Displaying items by tag: Waste Heat Recovery

Kyrgyzstan had a couple of prominent stories in the press towards the end of December 2023 with news of a new plant and continuing data showing that cement production has grown.

The Chüy project was first announced by the government in mid-2022 when it signed an investment agreement with a consortium comprising representatives from Terek-Tash and ZENIT. More information on the unit emerged this week when the Russian-Kyrgyz Development Fund revealed that it made a loan of US$45m towards the scheme based in the northern Chüy region of the country. The plan is to build a 1.7Mt/yr plant with a budget of US$160m. Equipment to build the plant is reportedly being sourced from companies in China and Russia. Special features of the project include a waste heat recovery unit and the use of ash from the Bishkek Thermal Power Plant in the production process. The plant is expected to be launched in 2024.

Graph 1: Cement production in Kyrgyzstan, 2018 - 2023. Source: National Statistical Committee of the Kyrgyz Republic.

One reason why the government might be keen to build a new plant is because cement production has mostly grown in each of the past five years, with the exception of 2020, when the Covid-19 pandemic began. In 2022 it increased by 7% year-on-year to 2.7Mt and the latest data from the National Statistical Committee indicates that it rose by 11% year-on-year to 2.6Mt in the 11 months to the end of November 2023. If this rate held in December 2023 then it looks likely that the country will have produced just under 3Mt in 2023. At the same time the country’s exports of cement have also been falling. In November 2023 the government of Kazakhstan’s Jambyl Region said that it had found investors to support construction of a railway line between the locale and Kyrgyzstan due to a ‘building boom’ in the latter country.

Earlier in 2023 the Eurasian Development Bank (EDB) said it had earmarked US$48m for the modernisation of equipment at the Kant Cement plant, operated by Kazakhstan-based United Cement Group (UCG), also in Chüy region. The plant is the biggest in Kyrgyzstan, running five wet process production lines, according to the Global Cement Directory 2023. The EDB linked its investment to a hydroelectric project in the country that it is also funding, pointing out that such structures require lots of cement and concrete. This follows a previous upgrade project by owner Kazakhstan-based United Cement Group (UCG) at the plant from 2021 to March 2023. This involved efficiency and environmental gains such as installing bag filters and converting a cement grinding mill to a closed circuit. China-based and CNBM subsidiary China Triumph International Engineering was the lead project partner. In early December 2023 UCG announced that it had signed another contract with China Triumph International Engineering over the summer to build a new dry production line at the site with a clinker capacity of 0.8Mt/yr. At the time of the announcement it said that preparation of the construction site had started and that work had begun on installing a pile foundation.

Finally, one more Kyrgyz news story of note in recent months was the announcement in October 2023 that the government had effectively nationalised the Kurmentinsky Cement plant in Issyk-Kul Region. The reason why it had done so was unusual because it said that a 93% share in the company running the plant had been transferred to the State Property Management Agency following the death of its former owner. The former owner was one Kamchybek Kolbaev, an organised crime boss who had been listed on the US Department of State Transnational Organized Crime Rewards Program and was reportedly killed by state security services in early October 2023. The remaining shares in the plant have been passed to its workers and the government further said that it intends to upgrade the site.

The cement sector in Kyrgyzstan is modest and in need of modernisation. It appears to be having a resurgence at the moment though with production mounting and at least two major plant projects underway. The country is in a compelling position economically and geopolitically given its membership of the Russia-backed Commonwealth of Independent States (CIS) and its proximity to China. Various projects backed by the latter’s Belt and Road Initiative, both underway and forthcoming, would certainly appear to benefit from more efficient local cement production and higher volumes.

India: Adani Group subsidiary Ambuja Cements plans to invest US$722m in renewable energy projects to help decarbonise its cement production. The producer has a renewable power capacity target of 1000MW, through solar and wind projects, by the end of the 2026 financial year. The proposals include a 600MW solar power project and 150MW wind power project in Gujarat, and a 250MW solar power project in Rajasthan. The company also plans to increase its waste heat recovery (WHR) capacity to 397MW by late 2028 from 103MW at present.

Ajay Kapur, the chief executive officer of Adani Group’s cement business, said "This strategic investment reaffirms our steadfast commitment to sustainable practices. We are not just aiming for a substantial increase in green power capacity but setting the stage for a transformative shift in the cement industry. They align not only with our growth trajectory but also with the national objective of decarbonisation and greener future and this helps us become competitive and sustainable."

Adani Group announced in mid-December 2023 that it was committed to investing US$100bn in the decade to the end of 2033 towards transitioning its operations to net zero CO₂ emissions by 2050.

India: UltraTech Cement plans to more than double the share of renewable electricity in its energy mix to 60% by the 2026 financial year, which will end on 31 March 2026, from 22% at present. Asian News International has reported that the group plans to reach 85% renewable energy use by 2030. It presently has 691MW-worth of installed renewable power capacity, comprised of 429MW of contracted renewable power plants and 262MW of waste heat recovery (WHR) plants. Other decarbonisation technologies in UltraTech Cement’s operations besides renewable power include its use of compressed natural gas and liquefied natural gas as vehicle fuel.

