Displaying items by tag: Sustainability
2019 in cement
18 December 2019It’s the end of the year so it’s time to look at trends in the sector news over the last 12 months. It’s also the end of a decade, so for a wider perspective check out the feature in the December 2019 issue of Global Cement Magazine. The map of shifting production capacity and the table of falling CO2 emissions per tonne are awesome and inspiring in their own way. They also point towards the successes and dangers facing the industry in the next decade.
Back on 2019 here are some of the main themes of the year in the industry news. This is a selective list but if we missed anything crucial let us know.
European multinationals retreat
LafargeHolcim left the Philippines, Malaysia and Indonesia, HeidelbergCement sold up in Ukraine and reduced its stake in Morocco and CRH is reportedly making plans to leave the Philippines and India, if local media speculation can be believed. To be fair to HeidelbergCement it has also instigated some key acquisitions here and there, but there definitely has been a feel of the multinationals cutting their losses in certain places and retreating that bit closer to their heartlands.
CRH’s chief executive officer Albert Manifold summed it up an earnings meeting when he said, “…you're faced with a capital allocation decision of investing in Europe or North America where you've got stability, certainty, overlap, capability, versus going for something a bit more exotic. The returns you need to generate to justify that higher level of risk are extraordinary and we just don't see it.”
The battle for the European Green Deal
One battle that’s happening right now is the lobbying behind the scenes for so-called energy-intensive industries in Europe as part of the forthcoming European Green Deal. The cement industry is very aware that it is walking a tightrope on this one. The European Union (EU) Emissions Trading Scheme (ETS) CO2 price started to bite in 2019, hitting a high of Euro28/t in August 2019 and plant closures have been blamed on it. The rhetoric from Ursula von der Leyen, the new president of the European Commission, has been bullish on climate legislation and the agitation of Greta Thunberg internationally and groups like Extinction Rebellion has kept the issue in the press. Cembureau, the European Cement Association, is keen to promote the industry’s sustainability credentials but it is concerned that aspects of the proposed deal will create ‘uncertainty and risks.’ Get it wrong and problems like the incoming ban on refuse-derived fuel (RDF) imports into the Netherlands may proliferate. What the Green Deal ends up as could influence the European cement industry for decades.
The managed march of China
Last’s week article on a price spike in Henan province illustrated the tension in China between markets and government intervention. It looks like this was driven by an increase in infrastructure spending with cement sales starting to rise. Cement production growth has also picked up in most provinces in the first three quarters of 2019. This follows a slow fall in cement sales over the last five years as state measures such as consolidation and peak shifting have been implemented. The government dominates the Chinese market and this extends west, as waste importers have previously found out to their cost.
Meanwhile, the Chinese industry has continued to grow internationally. Rather than buying existing assets it has tended to build its own plants, often in joint ventures with junior local partners. LafargeHolcim may have left Indonesia in 2018 but perhaps the real story was Anhui Conch's becoming the country's third biggest producer by local capacity. Coupled with the Chinese dominance in the supplier market this has meant that most new plant projects around the world are either being built by a Chinese company or supplied by one.
India consolidates but watches dust levels
Consolidation has been the continued theme in the world's second largest cement industry, with the auction for Emami Cement and UltraTech Cement’s acquisition of Century Textiles and Industries. Notably, UltraTech Cement has decided to focus its attention on only India despite the overseas assets it acquired previously. Growth in cement sales in the second half of 2019 has slowed and capacity utilisation rates remain low. Indian press reports that CRH is considering selling up. Together with the country's low per capita cement consumption this suggests a continued trend for consolidation for the time being.
Environmental regulations may also play a part in rationalising the local industry, as has already happened in China. The Indian government considered banning petcoke imports in 2018 in an attempt to decrease air pollution. Later, in mid-2019, a pilot emissions trading scheme (ETS) for particulate matter (PM) was launched in Surat, Gujarat. At the same time the state pollution boards have been getting tough with producers for breaching their limits.
Steady growth in the US
The US market has been a dependable one over the last year, generally propping up the balance sheets of the multinational producers. Cement shipments grew in the first eight months of the year with increases reported in the North-Eastern and Southern regions. Imports also mounted as the US-China trade war benefitted Turkey and Mexico at the expense of China. Alongside this a modest trade in cement plants has been going on with upgrades also underway. Ed Sullivan at the Portland Cement Association forecasts slowing growth in the early 2020s but he doesn’t think a recession is coming anytime soon.
