Displaying items by tag: Waste Heat Recovery

Germany: Mexico-based Cemex subsidiary Cemex Zement has set up an innovation acceleration partnership called Carbon Neutral Alliance to support its work to achieve net zero CO₂ emissions at its Rüdersdorf cement plant by 2030. The association will work to develop industrial-scale demonstration projects in line with the company’s Future in Action programme. Its scope will include carbon capture and storage (CCS), the transformation of captured CO₂ into building materials, synthetic fuels and green hydrocarbons, hydrogen production and waste heat recovery (WHR). Cemex plans to share the knowledge gained by the alliance across its global cement network.

Managing director and Rüdersdorf plant manager Stefan Schmorleiz said, "It is expected that CO₂ will be further processed to convert to new forms of energy and materials for use locally by industrial, residential, and transport sectors. Together with our partners, we will take feasibility studies through to economic solutions to decarbonising cement production.”

India: Ramco Cements says that its 16Mt/yr installed production capacity will increase to 20Mt/yr during its 2022 financial year that starts in April 2021 with the completion of a new plant at Kurnool in Andhra Pradesh and a third production line at its Jayanthipuram plant. The original plan to complete the work by the end of March 2021 was delayed by the coronavirus pandemic, according to the Hindu newspaper. The new integrated plant at Kurnool will have a clinker capacity of 2.25Mt/yr and a cement production capacity of 1Mt/yr. The third production line at the Jayanthipuram plant will have a production capacity of 1.5Mt/yr, increasing the plant’s total to 4.5Mt/yr.

The producer also plans to complete Phase 3 of the installation of a waste heat recover (WHR) unit at the Jayanthipuram plant. Phase 1 (9MW) was commissioned in September 2020, Phase 2 (9MW) in February 2021 and Phase 3 (9MW) is scheduled for after the third line is complete. So far the first two stages have reduced the cement plant’s power consumption from a thermal power plant by 15MW. The project has cost around US$30m.

Ramco Cements has spent US$345m out of its planned US$470m capital expenditure in the 2021 financial year, which ends on 31 March 2021.

India: ISGEC Heavy Engineering has won a contract for a double waste heat recovery (WHR) unit installation at Shree Cement’s Raipur cement plant. The Business Standard newspaper has reported that the supplier will install one unit on the plant’s pre-heater exhaust, and the other on the 10,500t/day kiln’s cooler exhaust.

Industrial and green energy boilers business head Vinod Luthra said, “This is indeed a very prestigious order for us and we thank Shree Cement for once again showing confidence in ISGEC's capabilities. This is the second project that ISGEC will be successfully setting up for Shree Cement."

Pakistan: The board of directors of Kohat Cement Company Limited (KCCL) has approved plans to establish a 7800 – 10,000t/day integrated cement plant at Khushab, Punjab. The company will also set up an 8 – 10MW waste heat recovery (WHR) plant and a 25MW coal-fired power plant at the site. The total estimated cost of the project is US$189m. The producer will raise finances through a mix of debt and equity. Commissioning is scheduled for mid-2023.

Dominican Republic/Philippines: Cemex says that it will commission two new energy saving installations at cement plants in the Dominican Republic and the Philippines in 2021. In the Dominican Republic, a new 41MW solar power plant will partly supply the company’s cement operations in the country. In the Philippines, it will commission a 4.5MW waste heat recovery (WHR) plant at its APO cement plant.

India: Ambuja Cements subsidiary ACC has held the groundbreaking ceremony for its upcoming 2.7Mt Ametha integrated cement plant near Kymore, Madhya Pradesh. The company says that the plant will be equipped with an additional 1Mt/yr grinding unit and a 15MW waste heat recovery (WHR) plant. It estimated that the new plant will generate over 5000 indirect jobs. The producer currently operates 3.6Mt/yr of clinker production and 2.7Mt/yr of grinding capacity in the state.

LafargeHolcim India chief executive officer and Ambuja Cements managing director and chief executive officer Neeraj Akhoury said, “Our Business Excellence Journey has been successful on account of the continuous support and guidance rendered to us by the State Government. It is a great privilege and honour for us to be one of the pioneers in the industrialisation journey of Madhya Pradesh. The new project will further strengthen our partnership and propel the growth of the State.”

