Displaying items by tag: Upgrade

Philippines: Cemex Philippines Solid Cement plant in Antipolo has lifted a new rotary kiln into position as part of a US$235m installation of a new production line at the site. Once complete the new line will add 1.5Mt/yr to the unit’s production capacity increasing the total to 3.4Mt/yr. The new production line will reuse waste hot gases to dry raw materials and high efficiency bag filters reduce improve emissions control. Cemex is also using its proprietary Low Temperature Clinker technology to reduce carbon dioxide emissions.

"This milestone demonstrates our full commitment to the development of the country and brings us closer to further strengthening our position in providing the infrastructure and building needs for economic development," said Ignacio Mijares, the chief executive officer (CEO) and president of Cemex Holdings Philippines.

China-based CBMI Construction has been contracted to build the new line. It lifted the new kiln in two days. Tong Laigou, chairman and general manager of CBMI Construction, said that the CBMI and Cemex Philippines' teams worked under strict protocols to secure the safety of the site.

Pakistan: Cherat Cement plans to spend US22m on an upgrade to Line 1 at its integrated plant in Nowshera district, Khyber Pakhtunkhwa province. The project includes the installation of a new crusher and general maintenance on the production line.

Belgium: IKN was presented with the first clinker from a modified calciner and IKN cooler installed at the CBR Cement integrated Antoing plant on 24 December 2020. The cement sector engineering supplier said, “We thank everybody involved for their determination and efforts in this challenging project: in spite of Coronanirus and a tough schedule there was no compromise on safety!” CBR Cement is a subsidiary of Germany-based HeidelbergCement.

India: Star Cement plans to increase the cement production capacity of its Guwahiti integrated cement plant in Assam by 2Mt/yr. It also plans to increase its clinker production capacity in Meghalaya by 2Mt/yr. The Free Press Journal newspaper has reported the total cost of the planned investment is US$137m. Managing director Sajjan Bhajanka said that the company would complete the work by mid-2023.

Switzerland: Dürr is supplying a regenerative thermal oxidation system (RTO) to Jura Cement Fabriken integrated plant in Wildegg as the main stage in its air pollution control system. The upgrade is intended to enable the cement producer to comply with anticipated lower gas emission limits for carbon monoxide, hydrocarbons, and ammonia (NH₃). The supplier says its solution combines Dürr’s Ecopure RTO multiple-chamber principle with an optimisation of the existing process technology in the calciner. It is scheduled to start operation in 2022.

Jura Cement operates two integrated plants in Switzerland. It is part of the Switzerland-based Jura Materials Group, which has been part of the Ireland-based CRH since 2000.

Cameroon: Nigeria-based Dangote Cement plans to increase the capacity of its 1.5Mt/yr Douala cement grinding plant near the Cameroonian capital of Yaoundé to 3Mt/yr. The Nigerian Guardian newspaper has reported that the company’s current expansion plan aims at exploiting multiple trade routes within the African Continental Free Trade Area (AfCFTA).

Aliko Dangote said that the plant is “our largest greenfield project in a neighbouring country with which we not only share a border but also a long history of brotherly relations dating from our colonial days. Owing to the rich culture and history that we share, we have a better understanding of Cameroon.” He added, “Our desire to increase our investment with the Phase-2 project is based on not only the fast growth rate of the Cameroonian economy but also due to the warm welcome extended to us and the enabling environment created by the government of Cameroon. Our choice of Cameroon for this multi-million-dollar investment is quite strategic. Cameroon is the largest economy in Central Africa and is well endowed with abundant natural resources. The country also enjoys political stability, adequate security and growing infrastructural development. In addition, President Biya has created an enabling environment that has continued to attract investors both from within and outside the African continent.”

UK: Cemex UK has announced plans for two new plastic packing production lines at Rugby cement plant. The company said that the lines will directly serve the plastic packing needs of packed cement production at the plant. The total investment cost of the installation will be Euro5.6m. Work will begin in early 2021 and be completed from June 2021. Cemex first entered the plastic packed cement market in 2011.

India: The government of India has granted licences to JSW Cement subsidiary Shiva Cement for the expansion of its cement plants in the state. The New Indian Express newspaper has reported that the company has received approval for an integrated capacity expansion of 1.1Mt/yr and a clinker capacity expansion of 1.3Mt/yr.

The state government approved a total of US$730m-worth of planned investments in various industries on 6 January 2020.

