Global Cement News

India: The India Cements Ltd (ICL) has returned to black in the second quarter of its 2015 financial year, which ended 30 September 2014, after reporting loss for four quarters in a row. It has reported profit for the quarter despite a drop in volume and rising cost pressures.

The India Cements reported a net profit before tax of US$1.22m for the second quarter of the 2015 financial year, compared to a loss of US$5.11m in the previous year. Sales volumes were down by 3% to 2.35Mt against 2.44Mt in the prior year. Net sales were higher at US$184m during the quarter, compared to US$176m in the previous year.

T S Raghupathy, special adviser to The India Cements, said that the Indian cement industry reported a 9% in the first half of the 2015 financial year. However, growth in the south was the weakest among the regions. Tamil Nadu, Telangana and Andhra Pradesh, the principal markets for India Cements, virtually saw de-growth, he added.

Vietnam: Semen Gresik is reportedly preparing to double the annual production capacity of 2.3Mt/yr of the Thang Long Cement plant in Hoanh Bo District, Quang Ninh Province, through building the second production line. The Thang Long Cement 2 project is on the list of projects approved by the prime minister in 2011 for investment during the 2016 - 2020 period and features in the country's sectoral master plan. Semen Gresik acquired a 70% stake in Thang Long Cement for US$157m in 2012.

Canada: ThyssenKrupp Industrial Solutions and McInnis Cement have announced a sales/purchase agreement valued at US$133m for the manufacture and supply by ThyssenKrupp Industrial Solutions (USA) of a complete cement production line.

The new 6000t/day capacity plant is currently under construction on a greenfield site in the Port-Daniel-Gascons area of Quebec, Canada. The new plant will be complete with a POLCID proprietary process control system to monitor and control all aspects of the plant and a POLAB laboratory automation system to assure product quality. The plant is scheduled for commissioning in 2016 with full production starting later in that year.

"The McInnis Cement project represents the most technologically advanced and environmentally sound plant of its kind, designed to meet or beat the most stringent requirements of both the Canadian and American environmental agencies," said Mark S Terry, president of the resource technologies division of ThyssenKrupp Industrial Solutions (USA). "Combined with the extensive experience of both project teams, we have the complete recipe for success for the Port-Daniel-Gascons facility.''

The main components include: a 1800t/hr quarry crushing plant, a raw material reclaim system comprises a bridge reclaimer for limestone and four portal reclaimers for other additives or fuel, a QUADROPOL vertical roller mill for raw grinding and a blending silo for raw meal storage, with a capacity of 10000t. The Polysius kiln line will consist of a five-stage, two-string PREPOL AS-MSC preheater, a 5.2m x 75m POLRO rotary kiln and a POLYTRACK cooler with intermediate roll crusher. Cement grinding will take place in two QUADROPOL vertical roller mills with SEPOL high-efficiency separators. The plant will be rounded off with three cement silos (with a capacity of 120,000t) as well as cement truck and ship loading facilities.

One highlight from the cement industry news over the last month was Skyonic's announcement that it has opened a commercial-scale carbon capture unit at the Capitol Aggregates cement plant in Texas, US. Details were light, but the press release promised that the unit was expected to generate US$48m/yr in revenue for an outlay of US$125m. Potentially, the implications for the process are profound, so it is worth considering some of the issues here.

Firstly, it is unclear from the public information released whether the process will actually make a profit. The revenue figures for the Skyonic unit are predictions and are dependent on the markets that the products (sodium biocarbonate, hydrogen and chlorine) will be sold into. Skyonic CEO and founder, Joe Jones, has said in interview that the sodium-based product market by itself could only support 200 - 250 plants worldwide using this process. Worldwide there are over 2000 integrated cement plants. Since Jones is selling his technology his market prediction might well be optimistic. It is also uncertain how existing sodium biocarbonate producers will react to this new source of competition.

Secondly, Skyonic is hoping to push the cost of carbon capture down to US$20/t. Carbon dioxide (CO₂) capture and transportation varies between industries depending on the purity and concentration of the by-product. For example, in 2011 the US Energy Information Administration estimated the cost for CO₂ capture to range from US$36.10/t for coal and biomass-to-liquids conversion up to US$81.08/t for cement plants. The difference being that capturing CO₂ from cement plant flue gas emissions requires more cleaning or scrubbing of other unwanted chemicals such as mercury.

With these limitations in mind, Skyonic is placing itself in competition with the existing flue gas scrubbing market rather than the carbon capture market, since the level of CO₂ removal can be scaled to local legislation. Plus, SO_x, NO₂, mercury and other heavy metals can be removed in the process.

Back on carbon capture, Skyonic is securing finance for a process it calls Skycycle, which will produce calcium-based products from CO₂, with a pilot plant planned at Capitol Aggregates for late 2015. This puts Skyonic back amongst several other pilot projects that are running around the world.

Taiwan Cement and the Industrial Technology Research Institute inaugurated their calcium looping project pilot in mid-2013. It was last reported to have a CO₂ capture rate of 1t/hr.

The Norcem cement plant in Brevik, Norway started in early 2014 to test and compare four different types of post-combustion carbon capture technologies at its pilot unit. These are Aker Solutions Amine Technology, RTI Solid Sorbent Technology, DNV GL/ NTNU/ Yodfat Engineers Membrane Technology and Alstom Power Regenerative Calcium Cycle. The project in conjunction with HeidelbergCement and the European Cement Research Academy (ECRA) is scheduled to run until 2017.

St Marys Cement in St Marys, Canada started its bioreactor pilot project in July 2014. This process uses flue gas to grow algae that can then be used for bio-oil, food, fertiliser and sewage treatment.

If Skyonic is correct then its sodium biocarbonate process in Texas is a strong step towards cutting CO₂ emissions in the cement industry. Unfortunately, it looks like it can only be a step since the market won't support large-scale adoption of this technology. Other pilots are in progress but they are unlikely to gather momentum until legislation forces cement producers to adopt these technologies or someone devises a method that pays for the capture cost.

Germany: HeidelbergCement has reported that its operating income before depreciation (OIBD) increased by 10% to Euro866m in the third quarter of 2014 from Euro789m in the same period in 2013. It attributed the rise to price increases, declining energy prices and improvement in the performance of the building products business in North America and the UK.

"In the third quarter, we generated the best operating income since the financial crisis started in 2008," said chairman of the managing board Bernd Scheifele.

The Germany-based construction materials producer's revenue rose by 4% to Euro3.81bn. Cement and clinker sales rose by 3.3% to 23.1Mt for the quarter. For the year to date increases in profit, revenue and cement sales volumes have been broadly similar to the third quarter. However, net profit fell by 40% to Euro368m in the third quarter of 2014 due to a one-off effect related to tax expenses.