railway siding at Amöneburg cement plant
18 November 2020Germany: Dyckerhoff has reopened a railway siding at its integrated Amöneburg cement plant. The additional transport link joins road and water connections at the site. The company said that reusing the railway siding made sense given low water levels in the River Rhine, that made parts of the waterway unnavigable in 2018, as well as adding a sustainable transport route. The railway tracks at the site have not been used actively since the mid-2000s. The cement producer has repaired the tracks on its site and a related signalling system.
Shree Cement orders vertical roller mills from Gebr. Pfeiffer
17 November 2020India: Shree Cement has ordered two vertical roller (VR) mills from Germany-based Gebr. Pfeiffer for the upcoming clinker line at its Raipur cement plant in Chhattisgarh. The supplier says that one of the mills will grind raw materials and the other will grind coal.
A MVR 6000 R-6 type raw mill will grind 800t/hr of raw material and have a drive power of 8700kW. Gebr. Pfeiffer said, “The grinding rollers of this mill can be equipped with roller tires for raw meal grinding as well as for cement grinding, provided that they have been designed according to the same force module. This saves money, because the identical components of rollers, tensioning system, roller arms, etc. mean that customers can reduce their spare parts inventory, since the same spare parts can be used for a raw meal mill and for a cement mill.” The mill will be equipped with an SLS 6000 VR high-efficiency classifier.
A MPS 2800 BK type mill will be used to grind coal with a capacity of 28t/hr, a drive power of 720kW and be “equipped with the latest design of the integrated SLS 2900 BK high-efficiency classifier optimised for MPS mills.”
The supplier said, “While the core components of the mills as well as the drive units will be supplied by Gebr. Pfeiffer from Europe, the Indian subsidiary Gebr. Pfeiffer (India) will provide components such as the mill and classifier housings, the steel foundation parts as well as internal parts of the classifiers.”
US: Austin Quinn-Davidson, the acting mayor of Anchorage in Alaska, has announced that the city’s new cement and petroleum terminal at the Port of Alaska will be completed by late 2021. The Anchorage Daily News has reported that the estimated US$203m terminal will last for 75 years and be able to endure future seismic events like the earthquake that damaged the port in November 2018.
Municipal manager Bill Falsey said, “Even in these challenging times, we can still do big and important and challenging things.” He estimated the eventual total cost of an upgrade to the port would be around US$1bn.