Saudi Arabia: Riyadh Cement Company awarded a US$34.8m contract to China-based Sinoma Energy Conservation to install a waste heat recovery (WHR) plant at its 3.7Mt/yr Riyadh cement plant. The installation will have a power generation capacity of 12.6MW.

India: Orient Cement has commissioned a waste heat recovery (WHR) plant at its Chittapur cement plant in Karnataka. Reuters has reported that the producer plans to subsequently scale up the WHR plant in a second construction phase.

Greece/Germany: Greece-based cement producer Titan Group and Germany-based Orcan Energy have entered a partnership to explore the development and deployment of Orcan’s innovative modular waste heat recovery (WHR) solutions across Titan’s international cement production base. Orcan’s solution converts cement process waste heat into electricity that it says can accelerate decarbonisation while reducing operational costs. As a first step, the partners will undertake an assessment of where Orcan Energy's WHR systems can be applied across Titan's facilities. The study will encompass a thorough pilot site evaluation, starting at several plants within the group. The initial focus will be on recovering waste heat from pre-heaters and clinker coolers.

Samir Cairae, Chief Technology Officer at Titan said “The collaboration with our waste heat recovery partner Orcan Energy has the potential to transform waste heat into zero-carbon clean energy, with a novel but well-proven modular approach."

Andreas Sichert, chief executive officer at Orcan Energy, said “We are thrilled to partner with Titan to use its vast and valuable waste heat resources. Our technology will help not only to reach the group’s extraordinary decarbonisation ambitions but also to significantly save electricity expenses. Our modular approach will allow Titan to flexibly respond to outside changes in uncertain times.”

Look out for an interview with Orcan Energy in the forthcoming November 2023 issue of Global Cement Magazine

China: Taiwan Cement (TCC) commissioned a 107MWh energy storage project at its Yingde plant in Guangdong province in August 2023. Subsidiary NHOA Energy worked on the project that linked the battery storage capacity to a 42MW waste heat recovery (WHR) system and a 8MWp solar photovoltaic unit. It uses lithium iron phosphate batteries supplied by Ningde Times.

The company’s say that the project is one of the largest industrial microgrids in the world. It is intended to provide energy flexibility to the cement plant by using NHOA Energy’s proprietary energy management system to manage peaks in energy demand and acting as a backup for critical equipment to avoid damage caused by sudden blackouts.

The NHOA Energy storage project is expected to store about 46000MWh/yr of electricity and save just under US$3m/yr in electricity costs. The system will also support the Guangdong Provincial Government’s energy storage development policy and be eligible to associated subsidies of over US$350,000/yr.

Giuseppe Artizzu, the chief executive officer of NHOA Energy, said “NHOA Energy’s proprietary energy management system will optimise the generation and consumption profile of the industrial microgrid, while also supporting the regional grid towards its 100% green energy objective, taking the energy transition in the area one step forward in total accordance with NHOA Group’s and TCC’s shared mission of fostering a positive change for the future of our planet.”

India: The India Cements expects to commission the upgraded grinding unit at its Sankar Nagar cement plant in Tamil Nadu later in September 2023. Hindu BusinessLine News has reported that the producer is undertaking the upgrade in order to increase efficiency and lower the plant’s operating costs. The producer has hired US-based Boston Consulting Group to ascertain other possible improvements to three of its plants in Andhra Pradesh and Telangana. At its Chilamkur cement plant in Andhra Pradesh, it is installing a waste heat recovery (WHR) system, scheduled for delivery in early 2024. FLSmidth and ThyssenKrupp Industrial Solutions are both reportedly conducting ‘detailed studies’ for possible future projects for The India Cements.

India: Adani Group subsidiary ACC has started commercial clinker production from the kiln of its new Ametha cement plant in Madhya Pradesh’s Katni District. BQ Prime News has reported that the kiln line has a clinker capacity of 3.3Mt/yr. It is capable of co-processing up to 15% alternative fuel (AF). The plant is also equipped with a 1Mt/yr grinding unit and a 16.3MW waste heat recovery (WHR) plant.

The Ametha cement plant raises ACC’s installed cement and clinker capacity by 9.8% to 37Mt/yr.

India: Ambuja Cements has concluded a deal to acquire a 57% stake in Sanghi Industries for US$202m. Reuters has reported that the company has offered to subsequently increase its stake in Sanghi Industries to as much as 83% for up to US$295m in total. It will fund the acquisition of any stake through internal accruals. Sanghi Industries operates the 6.1Mt/yr Sanghipuram cement plant, which is equipped with a 130MW captive power plant and a 13MW waste heat recovery (WHR) plant. The cement plant, in Gujarat, also has a single-jetty port on the Arabian Sea coast. Ambuja Cements' parent company Adani Group plans to more than double the Sanghipuram cement plant's capacity to 15Mt/yr.

Adani Group chair Gautam Adani said “By joining hands with Sanghi Industries, Ambuja is poised to expand its market presence, strengthen its product portfolio and reinforce its position as a leader in the construction materials sector. With this acquisition, Adani Group is well on course to achieve its target of 140Mt/yr of cement manufacturing capacity by 2028 ahead of time.”