Displaying items by tag: Clinker
Barbados: Trinidad Cement, owners of Arawak Cement Company, noted a decline in the Barbados cement market in 2023, according to its annual report.
Managing director Francisco Aguilera Mendoza said "In Barbados, the overall market declined by 14.3%, of which Arawak Cement Company experienced a decline of 8.8% in domestic cement volumes compared to 2022. Trinidad and Tobago’s cement export volume fell by almost 11% when compared to 2022, due to supply chain constraints and an increase in the local market demand. This drop in cement exports was almost fully compensated by our clinker exports to Barbados that started in 2023 after Arawak Cement’s change in its operating model.”
Cement sales in Saudi Arabia rise in April 2024
09 May 2024Saudi Arabia: Cement sales in Saudi Arabia recorded a 12.5% increase in April 2024 to 2.92Mt, up from 2.6Mt in 2023, despite the impact of Ramadan. This is according to a report by Aljazira Capital. However, cement exports saw a significant decrease, dropping by 30% year-on-year to 554,000t from 790,000t. Additionally, clinker inventories reached 43.4Mt in April 2024, marking an 18% year-on-year increase and a 3% rise from March 2024.
Clinker is the new gold in Kenya
08 May 2024Kenya-based East African Portland Cement (EAPCC) made the news this week with the reopening of the company’s Athi River cement plant after a month-long shutdown. The closure was conspicuous because the company is gradually working towards increasing the integrated plant’s production capacity. The first phase of the maintenance and upgrade project saw the replacement of the production line’s kiln shell in September 2022. The current aim is to increase the unit’s cement production capacity to 1Mt/yr by mid-2026. The recent shutdown appears to have been a more normal annual renewal and repair job but EAPCC has used it as a promotional opportunity. Notably, a spokesperson for EAPCC described clinker as the “new gold” in a recent video explaining what was going on.
It’s an improvement on the financial trouble EAPC found itself stuck within in the late 2010s before the government ended up taking a controlling share in the cement producer. On this front local media reported in July 2023 that the government had found a 'strategic investor' to buy a 30% stake in the company. Nothing more has been said on this topic since then though.
The highlighting of the recent shutdown is likely to be a public relations exercise intended to project stability, but that focus on clinker is telling given that the government introduced its Export and Investment Promotion Levy in July 2023. This legislation imposed a 17.5% fee on imported clinker in order to encourage the local industry. Cement producers that rely on imported clinker - including Rai Cement, Bamburi Cement, Savannah Cement, Ndovu Cement and Riftcot - attempted to lobby against the levy but it remains in place. This business environment helps to explain EAPCC’s renewed focus on clinker production.
One company that stands to benefit from the levy is National Cement, producer of the Simba Cement brand and a subsidiary of Devki Group. It made the news at the start of April 2024 when its subsidiary Cemtech commissioned a 6000t/day clinker plant at Sebit in West Pokot. National Cement already operates an integrated plant near Athi River, south of Nairobi. However, hot on the heels of the West Pokot plant, it is already considering building another integrated plant in the north of Kitui County, to the east of Nairobi. As reported in the local press this week, Cemtech has submitted an environmental impact assessment for the project to the local authorities.
The country has two other clinker producers: Holcim subsidiary Bamburi Cement and Mombasa Cement. The former company announced at the end of 2023 that it had signed a contract to build solar plants at its integrated plant in Mombasa and its grinding plant in Nairobi. The deal was framed as a money saver but additionally it may have been in response to a less than reliable local grid. It also said that it was removing Ordinary Portland Cement (OPC) from its product line from the start of 2024. This move challenged expectations about sustainability initiatives outside of richer countries. Yet, considering how Bamburi Cement argued against the clinker levy, there might have been some commercial thinking here too in order to sell products that use less clinker. Finally, despite completing its divestment of Uganda-based subsidiary Hima Cement for US$84m in March 2024, Bamburi Cement reported a loss of US$2.99m in 2023 compared to a profit of US$1.36m in 2022. Although it reported a rise in turnover and operating profit, it appears that taxes and legal costs related to the sale of Hima dragged the company into a loss.
Graph 1: Rolling annual cement production in Kenya, 2019 - September 2023. Source: Kenya National Bureau of Statistics (KNBS).
It’s been a difficult business environment in Kenya over the last decade given the number of companies that have faced serious financial difficulties. This list includes ARM Cement, EAPCC and Savannah Cement. The last of these companies, Savannah Cement, is currently in administration and is trying to sell its integrated plant. Yet, rolling annual cement production in Kenya has remained above 9.5Mt/yr since early 2022. The government is sticking to promoting local clinker production, and companies like Bamburi Cement, EAPCC and National Cement are making investments of varying scales. The focus, for now at least, is on clinker production in Kenya.
Kenya: Cemtech, a subsidiary of Devki Group, has submitted an Environmental Impact Assessment report to the National Environment Management Authority for a new clinker plant in Kitui County. The company aims to receive approval from the Kenyan government to establish the plant, according to the Business Daily newspaper. The company says that the plant will boost local cement production and increase employment opportunities.
