Displaying items by tag: pilot

Norway: Private accreditation body DNVGL has certified Aker Solutions’ 400,000t/yr carbon capture and storage (CCS) system installation at Germany-based HeidelbergCement subsidiary Norcem’s 1.2Mt/yr integrated Brevik plant in Telemark as safe. HeidelbergCement Northern Europe director of sustainability and alternative fuels Per Brevik said, “The promising results from pilot testing in Brevik give us confidence that realisation of the full-scale capture plant will be successful. We trust that the project risk related to novel technology elements is low.”

Following an 18-month test of the partial installation, the certification ensures that the full-scale project will receive government funding.

Germany: Hydraulic calcium hydrosilicate (hCHS)-based cement producer Celitement has gone from being a Schwenk-affiliated company to a full subsidiary of the 5.76Mt/yr integrated capacity cement producer. Celitement plans to upgrade its pilot plant at the Karlsruhe Institute of Technology (KIT), Baden-Württemberg, to increase production capacity. When this is completed, it will offer ‘single-digit tonne’ deliveries to ‘select investors’ and begin ‘large-scale practical testing.’ These will determine the feasibility of establishing an industrial Celitement plant.

Celitement was set up in 2009 to develop novel construction materials based on several patents for hCHS binding agents.

Germany: Currax and Siemens have announced their collaboration on a mill operations digitisation pilot project involving the Simotics Connect 400 motor data collector and transmitter. They hope that analysis of data processed via the Simotics 400 will better enable the remote operating of mills ‘to increase efficiency and component life’ and speeding the shift towards automation and production that is resilient to crises such as the coronavirus outbreak.

Vietnam: 20 factories in Quang Ninh, Thanh Hoa, Quang Nam and Thua Thien Hue provinces will be subject to a new carbon tax in a pilot project. The Ministry of Agriculture and Rural Development has started to put the programme into action following approval from Prime Minister Nguyen Xuan Phuc, according to the Vietnam News Agency Bulletin. The pilot project will start in 2020 and run until the end of 2021.

The scheme will include 11 cement companies and nine power plants. Cement producers and traders will be charged US$0.09/t of clinker, equivalent to US1.35/t of CO₂. The tax will also increase electricity costs for cement producers. It is expected to increase the production cost at plants by 0.29%.

Nguyen Van Vu, head of Finance and Planning Department under Vietnam Administration of Forestry (VAF), said that the tariff was lower than the World Bank’s Forest Carbon Partnership Facility pledge to pay for emission reduction efforts in North Central Region of US$5/t of CO2. The provinces running the tariff are expected to generate around US$7.4m/yr. Most of this revenue will be accrued in Quang Ninh, followed by Thanh Hoa, Thua Thien Hue and Quang Nam.

Belgium: Australia’s Calix says the Low Emissions Intensity Lime And Cement (LEILAC) consortium has successfully demonstrated CO₂ separation with more than 95% purity at its pilot unit at HeidelbergCement’s cement plant in Lixhe. Technology provider Calix said that preliminary test runs have been completed on the pilot. The technology concept has been shown to work on both lime and cement meal, with calcination near to target levels and high purity CO₂ successfully separated at the top of the reactor although not yet at full design capacity.

It added that it was still working on fixing commissioning issues. Testing will run until the end of 2020 to assess the risk of potential longer-term issues such as tube health and process robustness. In parallel, planning has commenced on the next scale-up of the technology, including conceptual design and engaging funding consortia.

Switzerland: LafargeHolcim has launched a four-year industrial automation plan called ‘Plants of Tomorrow.’ It includes Industry 4.0 concepts such as automation technologies and robotics, artificial intelligence, predictive maintenance and digital twin technologies for its entire production process. The plan is expected to show 15 – 20% operational efficiency gains. It also claims that the initiative is, “one of the largest roll-outs of Industry 4.0 technologies in the building materials industry.”

“Transforming the way we produce cement is one of the focus areas of our digitalisation strategy and the ‘Plants of Tomorrow’ initiative will turn Industry 4.0 into reality at our plants. These innovative solutions make cement production safer, more efficient and environmentally fit,” said Solomon Baumgartner Aviles, Global Head Cement Manufacturing.

The building materials company is presently working on more than 30 pilot projects covering all regions where the company is active. The company’s integrated cement plant at Siggenthal in Switzerland will be a trial site where the integration of all relevant modules will be tested.

One examples of where LafargeHolcim has started the plan include a partnership with Swiss start-up Flyability to use drones to increase the frequency of inspections at plants while simultaneously reducing cost and increasing safety for employees by inspecting confined spaces. The concept is being rolled out to several markets, including Switzerland, France, Germany, the UK, the US, Canada, India and Russia. It is also using a subsidiary, Maqer, to identify technology startups with promising technology. It aims to harness the potential of this through new partnership models with both manufacturing and software companies.

LafargeHolcim has already launched technology to track performance centrally and allocated resources to support the plant network in real time. More than 80% of LafargeHolcim’s cement plants are already connected to its Technical Information System that provides data transparency at plant, country, regional and global level. Some country operations have more than a decade of historic technical data available. Other systems allow the remote control of certain parts of the operations through online condition monitoring systems. Since its implementation in 2006, this system has saved over Euro70m and an additional 3Mt of cement sold through fewer breakdowns.

Belgium: The Low Emissions Intensity Lime And Cement (LEILAC) consortium partners and its external advisory board have held a ribbon-cutting ceremony at its pilot Direct Separation Calciner unit at the HeidelbergCement cement plant in Lixhe. The project started commissioning the unit in March 2019. Testing is now set to start to validate the performance of the pilot.

Sweden: HeidelbergCement’s subsidiary Cementa has completed a feasibility study into electrifying its cement plant at Slite in Gotland as part of its Cemzero project. A report from the first phase of the project has been submitted to the Swedish Energy Agency.

The study found that using electricity to supply heat during the clinker production process is possible using plasma technology, although this needs to be tested on a larger scale. Using an electrified process was found to be competitive compared to other options for achieving high reductions in carbon emission. The production cost of cement would be doubled approximately but the research suggested that this might only mean a small percentage increase to the end cost of a building or an infrastructure project. Finally, the study reported that any future electrification of the Slite plant would work well with a planned expansion to wind turbine generation at the site. It would improve the energy balance and reduce the maximum power surplus that might occur.

Cementa and energy company Vatenfall will now look at how to build a pilot plant.

France: The SOLPART (Solar-Heated Reactors for Industrials Production of Reactive Particulates) project plans to test a pilot-scale version of its solar reactor from February 2019. The 50kW solar reactor will test a fluidised bed system at its PROMES (PROcédés, Materials and Solar Energy) testing site in Odeillo. The ultimate goal of the project is to test using a rotary kiln and a fluidised bed system to produce cement, lime, gypsum and other non-metallic products using only solar energy. The pilot scale reactor will test calcining limestone at a rate of 50kg/hr. Industrial partners involved with the project include Cemex.

US: Elixsys has completed a 100hr continuous pilot test to extract ammonium sulphate and calcium carbonate from flue gas desulphurisation solids at a coal-fired power plant in Pennsylvania. Products made using the company’s proprietary process meet the specifications for fertiliser-quality ammonium sulphate and technical-grade calcium carbonate.

The company intends to start a commercial-scale project of its technology in 2019 once it finds a utility partner. Full-scale operations are planned by 2022. The company is also starting pilot testing on another process to extract metals from coal ash.