Displaying items by tag: grinding plant

Turkey: Çimsa Çimento has completed the divestment of its 1Mt/yr Kayseri and 1.2Mt/yr Niğde integrated cement plants and its Ankara grinding plant to Fernas Group. The transaction was valued at Euro110m. The sale was originally announced in mid-June 2022.

Malaysia: Cahya Mata Sarawak says that it has no plan to double the capacity of its Bintulu, Sarawak, grinding plant, Reuters News has reported. The company, however, noted the potential ‘opportunity’ offered by the construction of a new Indonesian capital in Nusantara, East Kalimantan, on the opposite side of Borneo.

A trio of slag cement stories have been in the sector news this week with reports from Australia, France and Sri Lanka. Of note from the first two reports is a focus on supplies of slag.

The first concerns Hallett Group’s US$80m supplementary cementitious materials (SCM) project in South Australia. This will see the company process slag and fly ash sourced from sites in the region to manufacture blended cement products and standalone SCMs. These will be principally milled, blended and distributed from a site at Port Augusta. However, an additional distribution site at Port Adelaide is also planned that can both import and export the company’s products in a bid to cut down on supply chain risk, particular for its mining customers. The company says it will replace up to 1.15Mt/yr of cement when fully operational, although initial production looks set to be about a third of this based on local media reports. Commissioning of the Port Adelaide distribution hub is scheduled for May 2023, following by the Whyalla Granulator in January 2024 and the Port Augusta processing plant in June 2024. Pointedly, Hallett Group is explicit about where is plans to source its SCMs from: Nyrstar Port Pirie and, potentially, Liberty GFG.

The second slag-themed story hails from France, where Hoffmann Green Cement has acquired ABC Broyage, which operates a slag grinding plant in North Dordogne. Like the project in Australia above, Hoffmann Green is focused on its supply chain. With this acquisition it will be able to grind its own blast furnace slag instead of buying it. Raw blast furnace slag will be imported via the port of La Rochelle where the company has storage silos. It will then be ground at the former ABC Broyage site and sent on to Hoffmann Green’s H1 and H2 production sites, located at Bournezeau in the Vendée region. Finally it will use it to manufacture its H-UKR and H-IONA cement products. There is no mention of how much the acquisition is costing Hoffman Green. Instead the emphasis, according to company founders Julien Blanchard and David Hoffmann, is very much to, “strengthen our control over our supply and secure our margins in the current highly inflationary context.”

Finally, the week’s third slag-themed cement story is from Sri Lanka, where local media reports that Insee Cement has started producing Portland Composite Cement, using SCMs such as slag, at its Ruhunu grinding plant. This story follows the trend of cement producers around the world switching to greater usage of blended cements, often for sustainability reasons. Unfortunately, political events in Sri Lanka are overshadowing everything else locally, with the president having fled amid social unrest provoked by the ongoing and severe economic crisis. To this end Insee Cement has astutely also donated medical supplies this week to the intensive care unit at the Colombo National Hospital.

These slag stories are important for the cement sector can be demonstrated by a recent update to the Center for International Climate and Environmental Research - Oslo’s (CICERO) research on global CO₂ emissions from cement production. When it published its estimate for 2021 it found that overall emissions were 2.6Bnt in 2021 or just over 7% of the world’s total CO₂ output. What is worse though, is that its data suggests that cement-based emissions have steadily grown year-on-year from 1.2Bnt in 2002. Apart from a dip in 2015 they have kept on rising! This can mostly be attributed to the growth of the Chinese cement industry in the early 2000s suggesting that a tipping point may be reached in the current decade as lowering cement production CO₂ intensity finally kicks in.

Slag and other SCM-based blended cements fit in here as they are one of the ‘easiest’ ways to reduce the clinker factor of cement and concrete and thereby reduce the sector’s CO₂ levels. Hence they keep popping up on the various roadmaps and reports for the cement industry to reach net zero. The flipside of this however is that slag is becoming harder to source as the demand for granulated blast furnace slag increases and less new steel plants get built, especially in North America and Europe. Hence the focus on the supply of slag in the first two news stories above. Blended cements may be the future but getting there will be far from simple.

Australia: Hallett Group plans to establish a slag cement grinding plant in Port Augusta, South Australia. Magnet News has reported the cost of the project as US$83.9m, towards which the producer has received US$13.4m in government funding. The plant will produce cement using South Australian ground granulated blast furnace slag (GGBFS) from Nyrstar’s Port Pirie and Liberty Primary Steel’s Whyalla steel refineries and fly ash from the site of the former Port Augusta power plant. Its operations will be 100% renewably powered. An accompanying new distribution facility at Port Adelaide will ship the cement to markets. The project will create 50 new jobs.

