Displaying items by tag: Upgrade

US: Grupo Cementos de Chihuahua (GCC) says that the upgrade to its Rapid City cement plant in South Dakota has started operation. The expansion has added 0.44Mt/yr of production capacity to the unit taking its total capacity to 1.18Mt/yr. The project cost US$105m and it started in 2016. Tie-in of the upgrade was finished in late November 2018. Production was suspended during the tie-in-process and has now resumed. The new facilities are now being stabilised.

“The Rapid City expansion comes at an opportune time, as our US cement plants are running nearly at full capacity, and we expect to see continued, steady growth in demand across our market area. We will be able to serve our customers better and operate our cement logistics network more efficiently with the additional capacity,” said Enrique Escalante, GCC’s chief executive officer (CEO).

GCC has 5.8Mt/yr of cement production capacity. Of this, 3.5Mt/yr is in the US, with plants in Pueblo in Colorado, Odessa in Texas, Tijeras in New Mexico, Trident in Montana and Rapid City in South Dakota. GCC expects to ramp up the new production capacity at Rapid City gradually over the next 18 to 24 months, in accordance with market conditions.

GCC’s cement production capacity in Mexico is 2.3Mt/yr from plants in Chihuahua, Juarez and Samalayuca in Chihuahua state. In the third quarter of 2018, GCC reactivated two idled kilns in Chihuahua to increase production of both oil well cement and construction cement.

US: France’s Fives Group has released detail about a project to upgrade the cement mill workshop at Giant Cement’s Harleyville plant in South Carolina. The contracts included the complete engineering, supply, fabrication, transport, installation and commissioning services for material handling, cement grinding and cement loading. New equipment included a clinker and additives transport circuit with a dedusting system, a classifying circuit with a FCB TSV Classifier, a new Fives TGT Filter, all gas and material connections as well as the ball mill internals revamping, a cement truck bulk loading area and a weighing station.

Engineering, offshore supplies and project management were handled by Fives FCB. Onshore supplies and all site works including civil and structural works, mechanical and electrical installations were covered by Fives Solios. Major milestones of the project included starting civil works in November 2017. Mechanical and electrical erection work ran from February to July 2018. First cement production was on 29 June 2018.

Bangladesh: Shah Cement has inaugurated the world’s largest vertical roller mill (VRM), supplied by Denmark’s FLSmidth, at its Muktarpur plant in Munshiganj. The FLSmidth OK 81-6 Mill has an 8.1m grinding table and six grinding rollers powered by two 5.8MW FLSmidth MAAG Max Drive gear systems. FLSmidth says that the mill is the largest VRM ever to be installed in a cement plant in terms of dimension, operating capacity and installed power. It was put in operation in September 2018

“We are proud to have the world’s largest vertical roller mill as part of our operations. We selected the FLSmidth OK 81-6 Mill for its exceptional efficiency and reduced power consumption – and we are expecting it to deliver as promised. As the largest single-unit grinding mill in the industry, we expect it to meet our production requirements for many years,” said Hafiz Sikander, Director of Operations, Cement Division of Shah Cement Industries.

The mill is designed to produce Ordinary Portland Cement (OPC), Pozzolana Portland Cement (PPC), Portland Slag Cement (PSC) and slag cement types. It is producing PPC at a capacity of 500t/hr at 3500 Blaine with 15% slag. In addition to the OK Mill, FLSmidth supplied the process and layout engineering, along with site advisory. The supporting equipment included FLSmidth Pfister weigh feeders, FLSmidth Airtech process bag filters, process fans and auxiliary equipment from raw material hopper discharge to process bag filter discharge.

Shah Cement Industries is the largest cement producing plant in Bangladesh, with a capacity of 8.0Mt/yr. The company is part of the Abul Khair Group, the largest business conglomerate in Bangladesh.

India: Sanghi Industries has signed a memorandum of interest with the Gujarat state government to expand its Kutch cement plant. It plans to invest around US$213m on the project, according to the Times of Indian newspaper. The plant will be expanded to a cement production capacity of 8.6t/yr from 4Mt/yr. The project is scheduled for completion by 2020 and it will create 350 new jobs.