One of the last news stories we covered before the Christmas break was that Lafarge Poland had selected China-based Nanjing Kisen International Engineering as the general contractor for a Euro100m-plus upgrade to its Małogoszcz cement plant. This appears to be the first major European cement plant upgrade project to be publicly run by a Chinese contractor. There may be other European projects in the sector run by Chinese companies ‘on the down-low.’

If it is the first then this is a significant milestone for the growth of the Chinese industry. It is a noteworthy first for Nanjing Kisen in the European Union. Europe is the home, after all, of a number of locally-based contractors and companies that can build or upgrade cement plants including FLSmidth, Fives, ThyssenKrupp, IKN and others. Indeed, all of the work on this project might actually be conducted by local companies, selected by the general contractor. For example, Lafarge Poland says that the general contractor will select a subcontractor on the Polish market.

It’s easy to fall into jingoistic nostalgia but should we really be surprised that China can competitively build cement plants given the ferocious growth of its own industry over the last few decades? Arguments by Western critics against growing Chinese dominance in industry have tended to home in on excuses why they might be ‘cheating’ such as intellectual property theft, unfair state aid or the use of low-cost infrastructure loans to countries along its Belt and Road Initiative. That last one carries some irony given that not so long ago discussions about developing world debt were framed in the context of the Cold War and the oil crisis in the 1970s. Western countries were seen as the bogeymen depending on one’s political outlook. With this in mind, the Financial Times recently reported on data released in December 2020 that suggested that China might be heading into its own overseas debt crisis. The takeaway message here is that attempting to apply China’s whopping infrastructure boom elsewhere might not work so well without the same level of control. Exporting production overcapacity abroad may simply turn out to be something like a giant Ponzi scheme! For the cement industry this may mean a pause or wind-down in the number of new plants backed by Chinese money, often with Chinese contractors tied in, and that the rise of Chinese engineering firms might not seem as unassailable as all that after all.

This leads into another noteworthy story that we also published before Christmas on China’s latest proposal to further reduce production capacity at home. The Ministry of Industry and Information Technology (MIIT) wants to tighten the ratio of production capacity that has to be closed before new capacity can be built from 1.25:1 to 1.5:1. The kicker is that the new rules also include a clause intended to restrict the use of so-called ‘zombie’ capacity in the swapping process by limiting eligibility to productions lines that have been operated for two or more consecutive years since 2013. These rules seem targeted at the present day but they could potentially push Chinese cement production capacity per capita to rates more similar to those found in developed economies elsewhere (i.e. halve existing Chinese production capacity). Many of the country’s kilns were built in the early 2000s and the average lifespan of a clinker kiln is 50 years. This suggests that the ministry is thinking seriously about culling capacity by the administration’s carbon neutrality target of 2060.

Chinese penetration in the European cement plant market is more of an after-thought given the pace of projects in Asia and Africa over the last decade and the maturity of the sector. It can also be misleading given that some very-European-sounding engineering companies are actually owned by Chinese concerns. Yet no doubt local contractors and suppliers would like to keep any business they can. On the other hand, more market share may be found in Europe over the coming decades from retrofitting CO₂ mitigating equipment or building the anticipated hydrogen revolution once the regulatory and financial framework starts to favour it. Or maybe shifts to service and/or machine intelligence-style packages are the way forward. Nanjing Kisen may be the first Chinese company to upgrade a European cement plant but the market focus may quickly move on. Time will tell.

Answers by email for when readers think the first cement plant or production line in the US will be built by a Chinese company.

Happy New Year from Global Cement

India: LafargeHolcim subsidiary ACC has commissioned a new 1.4Mt/yr unit at its Sindri cement grinding plant in Jharkhand. The plant now commands a total grinding capacity of 4.4Mt/yr. The company began work on the expansion in December 2019 in order to strengthen its presence in the Eastern region. It said that the state government and local authorities aided smooth commissioning.

LafargeHolcim India chief executive officer (CEO) and non-executive director ACC Limited Neeraj Akhoury said, "Strong ambition aimed at deliverance of high performance is what guided ACC to establish the commissioning of the Sindri GU-Phase-II within a record period.” He added, “I am proud of the flexibility and agility demonstrated by the team."

ACC managing director and chief executive officer (CEO) Sridhar Balakrishnan said, “The commitment, meticulous planning and collaborative approach by the Project Sindri team in these unprecedented times and commencing the cement production in a record time have set a new benchmark for ACC.”