KHD delivers state-of-the-art Mitchell cement plant

 

  • First clinker was produced at the new Mitchell cement on 23 April 2023.
  • KHD provided design and integration of the complete plant, as well as core pyroprocessing equipment.
  • New plant significantly reduces energy consumption and emissions per ton of cement.

First clinker has been produced at Heidelberg Material’s new state-of-the-art cement plant in Mitchell, Indiana. One of the most significant developments in the North American cement market, the US$600-million plant is the most modern and second-largest cement plant on the continent with a production capacity of 7000 tpd.


 “We are extremely pleased to have the new Mitchell kiln online and producing clinker. With the capabilities of the new facility, we will be able to supply our customers more efficiently, consistently, and sustainably than ever before,” commented Chris Ward, President and CEO of Heidelberg Materials North America.


 The project was delivered by KHD Humboldt Wedag (KHD), which was responsible for the design, engineering, procurement, and integration of the complete plant. KHD also supplied core components, including the double-string five-stage preheater with Pyroclon® LowNOX AF calciner, Pyrotop® mixing chamber and high-efficiency cyclones, and the 80m x 5.4m dia. three-pier kiln.


 “Heidelberg Materials’ Mitchell Plant modernization project, their largest-ever expansion in North America, has come to life. As the engineering and equipment supplier/integrator for the full line, KHD is proud to have helped Heidelberg Materials achieve this significant milestone,” said R. Dwayne Holland, President, Humboldt Wedag Inc.


Construction of the new line began in 2020 with the majority of work now complete. Replacing three older kilns dating back to the 1960s and 1970s, it will increase production capacity at the Mitchell site by more than threefold to 2.8 million tons per year, helping to ease cement supply constraints in the American Midwest market.


It also significantly improves the sustainability of cement production, incorporating features to minimize energy consumption, and enable the use of alternative fuels and raw materials to reduce greenhouse gas emissions. It thus represents a major step toward Heidelberg Material’s target to reduce carbon by 30% by 2025 and achieve net-zero concrete by 2050.


KHD also delivered an extensive onsite training program for Mitchell plant personnel, covering the operation and maintenance of the new plant.


“The first production of clinker at the Mitchell plant not only showcases KHD as a supplier of market-leading pyroprocessing equipment; it also highlights our ability to design and integrate complete cement plants. This comes down to our traditional strengths in process knowledge and plant layout, as well as our practical experience as a supplier of equipment and services to cement manufacturers around the world. We are excited to have demonstrated these skills to deliver a plant of this size and scale, which now sets the standard for the American cement market moving forward,” said Matthias Mersmann, CTO and member of the management board at KHD.

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