Mixed picture in Latin America
There have been winners and losers south of the Rio Grande in 2019. Mexico was struggling with lower government infrastructure spending hitting cement sales volumes in the first half of the year although US threats to block exports haven’t come to pass so far. Far to the south Argentina’s economy has been holding the cement industry back leading to a 7% fall in cement sales in the first 11 months of the year. Both of these countries’ travails pale in comparison to Venezuela’s estimated capacity utilisation of just 12.5%. There have been bright spots in the region though with Brazil’s gradual return to growth in 2019. The November 2019 figures suggest sales growth of just under 4% for the year. Peru, meanwhile, continues to shine with continued production and sales growth.
North and south divide in Africa and the Middle East
The divide between the Middle East and North African (MENA) and Sub-Saharan regions has grown starker as more MENA countries have become cement exporters, particularly in North Africa. The economy in Turkey has held back the industry there and the sector has pivoted to exports, Egypt remains beset by overcapacity and Saudi Arabian producers have continued to renew their clinker export licences.
South of the Sahara key countries, including Nigeria, Kenya and South Africa, have suffered from poor sales due to a variety of reasons, including competition and the local economies. Other countries with smaller cement industries have continued to propose and build new plants as the race to reduce the price of cement in the interior drives change.
Changes in shipping regulations
One of the warning signs that flashed up at the CemProspects conference this year was the uncertainty surrounding the new International Maritime Organistaion (IMO) 2020 environmental regulations for shipping. A meeting of commodity traders for fuels for the cement industry would be expected to be wary of this kind of thing. Their job is to minimise the risk of fluctuating fuel prices for their employers after all. Yet, given that the global cement industry produces too much cement, this has implications for the clinker and cement traders too. This could potentially affect the price of fuels, input materials and clinker if shipping patterns change. Ultimately, IMO 2020 comes down to enforcement but already ship operators have to decide whether and when to act.
Do androids dream of working in cement plants?
There’s a been a steady drip of digitisation stories in the sector news this year, from LafargeHolcim’s Industry 4.0 plan to Cemex’s various initiatives and more. At present the question appears to be: how far can Industry 4.0 / internet of things style developments go in a heavy industrial setting like cement? Will it just manage discrete parts of the process such as logistics and mills or could it end up controlling larger parts of the process? Work by companies like Petuum show that autonomous plant operation is happening but it’s still very uncertain whether the machines will replace us all in the 2020s.
On that cheery note - enjoy the winter break if you have one.
Global Cement Weekly will return on 8 January 2020
Mexico: Cemex Ventures has partnered with BCG and Tracxn to launch a list of 2019’s global 50 ‘most promising’ construction start-ups. Assessment categories were technical innovation, project management and sustainability. Companies like the UK’s Cloud Cycle, a concrete management platform provider, and the US’s Concrete Sensors, which provides remote concrete strength, temperature and relative humility measurement solutions, typify the promising developments in how the construction industry uses its cement.
Uzbekistan: The State Committee for Ecology and Environmental Protection plans to ask cement plants to establish sampling and analysis stations for sources of air pollution by the start of 2022. If they don’t the government will take measures up to and including suspension of production, according to the Trend News Agency. Uzbekistan was ranked in 16th place by AirVisual in a listing of the countries with the most air pollution in 2018.
US: Cemex USA’s Miami and Brooksville South cement plants in Florida have been awarded Energy Star certification for 2019 by the Environmental Protection Agency (EPA) for work on energy efficiency and sustainability. The current year’s recognition marks nine consecutive years of Energy Star certification for the Miami plant and the Brooksville South plant has achieved the certification seven out of the last eight years.
“Cemex is committed to delivering world-class products and services to its clients across the US and the globe while maintaining the highest sustainability standards in our industry,” said Cemex USA president Jaime Muguiro.
To earn the recognition, operations at each plant followed energy-efficiency principles established by the EPA’s Energy Star guidelines and implemented energy conservation technologies along with energy-reduction projects. The recognised facilities were among the top 25% of similar US facilities for energy conservation and met the Energy Star Plant Energy Performance Indicators.
Dalmia Cement takes steps towards carbon capture
25 September 2019Dalmia Cement threw down the gauntlet this week with the announcement of a large-scale carbon capture unit (CCU) at one of its plants in Tamil Nadu, India. An agreement has been signed with UK-based Carbon Clean Solutions Limited (CCSL) to use its technology in building a 0.5Mt/yr CCU. The partnership will explore how CO2 from the plant can be used, including direct sales to other industries and using the CO2 as a precursor in manufacturing chemicals. No exact completion date or budget has been disclosed.