When the Port Augusta grinding plant becomes operational in 2023, its products will reduce regional CO₂ emissions by 300,000t/yr, subsequently rising to 1Mt/yr, according to the company’s expansion plans.

Hallett Group chief executive officer Kane Salisbury said "We're talking about 1% of the entire country's 2030 [CO₂ reduction] commitment, delivered through this project." Salisbury added "We're looking at turning South Australia into a global leader in manufacturing green cement."

France: Hoffmann Green Cement Technologies has acquired ABC Broyage, which operates a slag grinding plant in North Dordogne. The producer says that ABC Broyage will import granulated blast furnace slag (GBFS) via La Rochelle and supply ground GBFS to its H1 and H2 green cement plants in Bournezeau. This will give Hoffmann Green Cement Technologies self-sufficiency in its raw materials processing.

Co-founders Julien Blanchard and David Hoffmann said “Managing our supply chain has always been one of Hoffmann Green's strategic priorities. After securing our supplies of co-products and their storage, we are now focusing on optimising their processing through the acquisition of ABC Broyage and the development of vertical integration.” Blanchard and Hoffmann noted that, besides strengthening the company’s control over its raw materials supply, ABC Broyage’s slag grinding capacity also secures its margins in the ‘current highly inflationary context.’

Latvia: Germany-based Christian Pfeiffer says that it has successfully commissioned the new Broceni grinding plant for Schwenk Latvija. The supplier said that the plant is able to produce cement up to a fineness of 5600 Blaine and is one of the most sustainable grinding plants in Europe.

Schwenk Latvija previously announced a planned investment of Euro34m in a new 170t/day mill and a 12,500t silo at the site of its former Broceni integrated cement plant.

Liberia: Fouta Cement has secured a US$21.2m financing package for the construction of its upcoming 350,000t/yr Monrovia grinding plant. The International Finance Corporation (IFC) has reported that the package consists of a US$5.4m loan from IFC's own account, a US$10.8m loan from the International Development Association's Private Sector Window Blended Finance Facility (IDAPSWBFF) and a US$5m from Bank of Africa United Kingdom (BAUK).

Fouta Cement's managing director Hamidou Gnan said "IFC's package of long-term investment and advisory services gives us the foundation and support we need to make the switch from reseller to manufacturer, thereby adding more value and creating more jobs in Liberia."

India: Star Cement plans to invest US$129m to establish a new 3Mt/yr clinker line. BusinessLine Online News has reported that producer currently operates 2.8Mt/yr-worth of clinker capacity across two units in Meghalaya. Star Cement says that it plans to increase its presence in the Northeast India, Bihar and West Bengal markets. It will additionally invest US$90 – 103m to establish two new grinding units with a combined capacity of 4Mt/yr at Guwahati and Silchar in Assam.

Star Cement said that projected infrastructure investment growth in Northeast India inspired its investment decision, while it opted for a 3Mt/yr kiln over a 2Mt/yr alternative due to the improved efficiencies it offers.

Zimbabwe: Lafarge Zimbabwe’s cement volumes fell by 55% year-on-year in the first quarter of 2022. The company restarted grinding units at its Manresa grinding plant in February 2022 following a roof collapse in October 2021. In a trading update, Lafarge Zimbabwe said that the disruption impacted its profit in the quarter. The producer took the opportunity to decommission one of its ball mills for replacement with a new vertical roller mill in mid-2022.

Chief executive officer Geoffrey Ndugwa said “The company is confident that volumes will recover and grow as the availability of cement stabilises, especially after the new vertical roller mill start-up in the second quarter of 2022.”

Chile: Melón has inaugurated a new 0.25Mt/yr grinding plant in Punta Arenas. The project had an investment of US$45m, according to the El Pingüino newspaper. In its first year of operation an output of 80,000t is planned. It is the first cement plant in the Magallanes Region. Spain-based Cemengal supplied a Plug&Grind Xtreme grinding unit for the project.

Jorge Eugenín, the chief executive officer of Cementos Melón, attended the event and said, “For us Magallanes has always been an interesting market. Its consumption is comparable to cities in developed countries.” He added that the region has a per capita cement consumption level of 550kg/yr compared to the Chilean mean of 280kg/yr.

The cement producer previously announced plans to double the production of the plant by building a second grinding mill if the market supported it. Eugenín commented that the announcement of a large-scale hydrogen project in the region by Total Eren in late 2021 could add further momentum to expansion plans for the new cement plant.