Displaying items by tag: Expansion

Iraq: Eggersmann Anlagenbau has expanded its refuse-derived fuel (RDF) production facility in Sulaymaniyah, operated by Ecocem Environmental Solution, part of the Faruk Investment Group. The expansion includes a new Eggersmann TEUTON ZS 55 single shaft shredder and four additional lanes for biological drying using the CONVAERO system. This system is integral to the Eggersmann RDF process, which converts municipal solid ‘waste’ into high calorific value RDF used by the regional cement producers Gasin Cement Company and Bazian Cement Company. The facility, which has a capacity of 1100t/day of RDF, will see an increase with the expansion. The Eggersmann FUEL process utilises biowaste in RDF production, improving both the quantity and quality of the fuel through biological drying in the CONVAERO system, relying on the natural warmth of the composting process. This method reduces methane emissions at landfill sites by integrating biomass into the fuel, according to the company.

Business development manager at Eggersmann, Eugen Becker, said "A particularly high quality substitute fuel is being produced with the Eggersmann FUEL process in Sulaymaniyah, whose net calorific value can be precisely tailored to the customer’s needs over the adjusting of the drying period. This quality makes a noticeable economic difference."

Mexico: Geocycle Mexico has installed a new crusher at its Macuspana waste management plant in Tabasco. The alternative fuels (AF) supplier says that the expansion will help it to reduce cement plants in Southeast Mexico’s reliance on fossil fuels.

Geocycle Mexico director Oscar Rivas said "The crusher will significantly increase our ability to solve major waste management challenges in the region, and will allow us to produce a useful resource from different types of waste. He continued “Once crushed and formulated, they can be used in the cement manufacturing process, avoiding their burial and thus contributing to decarbonisation efforts in the region."

Brazil: Secil subsidiary Supremo Secil Cimentos will invest US$20.3m in an upcoming expansion of its Adrianópolis cement plant. Commencing in July 2024, the expansion will raise the plant’s clinker capacity by 10% and enable it to increase its alternative fuel (AF) substitution rate from 25 – 30% to 40%, and eventually to 50% by 2030. To date, AF use at the plant has reduced its cumulative consumption of petcoke by 100,000t.

CEO Paulo Nascentes highlighted the transformative impact of the Adrianópolis plant on its host community, with its initial investment of US$176m and a subsequent US$41.7m in previous upgrades to date. "One of the reasons why the Paraná government allowed the plant was because Adrianópolis was very neglected. The arrival of Supremo transformed the city," he said.

France: Lafarge France has ignited the new kiln at its Martres-Tolosane cement plant following a Euro120m upgrade. Local press has reported that the upgrade replaced the plant’s existing kilns and preheater tower with entirely new equipment. The new kiln has tripled the plant’s capacity, to 2.1Mt/yr from 0.7Mt/yr. Meanwhile, the new preheater tower will help to reduce the plant’s electricity consumption by over 20%. As a result of the upgrade, the Martres-Tolosane plant can now support an alternative fuels (AF) substitution rate of 60%, compared to 20% beforehand. Lafarge France aims to carry out further work to reach 85% AF substitution at the plant by 2027. Other planned projects include the installation of a carbon capture system.

Lafarge France CEO François Petry said “We are going to create a research and innovation centre here dedicated to the capture of CO₂, with the ambition of ultimately making the Martres-Tolosane plant net zero carbon.”

Brazil: Secil Supremo Cimentos has appointed FLSmidth to carry out a pyro process upgrade at its Adrianópolis cement plant in Paraná. The Denmark-based supplier says that it plans to carry out modifications on the plant's preheater, cooler and related auxiliary equipment. It says the new equipment will expand the plant's capacity to 3900t/day, corresponding to an annual production capacity of 1.42Mt/yr. It will also enable it to increase its alternative fuel (AF) substitution rate to 40%. Secil Supremo Cimentos' AF mix consists of shredded tyres, wood and other refuse-derived fuels.

FLSmidth's head of capital sales, Jens Jonas Skov Larsen, said “We are grateful for our continued partnership with Supremo, which has consistently invested in the latest technology. As the plant was already operating an ILC five-stage preheater from FLSmidth, it was well positioned to use AF.”

US: Vicat subsidiary National Cement Company of Alabama inaugurated its new US$300m production line at its Ragland cement plant on 21 July 2022. Local press has reported that the line includes a new rotary kiln, equipped for alternative fuel (AF) use.

President Spencer Weitman said “This puts us into the next 40 or 50 years. And it’s prolonged the life of the plant to move us forward into the next entry hopefully.”

Peru: FLSmidth has secured a contract for the supply of a new pyro line for Cementos Pacasmayo’s Pacasmayo cement plant near Lima. The new line will give the plant an additional production capacity of 0.6Mt/yr. The supplier says that it plans to install a Cross-Bar cooler, low-NOx calciner, Jetflex burner, equipment for dosing and feeding and process automation. FLSmidth says that the upgrade will reduce the plant’s energy consumption and open new opportunities for the use of alternative fuel (AF).

FLSmidth’s head of projects and upgrades and senior vice president Anders Josefsen said “We are very excited to work with Cementos Pacasmayo on this project – not only on growing the business, but doing it in a sustainable way. The new line will be equipped with a state-of-the-art pyro system including several of our MissionZero solutions. With this, Pacasmayo makes a significant investment in future-proofing its production.” He added “The Pacasmayo project is a prime example of our capabilities within process design: ensuring the integration to an existing plant, while also demonstrating our ability to deliver equipment that meets demands for energy and fuel efficiency.”

India: UltraTech Cement plans to increase the production capacity at its Maihar cement plant by 50%. FLSmidth will carry out the expansion project, which also involves the installation of a new calciner and JetFlex burner along with other pyroprocessing equipment. The supplier says that the upgrade will facilitate greater alternative fuel substitution at the plant in Madhya Pradesh.

FLSmidth’s cement president Carsten Riisberg Lund said “We are pleased to continue our long-lasting collaboration with UltraTech Cement. With the new upgrades to the pyro sections, installing MissionZero flagship offerings, such as the low-NO_x calciner and JetFlex burner, UltraTech makes a significant investment in future-proofing its sustainable production.”

Hungary: Italy-based Entsorga has completed the installation of an automated alternative fuel (AF) line at a Hungarian cement plant. The plant is believed to be Nostra Cement’s 1.0Mt/yr integrated Kiralyegyháza cement plant, which in early 2020 received an AF fuel store expansion aimed at bringing AF substitution rates to 80% from 60%. The upgrade consists of an Entsorga Spider crane and Pelican power system which will be able to maintain a continuous feed to the plant’s calcination system 24 hours a day.

Entsorga CEO Francesco Galanzino said, “Bringing a commission to a successful conclusion in the middle of the maximum intensity period of the coronavirus crisis has been a great satisfaction. The cement plant will make significant savings in CO₂ emissions.”

UK: Waste processing specialist Re-Gen Waste has invested Euro5.78m in expanding its 80,000t/yr capacity refuse-derived fuel (RDF) processing plant on the Carnbane industrial estate in County Down. Irish News has reported that the expansion will create 30 new positions when the facility, which processes municipal solid and unrecyclable household waste into substitute fuel for cement kilns, becomes fully functional in November 2019. Managing director Joseph Doherty emphasised the importance of the project in bringing the UK closer to the responsible treatment of its 27Mt/yr mixed domestic refuse output “as a resource with a home in our economy.”