UK: Seratech has developed a process using olivine, a mineral abundant in Earth's mantle, to produce ‘carbon-negative’ cement. The company's method involves replacing some of the clinker with silica extracted from olivine. Magnesium sulphate derived from the olivine reacts with CO₂ to form nesquehonite, a mineral that sequesters CO₂. This method uses CO₂ captured from emissions sources or directly from the air.
Sam Draper, CEO, explained the process: “The researchers extracted these compounds by dissolving powdered olivine in sulphuric acid. After separating the silica and magnesium sulphate, they bubbled CO₂ through the magnesium slurry to form nesquehonite.”
According to Draper, replacing 35% of regular cement with this silica would yield carbon-neutral results, while a 40% substitution could achieve carbon negativity. Current building standards allow up to 55% of cement to be replaced by this material, although robust testing has yet to be conducted.
India: Star Cement has launched a new clinker line at its Lumshnong, Meghalaya, cement plant. Capital Market News has reported that the line has a capacity of 3.3Mt/yr.
UltraTech Cement expands with Gebr. Pfeiffer technology
16 April 2024India: UltraTech Cement will integrate vertical mill technology from Gebr. Pfeiffer for three new clinker production lines. Gebr. Pfeiffer SE and its Indian subsidiary, Gebr. Pfeiffer India, will fulfil a subsequent order.
At the Happy 3 plant, cement raw material grinding will be conducted using an MVR 5000 R-4 mill, equipped with a 5300kW drive, capable of grinding about 705t/hr to a product fineness of 1.5% R 212µm. Additionally, three MPS 3550 BK mills, each with a 1300kW gearbox, will grind about 45t/hr of petcoke or 90t/hr of coal. These mills come with an integrated SLS 3750 BK classifier.
Gebr. Pfeiffer's MVR mills are distinct in their use of rollers according to the R=C principle. This design allows the same rollers to be used with parts for both raw meal and cement grinding. The MVR 5000 R-4 mill at Happy 3 features four actively redundant rollers, maintaining about 70% production capacity during maintenance. Gebr. Pfeiffer equips MVR mills with maintenance-oriented condition monitoring systems, enabling the implementation of digital maintenance strategies.
Handling of the order will be a collaborative effort between Gebr. Pfeiffer SE and Gebr. Pfeiffer India with all customer support and plant planning managed by Pfeiffer engineers in Noida. Core components like gearboxes, grinding bowls and roller suspensions will be shipped from Europe, while other parts like foundations and classifiers will be provided by the Indian subsidiary. Support for the plants will be managed by the customer support centre in Noida, accessible via remote data or on-site personnel.
Vietnam: The Vietnam Cement Association (VNCA) has urged the government to address the cement industry's challenges, following a continuous decline in sales since 2022. Despite having 61 cement plants with a combined capacity of 117Mt/yr, the industry recorded sales of only 87.8Mt/yr in 2023, marking a 16% year-on-year fall in domestic consumption to 56.6Mt and a 1% decline in exports to 31.2Mt. The downturn in both domestic and export markets has resulted in excess inventory, leading many plants to reduce capacity or halt operations, with some facing bankruptcy or the risk of foreign acquisition.
Several factors have contributed to the industry's difficulties, including reduced domestic demand due to reliance on traditional construction techniques in major infrastructure projects, a stagnant real estate market, escalating fuel costs, and increased export taxes on clinker. To combat these issues, VNCA proposes promoting concrete use in high-speed infrastructure projects, especially in the Central region and the Mekong Delta. It also advocates maintaining or eliminating export taxes on clinker for the next two years and providing VAT exemptions. Additionally, VNCA calls for financial support, requesting banks to offer debt relief and reduced interest rates to cement companies. The association also advises against further foreign investment in Vietnam's cement sector.
New Cemtech clinker plant commissioned in West Pokot
09 April 2024Kenya: President William Ruto has commissioned a Cemtech clinker plant in Sebit, West Pokot, valued at US$345m. Construction of the plant began in 2010 and it will produce 6000t/day of clinker with a cement capacity of 2Mt/yr. After production, the clinker will be transported to a grinding plant in Eldoret.
Mining Principal Secretary Elijah Mwangi said "The production is enough feed for all cement plants in the country. The demand for this critical material will now be met with the excess available for export." The opening of this plant is a ‘major relief’ for cement companies in Kenya, which have historically had to import 60% of their clinker. Currently, National Cement and Mombasa Cement manufacture clinker, while Bamburi Cement, Savannah Cement, Rai Cement, and Ndovu Cement import it.
Located at the Sebit limestone mines in Kipkomo subcounty, the plant has generated over 2000 job opportunities.
Vietnam cement exports fall
09 April 2024Vietnam: In the first quarter of 2024, Vietnam's cement and clinker exports maintained a volume of 7.9Mt but represented a 11.7% year-on-year decrease in value to US$298m, according to the General Statistics Office.
The value decrease is reportedly attributed to China's sluggish real estate market and anti-dumping duties imposed by the Philippines. Export prices also declined slightly, with the average price in 2023 dropping by 3% year-on-year. The Vietnam Cement Association anticipates further challenges for these exports in 2024, facing increased competition from the Philippines, Central America and South Africa. Domestic production is expected to exceed demand, with consumption estimated at 60-62Mt, prompting intensified export efforts to manage an excess production of around 30Mt.