Global Cement News

Indonesia: JFE Engineering Corporation has started work on a 28MW waste heat recovery (WHR) project for PT Semen Indonesia, the leading state-owned cement company in Indonesia. The WHR project will be designed and manufactured by the Japanese engineering firm with installation by local contractors at the Tuban cement plant in West Java. Commissioned of the plant is scheduled for the end of 2014.

The Semen Indonesia project is the second WHR build JFE Engineering has undertaken in Indonesia following a previous project for Semen Padang. This project is expected to reduce CO₂ emissions by 130,000t at full load operation. Further collaboration between JFE Engineering and Semen Indonesia, following a strategic agreement signed on 23 October 2013, will see coordination between the companies on WHR projects and waste management in Indonesia and Vietnam.

The project from JFE Engineering is part of a feasibility study of the Joint Credit Mechanism (JCM) by the Ministry of Environment of Japan (MOEJ), to offset Japan's emissions targets through low carbon projects overseas. Once awarded accreditation on the scheme, the project will be supported by a subsidy from the MOEJ.

US: KHD Humboldt Wedag International AG's Americas Customer Service Centre has signed a contract with Holcim (US) for engineering, delivery of equipment, and site services to modify the existing production line at its Hagerstown, Maryland cement plant. The contract, which includes a KHD designed PyroProcessing System, will increase the line's production rate to 2400t/day and be compliant with the new NESHAP environmental regulations.

The project incorporates constructing a five-stage single-string KHD LowNO_x Preheater over the existing kiln, while the kiln is in operation. Additionally, KHD will modify the existing six-pier rotary kiln to a two-pier kiln and add a new KHD PYROFLOOR clinker cooler. The existing kiln will be cut to achieve a final length of 51m, transforming the existing long dry kiln system into a new, modern, energy efficient, fuel efficient, and environmentally friendly PyroProcessing system. The new system will be supplied with a new whole tire handling system and will be capable of co-processing up to approximately 7% of whole tires as an alternative fuel.

To reduce SO_x emissions KHD will supply a dry lime injection system. To reduce NO_x emissions KHD will supply PYROJET LowNO_x burners, a PYROCLON® Low NOX calciner with PYROLOOP® and a modification of the existing SNCR system. New dust collectors will be supplied to meet stringent particulate emissions requirements.

KHD's scope of supply for the project starts with a modification to the raw material feed system and ends with the clinker handling system into the existing clinker storage hall. The scope consists of all electrical and auxiliary equipment, a new raw material grinding VRM system, coal dosing systems, as well as civil and structural engineering and the supply of structural steel.

Commissioning of this new system is planned for mid-2016.

Sweden: Following the devastating hurricane in the Philippines, Sweden's Cementa AB has announced that it will donate its annual Christmas gift of Euro22,400 to Médicins sans Frontières (MSF) (Doctors Without Borders), which is operating in the worst-affected regions.

The move makes a break with Cementa's traditional method of splitting its Christmas gift to several organisations. The company said that the need was so great in selected regions that it had decided instead to support only one organisation in 2013.

"We see this as a chance to actively do something for the affected areas in the Philippines," said Fredrik Jansson, Vice President Sales and Marketing at Cementa AB. "Hopefully others in the construction industry (will support) the same initiatives in support of the affected areas."

Egypt: Suez Cement has introduced a new filter system to reduce dust emissions to up to 10mg/m³, a level referred to by the company as being 'well below Egyptian and European standards.'

The Egyptian group plans to spend Euro55m to improve the environmental standards of its five in-country facilities.

Mounir Abdel Nour, Trade and Industry Minister, took part in the inauguration ceremony, saying that the new filter system is, "A perfect example of how the Egyptian government and industries can work together to provide facilities with the best technology in terms of production and environmental impact."

"The new filter system makes use of the most highly advanced technology so that the plants can produce the lowest level of dust emissions possible,'' added Bruno Carre, Suez Cement group managing director.

Omar Mohanna, Group chairman, underscored that 2013 has been a challenge for the Egyptian cement industry, with problems in terms of fuel and energy supply. To stay competitive, the industry must find better energy sources in addition to the existing plans to make use of wind energy and alternative fuel sources, Mohanna added, saying that he hoped the Egyptian government would continue to support efforts that work towards this end.

US: Renovation of Lafarge's 50-year-old cement plant in Ravena, New York will be completed by mid-2016, preserving 112 jobs at the plant.

This is the first fixed timeline for the project since it was proposed in 2008. Delays have been blamed on the poor state of the economy. Lafarge also needed to obtain state and federal environmental permits, a process that involves rounds of reports and public hearings.

Construction is expected to cost several hundred million US$. A specific price tag has not been disclosed.

Company officials say that renovation was necessary in the face of stricter pollution controls from the federal government. Either they would shut down and abandon the location, or gut it and build a massive new kiln to meet the stronger standards. Pollution is a particularly sensitive issue as the cement plant and its quarry sandwich the middle school and high school for the Ravena-Coeymans-Selkirk district.