Displaying items by tag: Upgrade

New Zealand: Golden Bay Cement has commissioned a waste tyre feeding line at its Golden Bay integrated cement plant in Northland. The producer will cut CO₂ emissions by 13,000t/yr by substituting tyres for coal. It will eliminate the 5000t/yr of iron sands used in production and reduce coal use by 15%. The New Zealand government’s Waste Minimisation Fund supplied US$11.2m towards the US$17.5m project.

Government environment minister David Parker told Live News, "This innovative project is a win-win-win for the environment. It reduces a significant waste problem, reuses a valuable resource, and reduces carbon emissions by about 13,000t/yr.” He added that the line, "will divert from landfill or stockpiles about 42% of the estimated 3m waste tyres in Auckland each year. New Zealand needs to address its longstanding problem with waste so we can become the low-waste, low-emissions economy we need to be. "

Hungary: Lafarge Hungary, part of LafargeHolcim, has awarded a contract to Germany-based Loesche subsidiary A TEC for the supply of an alternative fuel (AF) flash dryer for the 1.0Mt/yr kiln line at its Királyegyháza cement plant in Baranya county. The supplier says that the dryer will use residual hot gas from the chlorine bypass system in conjunction with a satellite burner for firing the material in the kiln. The project also includes the installation of a new AF receiving, handling, and dosing system for a second AF flow firing directly into the kiln burner. A TEC says that it will commission the project in the second quarter of 2021 after the end of the plant’s 2020/2021 winter shutdown.

UK: Cemex has announced a Euro21m investment in an upgrade to its Rugby cement plant. The planned upgrade incorporates green hydrogen into the plant’s cement production process. The company says that the upgrade will enable it to shift to 100% alternative fuel (AF) substitution from fossil fuel use. It said the move is a step towards carbon neutrality in line with its Future in Action programme. The upgrade is expected to be fully operational in June 2021.

Europe, Middle East, Africa and Asia regional president Sergio Menendez said, “We believe that this very significant investment in this upgraded facility supports Cemex’s position to minimise the use of fossil fuels for both environmental and economic reasons. It will enable the Rugby plant to consistently operate with up to 100% AF, which will contribute to our climate action targets.”

France: LafargeHolcim subsidiary Lafarge France has completed a Euro6m modernisation of the two waste processing lines at its Port-La-Nouvelle cement plant. The final phase of modernisation aimed at increasing dosing and injection capacities, optimising unloading, replacing fire detection and protection systems and expanding the control laboratory. The company said that the modernisation will enable it to use 80,000t/yr of refuse-derived fuel (RDF) in cement production at the plant. It says that this will reduce carbon dioxide (CO₂) emissions by 30,000t/yr. As a result, the plant’s fossil fuel consumption will decline by 75% in 2021 and by 90% in 2022 compared to 2020 levels. Its long-term aim is to become Europe’s first fossil fuel-free cement plant.

Spain: The regional government of Extremadura has granted a licence to Cementos Balboa for the use olive pumice and tyres as alternative fuels (AF) at its Alconera cement plant. Agencia EFE has reported that the company has begun work on modifications to the plant’s kiln line in order to enable it to reach a thermal substitution rate of 70%. The project includes building reception, storage, dosage and injection units for the fuels. Once complete the plant aims to process 130,000t/yr of olive pomace, 121,000t/yr of refuse-derived fuel (RDF) and 69,000t/yr of tyres. The plant currently uses petcoke.

Philippines: Holcim Philippines plans to invest US$2.5m on increasing its alternative fuels use until 2022. The subsidiary of Switzerland-based LafargeHolcim says it will spend the money on installing new equipment and improving storage and feeding facilities at its Bulacan cement plant in Barangay, Norzagaray. It also plans to support its Geocycle subsidiary in supplying higher amounts of post-consumer and municipal solid wastes.

“This investment ensures we can continue being a reliable partner in the country’s sustainable development, while also meeting our objectives of making our operations more efficient and respectful of nature,” said Holcim Philippines president and chief executive officer (CEO) John Stull. In 2020 the company co-processed close to 130,000t of qualified wastes from local governments, industry partners and agricultural processors in its plants in Luzon and Mindanao led by its Geocycle unit.

France: Vicat started using a CO₂ntainer system supplied by UK-based Carbon8 Systems at its Montalieu-Vercieu cement plant in November 2020. It uses captured CO₂ from the unit’s flue gas emissions to carbonate cement-plant dust and produce aggregate, which can then be used to make products such as concrete. The system has particular relevance for a plant burning alternative fuels due to the additional chlorinated dust created compared to the use of conventional fossil fuels. The company says it is the first European cement producer to use the process at an industrial scale. Previously, Carbon8 Systems said that its CO₂ntainer would process and convert up to 12,000t of cement bypass dust in its first phase of operation.

Vicat Group scientific director Laury Barnes-Davin said, “We were drawn to Carbon8 Systems’ two-part technology: capturing the CO₂ that Montalieu emits, and using it to produce an aggregate that can be marketed in the construction industry. It opens up great potential for our operations not just in France but also in all the countries where we work across the globe.” The group hopes to reach a 100% alternative fuel substitution rate in France by 2024.

Turkey: Denmark-based FLSmidth has released details about a new clinker production line it is currently supplying to Bursa Çimento. Work at the site is underway at present covering the line from crushing to clinker cooling. The new line is scheduled to start at the end of 2022. FLSmidth says the equipment it is supplying includes a Hotdisc Combustion Device, which will help increase the substitution rate to 86%, the highest in Turkey. The order also includes an OK Raw Mill, a Rotax-2 kiln, Pfister feeders and new air pollution process filters.

"The modernisation of our Bursa site is a strategic investment, providing us with a more competitive cost base,” said Osman Nemli, General Manager at Bursa Çimento. “But just as important is the entire upgrade which focuses on reducing emissions and power consumption. In this way, we are proactively mitigating future possible environmental regulation."

Bulgaria: HeidelbergCement subsidiary Devnya Cement is planning to invest Euro5m in two upgrades to achieve 100% alternative fuel (AF) substitution in the kiln line of its Varna cement plant. SeeNews has reported that the line, established in 2015, currently uses 60% AF.

General manager Silvio Thiede said, “We have the ambitious goal to reduce our net carbon dioxide emissions to zero by 2050, at all of our plants."

Austria: Loesche subsidiary A TEC has won a contract for the supply and installation of a Flash Dryer for alternative fuels (AFs) in the kiln line of Lafarge Zementwerke's 1.1Mt/yr Mannersdorf cement plant in Lower Austria. The supplier said that it will complete the project in early 2021.

The company said, “Reaching high thermal substitution rates (TSR) requires firing of alternative fuels at the kiln burner. To reach a stable sintering zone for the required clinker quality a high fuel quality (high LCV, small particle size) is needed, otherwise the clinker quality may suffer or the TSR can be limited. With the A TEC Flash Dryer various waste heat sources can be used (clinker cooler flue gas, bypass gas, preheater gas, etc.). The material is dosed to the hot gas flow in the flash dryer and transported with this gas flow, while the moisture is evaporated, to a cyclone and a subsequent filter where the fuel is separated from the gas flow and on-line fed to a kiln burner or a satellite burner. In addition to the drying the lifting effect of the gas can separate 3D impurities which contributes in a further increase of the fuel quality.”