Displaying items by tag: grinding plant
Kanodia Cement commissions Amethi grinding plant
19 April 2022India: Kanodia Cement has commissioned its new Amethi cement plant in Uttar Pradesh. The plant consists of four grinding units spread over an area of 18ha. Indo-Asian News Service has reported that the facility’s equipment includes two 12-spout rotary packers and six floor-mounted truck loading machines, supplied by Denmark-based FLSmidth. Kanodia Cement says that the new plant marks progress in line with its sustainable development plant. Its operations will directly and indirectly employ 1000 people.
Ghana: Denmark-based Investeringsfonden for Udviklingslande (IFU) and Norway-based Norfund have invested US$27.9m in CBI Ghana. The funding will support the cement producer’s upgrade of a clay calcination unit at its 0.6Mt/yr Tema grinding plant in Accra. Denmark-based FLSmidth is supplying the equipment for the project.
Namibia: Immigration authorities have apprehended eight Chinese employees of Whale Rock Cement at the company’s Otjiwarongo grinding plant who failed to produce working permits during an inspection. Namibian Press Agency News has reported that seven of the workers have been in Namibia since mid-2021, while the eighth arrived in March 2022.
Calcined clay projects in Africa
06 April 2022African cement producers have confirmed their interest in calcined clay over the last month with two new projects. The big one was announced last week when FLSmidth revealed that it had received an order from CBI Ghana. This follows the launch of a Limestone Calcined Clay (LC3) project in Malawi in mid-March 2022 in conjunction with Lafarge Cement Malawi.
FLSmidth says that its order includes the world’s largest gas suspension calciner system and a complete grinding station. The kit will be installed at CBI Ghana’s plant near Accra in the south of the country. The new clay calciner system is expected to substitute 30 - 40% of the clinker in the final product, resulting in a reduction of up to 40% CO2/t of blended cement compared to Ordinary Portland Cement (OPC). Overall the equipment manufacturers reckon that the grinding plant will reduce its CO2 emissions by 20% compared to its current output. There has been no indication of how much the order costs but CBI Ghana expects energy and fuel savings, as well as lower overheads from clinker imports.
The public announcement of the Ghana project was also foreshadowed by the visit of Professor Karen Scrivener to the Ghana Standards Authority in February 2022. This was significant because Scrivener is the head of the Laboratory of Construction Materials at the Ecole Polytechnique Fédérale de Lausanne (EPFL) and has been one of the key instigators of the LC3 initiative since the early 2000s. Other calcined clay cements are available such as Futurecem or polysius activated clay (see below) but LC3 is arguably the most famous given its promotion in developing countries.
The Malawi project is at a much earlier stage. The government launched the public private partnership LC3 project in mid-March 2022 in conjunction with Lafarge Cement Malawi and Terrastone, a brick manufacturer. The Ministry of Mining is currently developing a memorandum of understanding with the Gesellschaft für Internationale Zusammenarbeit (GIZ), a Germany-based development agency. India-based Tara Engineering has also been linked to the scheme.
One thing to note about the Malawi project is that it is the first calcined clay project in the cement industry based in East Africa. All the other African ones are based in West Africa. The other two projects in this region are run by Turkey-based Oyak Çimento and its subsidiary Cimpor. The first of these is a 0.3Mt/yr calcined clay and a 2400t/day cement grinding production line that was commissioned in mid-2020. This plant is based at Abidjan in Ivory Coast. The second is a new plant that Germany-based ThyssenKrupp Industrial Solutions is building for Oyak Çimento at Kribi in Cameroon. This unit has a 720t/day calcined clay and a 2400t/day cement production capacity and it will use the supplier’s ‘polysius activated clay’ technology. ThyssenKrupp’s involvement came to light in early 2020 and commissioning was scheduled for late 2021. However, no update on the state of the project has been issued so far in 2022.
As the above examples show, Sub-Saharan Africa has at least one live calcined clay plant, two plants are being built and there’s one more at the development stage. This puts the region neck-and-neck with Europe, which has a similar mixture of current and developing projects. This column has been covering the wider trend of the growing usage of various types of blended cements recently, particularly in Europe and the US, with slag cements, Portland Limestone Cement (PLC) and more. With PLC, for example, note the transition of another two North American cement plants to PLC this week alone. As for calcined clay cement, it is fascinating to see the focus move to a different part of the world. Several commentators have predicted that the future looks set to be dominated by blended cements using whichever supplementary cementitious material (SCM) is most available for each plant. The growth in calcined clay confirms this view.
Global Cement is researching clay calcination use in the cement industry for the next edition of the Global Cement Directory. Email This email address is being protected from spambots. You need JavaScript enabled to view it. with any information on new industrial and research installations.