Argentina: Aumund Brazil and Aumund China have collaborated with Sinoma Tianjin TDI to supply two clinker-conveying orders for cement plants. No value for either order has been disclosed.

Aumund will supply three chain bucket elevators, eight belt bucket elevators, five pan conveyors and a drag chain conveyor for Line 2 at Loma Negra’s L’Amali cement plant. The order also includes 19 silo discharge gates. In August 2017 Loma Negra awarded Aumund the order to build a second kiln line with a capacity of 5800t/day at the L’Amali plant in Olavarria in Buenos Aires province. The new line, which will produce 2.7Mt/yr of clinker, will be located adjacent to the existing kiln line. Production will start early in 2020.

In June 2018 Aumund Brazil worked with Aumund Brazil and Sinoma to supply four belt bucket elevators, three chain bucket elevators and three pan conveyors via Sinoma TDI to Cementos Avellaneda. Cementos Avellaneda is a joint venture operated by Brazil’s Votorantim Group and Spain’s Cementos Molins.

Saudi Cement: City Cement’s Al Madina Cement subsidiary says it has reached a final settlement with China’s Sinoma International about the construction of a second production line. The parties have agreed an 8% discount on the total cost of the project worth around US$11m. Trial operation on the second line at the plant was originally announced in late 2014.

Egypt: South Valley Cement says it is in a dispute with China’s Sinoma CDI over an upgrade to its Beni Suef plant. The cement producer alleges that Sinoma has not met its contractual obligations on the project to build new mills. South Valley Cement says that Sinoma has liquidated letters of guarantee worth nearly US$2m, left the construction site and started arbitration proceedings. South Valley Cement is now considering its legal options. The status of the upgrade project remains unknown.

China: Anhui Conch’s Wuhu Conch subsidiary has installed bag filters on its Line 3 production line. Dust emissions are stable at 7 – 8mg/m³. The cement producer said that this was in full compliance with national emissions standards.

India: Chandrababu Naidu, the chief minister of Andhra Pradesh, has laid the foundation stone for Ramco Cements’ new 3.15Mt/yr integrated plant at Kalavatala, Kolimigundla Mandal in Kurnool District. The project has an investment of nearly US$210m. The plant will include a waste heat recovery (WHR) unit and a captive power plant. A 25km railway line from Samjamala has also been proposed to support the plant. Once the required statuary clearances are obtained the plant is expected to take 15 months to build.

Other new projects the cement producer has scheduled include an upgrade at its Jayanthipuram plant in Krishna District to 4.6Mt/yr from 3.1Mt/yr with a 27MW WHR unit. The project has a cost of just over US$100m and it is expected to be commissioned in March 2020. The company is also upgrading the grinding capacity of its Vizag plant to 2Mt/yr from 0.9Mt/yr. This project has an investment of around US$25m and is also expected to be commissioned in March 2020. Once these three projects are completed Ramco Cements says that it will become the largest producer in Andhra Pradesh with a production capacity of nearly 10Mt/yr.

In the east of the country Ramco Cements us building a new 0.9Mt/yr grinding plant in Odisha with a railway terminal for around US$70. This is expected to be commissioned by September 2019. In West Bengal the company is upgrading the grinding capacity at its Kolaghat plant in East Midnapore district to 2Mt/yr from 0.9Mt/yr for around US$60m. This project also includes a railway terminal and it is scheduled for commissioning in April 2019. Altogether the company plans to reach a cement production capacity of 20Mt/yr by 2020 across the country.

India: The board of Ambuja Cements has approved an extension to its Marwar Mundwa integrated plant project in Rajasthan. The clinker production capacity of the plant has been increased to 3.1Mt/yr and an additional 1.8Mt/yr cement grinding capacity has been added. The total investment of the project has been increased to around US$326m. A waste heat recovery (WHR) unit has also been added to the project. Once completed the plant will increase the subsidiary of LafargeHolcim’s production capacity of 31.5Mt/yr.