Displaying items by tag: grinding plant

Charah Solutions has been steadily building up its fly ash distribution business in recent years with an eye on the supplementary cementitious materials (SCM) market. This week it opened the third of its new series of SCM grinding plants, at Oxnard in California, US. The unit sticks out because it is focusing on grinding natural pozzolans. The plant will receive natural pozzolan by truck and rail and then use Charah’s patented grinding technology to produce pozzolan marketed under its MultiPozz brand. The previous plants in this series mentioned natural pozzolans but this is the first to promote it explicitly.

The change is potentially telling because global demand for granulated blast furnace slag (GBFS) outstrips supply. Both performance benefits and environmental regulations are pushing this. It’s a similar situation for fly ash, also driven by trends to close coal-fired power stations in some countries. As Charles Zeynel of SCM trading firm ZAG International explained in the March 2019 issue of Global Cement Magazine, “...volcanic pozzolans are a potential SCM of the future. This is gaining traction, but it’s slow progress at the moment. This will be the answer for some users in some locations.”

The problem though is that natural pozzolans are down the list of preferred SCMs for their chemical properties after silica fume, GBFS and fly ash. The first is expensive but the latter two were traditionally cheap and easy to obtain if a cement or concrete producer had access to a source or a distribution network. Natural pozzolans are very much subject to variations in availability.

It’s no surprise then that Charah is promoting natural pozzolans in a Californian plant given that state’s environmental stance. It’s unclear where Charah is sourcing their pozzolan from but they are not the only company thinking about this in the US. Sunrise Resources, for example, is working on the environmental permits for a natural pozzolan mine near Tonopah in Nevada. As it described in its company presentation, California and Nevada are the most affected states in the fly ash supply crisis because they are, “...at the end of the line when it comes to rail deliveries from power stations in central and eastern USA.” It also estimated that California used 0.9Mt of pozzolan in its cement production of which about 90% is fly ash. The state produced 9.6Mt in 2015. Other companies are also mining and distributing natural pozzolans in the US as the website for the National Pozzolan Association (NPA) lists. Although, if this line-up is comprehensive, then the field is still fairly select. Most of these companies are based in the west of the country.

One last thing to consider is that various groups are tackling a potential future lack of SCMs for the cement industry by making their own pozzolanic materials through the use of calcined clay. These groups include the Swiss-government backed LC3 project and Cementir’s Futurecem products. Using clay should bypass the supply issues with natural pozzolans but the cost of calcining it requires at the very least an investment to get started.

As concrete enthusiasts often point out, a variant of pozzolanic concrete was used by the Romans to build many of their iconic structures, some of which survive to the present day. To give the last word to the NPA, “What is old is new again: natural pozzolan is back!” If environmental trends continue and steel and coal plants continue to be shut then it might just be right.

Chile: The Servicio de Evaluación Ambiental (SEA), the country’s environmental body, has approved the environmental impact assessment for a new 0.5Mt/yr grinding plant that Melón is planning to build in Punta Arenas. The unit will have an investment of US$45m, according to the Diario Financiero newspaper. Spain’s Cemengal will supply the mill for the project.

Poland: FLSmidth MAAG Gear has successfully tested a MPU/274G type gear unit at its Elblag production plant. The product is intended for JK Cement’s new cement grinding plant in Aligarh, Uttar Pradesh. Shipping is scheduled for late June 2019. No value for the order has been disclosed.

France: Cem’In’Eu has obtained NF hydraulic binders certification for its Aliénor plant in Tonneins from the Technical Association of Hydraulic Binders. It covers CEM I 52.5 R cement. The cement producer is currently seeking NF certification for other types of cement in its product range. The latest certification follows ISO 9000 and ISO 14000 accreditation at the cement grinding plant.

France: Cem’In’Eu has ordered a 0.25Mt/yr grinding unit from Fives for its Portes les Valence plant in Drôme. The plant has an investment of Euro24m and it is scheduled to open in the second half of 2020. The scope of supply includes raw materials loading, clinker, limestone and gypsum hoppers, a 34t/hrt CEM II A/L FCB B-mill (ball mill) operating in a closed circuit with a FCB TSV dynamic classifier. The Portes les Valence project follows the opening of Cem’In’Eu’s grinding plant at Aliénor in Tonneins in 2018.

Peru: Cemento Inka plans to start civil engineering work on its new 0.7Mt/yr grinding plant at Pisco by September 2019. The US$20m project is expected to take 12 months to complete with a commissioning date scheduled for the second half of 2020, according to the Gestión newspaper. The cement producer is also in talks with quarry owners to source limestone for the unit.

Burkina Faso: Harouna Kaboré, the Minister of Commerce, Industry and Handicraft, has inaugurated a new mill at Cimburkina’s cement grinding plant at Kossodo in Ouagadougou. By installing the new mill the unit has doubled it production capacity to 2Mt/yr, according to the Sidwaya newspaper. The upgrade cost US$25m.

François Sangline, the director general of the subsidiary of Germany’s HeidelbergCement, said that the 2000t limestone silo feeds the production line consisting of two 150t/hr cement grinding mills. This is followed by a 120t/hr bagging unit. Sangline noted that the country’s cement consumption of 2.5Mt/yr is below the domestic cement production capacity of 6Mt/yr. Due to this he lobbied the government to protect local production against imports and fraud.

France: Cem'In'Eu plans to raise Euro55m by the end of 2019 to support building new cement grinding plants in Europe. It opened its first 0.25Mt/yr grinding plant at Tonneins, Lot et Garonne in 2018, according to Les Echos newspaper. Construction of a new plant at Portes-lès-Valence, Drôme is scheduled to start in mid-2019. Construction of a larger 0.5Mt/yr plant at Montreuil-Bellay, Maine-et-Loire is anticipated to start in September 2019 for a commissioning date of February 2021. This project will cost Euro35m. Other projects are planned for Chalon-sur-Saône, Saône et Loire and Ottmarsheim.

International projects include a plant at Ottmarsheim, Haut-Rhin in Switzerland and Thamesport in the UK. The former is expected to gather all the necessary permits by September 2019 with construction to follow by the end of the year. An additional project is being planned at the port of Gdynia in Poland.

Guinea: LafargeHolcim Guinea has ordered a MVR 2500 C-4 vertical roller mill from Germany’s Gebr. Pfeiffer for its Sonfonia cement grinding plant in Conakry. The cement mill will have a total drive power of 1300KW. It has been designed to grind 75t/hr of CEM IV 32.5 and 69t/hr of CEM IV 42.5 to a specific surface of 3440cm²/g and 3340cm²/g acc. to Blaine respectively. The order for the mill was placed by the China’s CBMI working as a general contractor on the project. No value for the order has been disclosed.

Honduras: Colombia’s Ultracem plans to build a new cement grinding plant in Cortés, Honduras. At present the company has invested US$2m in the country and it employs 60 people, according to La Prensa newspaper. The new production plant will create another 100 jobs. The cement producer currently operates a grinding plant at Barranquilla in Colombia.