UAE: Switzerland-based ABB has carried out an upgrade of the control system for UltraTech Cement subsidiary Star Super Cement at the company's Dubai grinding plant. The supplier says that it installed its ABB Ability 800xA distributed control system (DCS) across three grinding units at the facility. The DCS will communicate between the plant and the company's Ras Al Khaimah clinker plant. ABB previously supplied electric and automation engineering services for the Ras Al Khaimah plant in 2012.
ABB Process Industries global cement lead Max Tschurtschenthaler said that Star Cement's operations will benefit from improved operator visibility, easier maintenance and reduced downtime due to the new systems.
FLSmidth to deliver clay calcination plant and grinding plant expansion at CBI Ghana's Tema grinding plant
30 March 2022Ghana: FLSmidth has secured a contract for the supply of a clay calcination plant at CBI Ghana's 0.6Mt/yr Tema grinding plant in Accra. The supplier says that it will also install a complete grinding station to more than double the plant's production capacity. FLSmidth says that the entire project will reduce the Tema facility's CO2 footprint by 20%. When commissioned, the new clay calcination plant will be the largest in the world, according to the supplier.
CBI Ghana chief executive officer Frédéric Albrecht said “Ghana is the perfect location for using clay as an environmentally friendly alternative to clinker. West Africa is traditionally a clinker and cement-importing region due to the lack of suitable limestone reserves. Developing countries with their young populations and a growing need for infrastructure and housing represent the future in cement consumption. Calcined clay cements are the most sustainable alternative to traditional clinker-based cement."
UK: Hercules Enterprises plans to establish an up to 0.5Mt/yr grinding plant at Sheerness on the Isle of Sheppey in Kent, according to Kent Online News. The plant would comprise two clinker grinding lines, a mobile ecohopper, a mechanical transport system for transfer of material into storage, a 47,000m3 clinker storage hall, six 3000m3 cement silos, three 3000m3 fly ash silos, two packing plants and a palletising hall.
Lanwa Sanstha Cement to invest US$60m in Phase 2 of Hambantota grinding plant construction
08 March 2022Sri Lanka: Lanwa Sanstha Cement says that it will invest US$60m in expanding its newly commissioned Hambantota grinding plant in order to enable it to serve 60% of local demand.
President Gotabaya Rajapaksa said "Construction is a key contributor to the local gross domestic product (GDP). Our construction sector has a competitive edge in the global context, given its focus on technology and its emphasis on ethics and sustainability. We are certain this endeavour would serve to boost investor confidence, which is timely."
Sri Lanka: Lanwa Sanstha Cement has successfully commissioned its 2.8Mt/yr Hambantota grinding plant in the Mirijjawila Export Processing Zone. Daily News (Sri Lanka) has reported that the facility is equipped with two bridge ship unloaders and an automated stacker reclaimer yard. It will produce the company’s full range of cements, including ordinary Portland cement (OPC), Portland composite cement (PPC) and blended hydraulic cement (BHC) catering to the rising local demand from landmark projects including the Port City and the network of expressways.
Nigeria: Dangote Cement’s revenue grew by 33.8% year-on-year to US$3.33bn in 2021 from US$2.49bn in 2020. Its sales volumes rose by 13.8% to 29.3Mt from 25.7Mt driven by a strong domestic market, although international volume growth was strong. Earnings before interest, taxation, depreciation and amortisation (EBITDA) increased by 43.2% to US$1.65bn from US$1.15bn.
“Over the last two years, we have finalised the deployment of 6Mt new capacity in Nigeria. Looking ahead, we are now focused on a less capital-intensive expansion cycle, which includes building grinding plants across West and Central Africa to leverage and strengthen Dangote Cement’s regional integration. We are on track to deploy grinding capacity in Cote d’Ivoire and Ghana. In addition, our Alternative Fuel Project is at an advanced stage which aims to leverage waste management solutions, reduce CO2 emissions, and source material locally. This year, we co-processed 89,000t of waste representing a 60% increase over 2020,” said chief executive officer Michel Puchercos.
The group noted that Cement demand in Nigeria was sustained by increasing housing infrastructure, commercial construction, and government projects including major highways, roads, and railways. In May 2021 it re-started exporting clinker from its Onne and Apapa terminals and delivered seven clinker shipments with a total volume of 197,000t in 2021. It also exported 706,000t in 2021 by road to Togo and Niger. Internationally, the group said that it performed well but it also faced challenges in Cameroon, Ghana and Sierra Leone, where freight costs had increased substantially, causing volatility in the landing cost of cement and clinker.