India: Ramco Cements’ nine-month profit for the period ending on 31 December 2020 was US$77.9m, up by 23% year-on-year from US$63.3m in the corresponding period of the 2020 financial year. Cement sales volumes dropped by 18% to 67.6Mt from 82.7Mt. Its revenue from sale of products fell by 9% to US$488m from US$535m.

The company reported that it has redeposited US$3.54m for its appeal against cartelisation charges that carrya penalty of US$35.4m. It said, “The company, backed by legal opinion, believes that it has a good case and hence no provision is made.”

The cement producer plans to commission a 1.5Mt/yr clinker line and a 9MW waste heat recovery (WHR) system at Jayanthipuram, Andhra Pradesh and a 2.25Mt/yr clinker line at Kurnool, Andhra Pradesh in the first quarter of its 2021 – 2022 financial year. A 1Mt/yr grinding unit, a 12MW WHR unit and a thermal power plan are expected to be commissioned later in the year.

Oman: Raysut Cement has held a groundbreaking ceremony for a new 9MW waste heat recovery (WHR) unit at its Salalah cement plant. The Times of Oman newspaper has reported that China-based Sinoma Overseas Development will undertake the engineering, procurement and construction work on the project.

The producer said that the installation “Will contribute significantly to our ambitious targets such as reducing power consumption by 25 - 30%, reducing CO₂ emissions and above all reducing in water consumption by more than 50%.”

Manoj Kumar Rustagi was on hand yesterday to discuss JSW Cement’s operations in the UAE at the Virtual Middle Eastern Cement Conference. At the event, jointly organised by Global Cement Magazine and the Arab Union for Cement and Building Materials (AUCBM), Rustagi mainly stuck to the development of the producer’s new integrated plant in the Fujairah Free Zone but he also gave an overview of JSW Cement’s presence in India. For example, as part of an industrial conglomerate, JSW Group, the cement producer benefits from links to steel production by JSW Steel that enables it to use blast furnace slag. Notably, JSW Cement’s Shiva Cement subsidiary announced plans at the end of November 2020 to spend around US$200m on a new 1.4Mt/yr integrated cement plant in Sundergarh district, Odisha with the clinker production line supplied by ThyssenKrupp Industries India.

JSW Cement is not alone in ordering new production capacity. This week, UltraTech Cement approved a planned increase of 12.87Mt/yr for around US$740m. This is in addition to new capacity projects of 6.7Mt/yr that are currently underway. All of these new projects are scheduled to be commissioned in a phased manner by the end of the 2023 Indian financial year (by March 2023). It is unclear at present how exactly these projects are distributed but they are centred in the Northern, Central and Western Zones of the country, and the new tranche includes the previously announced Pali plant in Rajasthan. At this price the inference is that the much of the new capacity will be in the form of grinding plants and/or upgrades to existing clinker lines. Around the same time as this, LafargeHolcim said it wants to spend US$112m on waste heat recovery (WHR) plants for six of its cement plants in India by the end of 2022.

Graph 1: Change in Indian cement production year-on-year (%). Source: Office of the Economic Adviser.

These three projects by major producers suggest that the Indian cement sector is recovering from the effects of the coronavirus lockdown in late March 2020. Graph 1 above shows the sector finally recovering in October 2020, with growth of 3% year-on-year to 26.9Mt. Kumar Mangalam Birla, the chairman of Aditya Birla Group, credited the economic situation with the Indian government’s Atmanirbhar Bharat stimulus program for his decision to commit to UltraTech Cement’s spending spree. This outlook gels with that of Fitch Ratings. The credit ratings agency has forecast in a recent report that ‘strong’ margins during the first half of the 2021 financial year (April – September 2020) are going to limit the financial risks to the larger Indian cement companies despite the lower cement sales volumes due to coronavirus. Pent-up demand helped the industry recover after the lockdown and this was further aided by lower energy/fuel costs and general cost cutting.

Needless to say all of the above is good news for the Indian cement industry after the year it has had. One thought to consider from all of this is who might UltraTech Cement order its mills and clinker lines from? Atmanirbhar, the name of the Indian stimulus plan, has been described as ‘self-reliance’ or ‘self-sufficiency’ in the local press. Unfortunately, relations have been poor between India and China in 2020 due to armed skirmishes along the Line of Actual Control on the border, amongst other issues. Ordering a new clinker production line from, say China-based Sinoma, may not look especially ‘self-sufficient’ in the current climate.

The proceedings pack and video from the Virtual Middle Eastern Cement Conference 2020 is availabe to buy now

India: 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.