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Displaying items by tag: grinding plant
India: Residents of Kamrup, Assam, have petitioned the district government to block Taj Cement’s plans to build a new 1Mt/yr grinding plant at Chamata Pathar. The residents’ petition cites groundwater and ecological concerns over the plan. The Sentinel newspaper has reported that the plant will be the third cement facility in the immediate area. The area adjoins the Amchang and Pabitora Wildlife Sanctuaries.
The Greater Dimoria Citizens’ Protection Committee said “The current cement factories have already taken a toll on our environment and health. The proposed Taj Cement plant will only make matters worse, putting our lives and the nearby wildlife sanctuaries at risk.”
Ambuja Cements to acquire grinding unit in Tamil Nadu
15 April 2024India: Ambuja Cements will acquire the grinding unit of My Home Group in Tuticorin, Tamil Nadu, for US$49.6m. The unit has a capacity of 1.5Mt/yr. The acquisition is spread across a 24.6-hectare site near Tuticorin Port and comes with a long-term fly ash agreement.
The CEO of Cement Business at Adani Group, Ajay Kapur said "In addition to the infrastructure and geographical advantages, Ambuja Cements will also inherit the existing dealer network and retain current employees, facilitating a smooth transition and enabling the rapid ramp-up of utilisation."
The total cement capacity of Adani Group now stands at 78.9Mt/yr.
Update on France, April 2024
10 April 2024Heidelberg Materials announced this week that it is preparing to close its integrated cement plants at Beffes and Villiers-au-Bouin in France by October 2025. It framed the restructuring as a response to ‘a significant decline in cement sales in France’ and a plan to focus on low-carbon products. Unfortunately, local media reported that around 170 jobs will be lost at the two sites. The company says it is looking at ‘socially acceptable solutions’ including redeployment to other locations in the country.
Investment has been forthcoming from Heidelberg Materials France in recent years. It reminded everyone that it initiated a Euro400m scheme at its France-based subsidiary Ciments Calcia in late 2020. Most of this was earmarked towards a new production line at the Airvault plant, which is currently being built. Other schemes at the Beaucaire, Bussac-Forêt and Couvrot integrated plants followed. More recently, Heidelberg Materials launched a carbon capture, utilisation and storage (CCUS) project at Airvault, part of the GOCO2 initiative, with the aim of starting initial capture in 2030 with full 1Mt/yr capture planned later. What the company didn’t mention though was at the time of that 2020 investment it was also preparing to convert the integrated Gargenville plant into a grinding unit, stop white cement production at its Cruas plant with the intention of turning the site into a terminal and it wanted to reduce its workforce by around 140. To be fair to Heidelberg Materials though, it did have the same goal of reducing its specific net CO2 emissions. The added detail this week was that the group aims to generate half of its revenue from sustainable products that are either low-carbon or circular by 2030.
Heidelberg Materials France is not alone with its ambitions for low-carbon products. Holcim notably opened in early 2023 what it said was the first calcined clay unit in Europe at its Saint-Pierre-la-Cour cement plant. Heidelberg Materials then followed in May 2023 with the announcement of a calcined clay project at its Bussac-Forêt cement plant. Other clay projects from Vicat, NeoCem and Neo-Eco have been reported since then. The other prominent France-based blended cement producer that has steadily been building its business in recent years is Hoffmann Green Cement. More general plant upgrade projects that are also worth mentioning include Eqiom’s (CRH) upgrade to its Lumbres plant in February 2024 and the ignition of a new kiln at Lafarge France’s Martres-Tolosane plant in October 2023. Both of these projects have been framed as driving sustainability.
Graph 1: Cement production in France, 2014 - 2022. Source: France Ciment.
Heidelberg Materials’ assessment about the poor state of the cement market has been confirmed by local media. Sales reportedly started falling in 2022, were down by 6% year-on-year in 2023 and further downward pressure is expected in 2024. Production data shown in Graph 1 above released by France Ciment, the national cement association, doesn’t really show what has been happening with sales. Over the last 20 years production hit a high of around 22Mt in the mid-2000s before settling around 16 - 17Mt/yr from 2015 onwards. The more telling trend, perhaps, has been the increase in CEM II blended cements from 50% in 2012 to 64% in 2022. Cement production may have stayed roughly the same over the last decade but it is using less clinker than it used to. Hence the pressure on companies like Ciments Calcia to reduce clinker capacity.
A further cost pressure facing cement producers in France is the impending end to the price cap on electricity scheduled by the end of 2025. The government enacted the scheme in late 2021 at the end of the Covid-19 pandemic, but then carried on as energy prices spiked following the Russian invasion of Ukraine. France Ciment lobbied in August 2023 for further protection for the sector using the argument that decarbonisation was not possible without electricity available for a reasonable price. It added that decarbonising the cement sector in France with carbon capture would cost around Euro3.5bn. Electricity prices started rising in February 2024 as part of the government’s phase out of the scheme.
Finally, 17 people were arrested on 5 April 2024 in connection with a demonstration at Lafarge France’s Val-de-Reuil ready-mixed concrete plant in Eure. Environmental activists reportedly trespassed on the site, according to local press, causing an estimated Euro450,000 in damages with acts such as spraying foam into machinery, ripping up bags of cement, breaking windows and more. The activists presented their actions as a response to both the environmental impact of cement and concrete production and the ongoing legal allegations about Lafarge’s actions in Syria in the early 2010s. Lafarge France’s La Malle integrated plant was also similarly targeted in December 2022 when around 200 activists stormed the site and caused damage to machinery and property. Lafarge’s response at the time was to remark that there was a feeling of misunderstanding given that the La Malle plant was piloting various decarbonisation methods.
All of this presents a febrile picture of the cement sector in France. Sales are down, electricity costs are set to go up and producers are switching to low-carbon cement products. Alongside this they are also closing clinker production plants but are also investing in new decarbonisation projects. At the same time environmental protestors have also been targeting cement and concrete plants and Lafarge’s association with its former actions in Syria appear to have made it more of a target than the other manufacturers. It is unsurprising then that Holcim, the parent company of Lafarge France, has raised the risk of damage to the group’s reputation, with both the general public and investors, should it fail to meet its targets. Reaching net zero was never going to be easy but setting unrealistic targets is increasingly not an option.
UltraTech increases production capacity
03 April 2024India: UltraTech Cement has allocated US$3.8bn for capacity expansion over the next three years, including the acquisition of Kesoram Cement. The company aims to increase grey cement production to 198Mt/yr. Recently, it commissioned two new greenfield capacities totalling 5Mt/yr in Chhattisgarh and Tamil Nadu, raising its total capacity to 152Mt/yr. This exceeds more than 150% of the capacity of the US and 80% of Europe's capacity.
In the last year, UltraTech Cement increased its capacity by 19Mt/yr, with an additional 36Mt/yr being added at 16 locations.
India: Udaipur Cement has commissioned a new grinding unit at its Udaipur cement plant in Rajasthan. The unit more than doubles the plant’s grinding capacity from 2.2Mt/yr to 4.7Mt/yr. Capital Market News has reported that the Udaipur plant now has an integrated capacity of 3Mt/yr, following the establishment of a second 1.5Mt/yr clinker line there in October 2023.
The company said "Udaipur Cement has been a pioneer in the promotion of various green initiatives. The company is the only one in the entire Indian cement industry with a 1MW floating solar power plant at its mines. During the fourth quarter of the 2024 financial year, the company also doubled its Udaipur cement plant’s waste heat recovery capacity from 6MW to 12MW. This has enabled Udaipur Cement to achieve a green energy share of more than 50% in total electrical energy consumption."
India: UltraTech Cement has increased its cement production capacity by 2.4Mt/yr through debottlenecking at integrated and grinding plants in Gujarat, Rajasthan and West Bengal. Following the improvement exercise its total domestic capacity is 141Mt/yr and worldwide it is 146Mt/yr. The improvements were made at the Pali integrated plant in Rajasthan and grinding plants at Magdall in Gujarat, Sonar Bangla in West Bengal and Neem ka Thana in Rajasthan.
Netherlands: Ireland-based Ecocem has agreed a deal with Overslagbedrijf Moerdijk (OBM) to expand production and storage capacity at the company’s Moerdijk slag cement grinding plant. The project is intended to allow the unit to both produce and store the company’s advanced cement technology (ACT) product. It will quadruple the storage capacity for key materials at the site up to 40,000t. Ecocem has signed a long-term agreement to lease the site from OBM, who will manage the handling and storing materials on Ecocem’s behalf.
This expansion of the Moerdijk plant is part of Ecocem’s plans to expand its manufacturing and storage capacity to support the commercialisation of ACT across all its plants. It follows the expansion of its Dunkirk plant in France, which was announced in June 2023. These expansion plans will be supported by licencing and partnership strategies to accelerate availability and adoption of scalable low clinker cement at speed.
Conor O’Riain, Managing Director (Europe), at Ecocem, said: “We are increasing our capacity at all of our locations and our deal with OBM is a hugely important aspect of our expansion strategy. It will accelerate our ability to manufacture ACT our low clinker cement technology and make it available commercially by 2026. At the same time, we are actively pursuing licensing and partnership agreements in the construction industry to ensure the benefits of this technology are shared widely and we accelerate progress to Net Zero.”
In February 2024 Ecocem said that its ACT technology received an ETA (European Technical Assessment), which provides the technology with a route to full commercialisation by 2026.
India: Adani Group will invest US$603m in the construction of a 4Mt/yr clinker plant at Chorgadi and grinding plants in Dewas and Bhopal. The combined capacity will be 8Mt/yr. The move is part of a US$9bn investment which the company says will create 15,000 jobs across various sectors.
Ambuja Cements to build 4Mt/yr grinding plant in Jharkhand
21 February 2024India: Ambuja Cements is planning to build a 4Mt/yr cement grinding plant at Motia Village, Godda District in Jharkhand. The project has a budget of US$120m. The proposed plant will use fly ash supplied from the nearby Andani Power Godda thermal power plant.
Ajay Kapur, CEO – Cement Business at Adani Group, said “We believe that Jharkhand holds immense potential in terms of resources, infrastructure and skilled manpower, making it an ideal location for this project.”
Ambuja Cements operates two cement plant in Jharkhand with a combined production capacity of 6Mt/yr.
India: JSW Group plans to build a US$7.83bn steel complex in Jagatsinghpur district, Odisha. The complex will include a cement grinding plant. The Business Standard newspaper has reported that JSW Group's expansion plans in Odisha also include an electric vehicle and battery plant, at a cost of US$4.82bn. The group said that the investments reflect its commitment to diversifying its capabilities and contributing to the economic growth of Odisha.