The move is a serious declaration of intent from the Indian cement producer towards its aim of becoming carbon neutral by 2040. Dalmia has been pushing its sustainability ‘journey’ for several years now hitting targets such as reaching 6Mt of alternative raw materials usage in its 2018 financial year and reaching a clinker factor of 63% at the same time. In an article in the November 2018 issue of Global Cement Magazine it said it had achieved CO2 emissions of 526kg/t from its cement production compared to 578kg/t from other Indian members of the Cement Sustainability Initiative (CSI). In its eastern operations it had gone further to reach 400kg/t.
Using CCU is the next step to this progression but Dalmia’s approach is not without its caveats. Firstly, despite the size of the proposed project it is still being described as a ‘large-scale demonstration.’ Secondly, the destination of all that captured CO2, as mentioned above, is still being considered. CCSL uses a post-combustion capture method that captures flue gas CO2 and then combines the use of a proprietary solvent with a heat integration step. Where the capture CO2 goes is vital because if it can’t be sold or utilised in some other way then it needs to be stored, putting up the price. Technology provider CCSL reckons that its CDRMax process has a CO2 capture price tag of US$40/t but it is unclear whether this includes utilisation sales of CO2 or not.
The process is along similar lines to the Skyonic SkyMine (see Global Cement Magazine, May 2015) CCU that was completed in 2015 at the Capitol Cement plant in San Antonio, Texas in the US. However, that post-combustion capture project was aiming for 75,000t/yr of CO2. Dalmia and CCSL’s attempt is six times greater.
Meanwhile, Cembureau, the European cement association, joined a group of industrial organisations in lobbying the European Union (EU) on the Horizon Europe programme. It wants the budget to be raised to at least Euro120m with at least 60% to be dedicated to the ‘Global Challenges and European Industrial Competitiveness’ pillar. This is relevant in a discussion on industrial CO2 emissions reduction because the scheme has been supporting various European cement industry projects, including HeidelbergCement’s work with the Low Emissions Intensity Lime And Cement (LEILAC) consortium and Calix at its Lixhe plant in Belgium and its pilots in Norway. As these projects and others reach industrial scale testing they need this money.
These recent developments provide hope for the future of the cement industry. Producers and their associations are engaging with the climate change agenda and taking action. Legislators and governments need to work with the cement sector to speed up this process and ensure that the industry is able to cut its CO2 emissions while continuing to manufacture the materials necessary to build things. Projects like this latest from Dalmia Cement are overdue, but are very encouraging.
Switzerland: LafargeHolcim’s executive committee has taken on Magali Anderson in the newly-created role of Chief Sustainability Officer. Anderson is a mechanical engineer with extensive managerial and functional experience who joined LafargeHolcim in 2016 as its Head of Health and Safety. LafargeHolcim CEO Jan Jensich has stated that the appointment “will accelerate LafargeHolcim’s vision of running its operations with zero harm to people and the environment.”
National Parks appoint Tarmac lead partner
20 September 2019UK: The body responsible for the UK’s 15 National Parks has acknowledged the building materials and construction company Tarmac as its lead partner in recognition of its sustainable practice at the UK National Parks Conference at the Yorkshire Dales National Park headquarters. The Conference on the occasion of the 70th anniversary of the inauguration of the National Parks was supported by Tarmac.
INSEE Cement launches first sustainability report
26 July 2019Sri Lanka: INSEE Cement has launched its first Global Reporting Initiative (GRI) based and externally assured sustainability report. The report was officially made public at an event in Colombo featuring a panel discussion on sustainability.
Germany: HeidelbergCement’s specific CO2 net emissions per tonne of cementitious material fell by 1.4% year-on-year to 599kg CO2/t in 2018 from 608kg CO2/t in 2017. Despite this its absolute gross CO2 emissions increased by 3% to 76.7Mt from 74.2Mt as clinker, cement, aggregate and concrete sales volumes all grew in 2018. The group has published the data in its Sustainability Report for the 2018 financial year.
“Cutting our CO2 emissions and handling natural resources considerately are priorities for all our business lines,” says Bernd Scheifele, chairman of the managing board of HeidelbergCement. "We focus primarily on the development of sustainable products and the implementation of concrete measures at plant level in order to achieve our sustainability goals.” The company has set itself the target of a 30% reduction in its specific net CO2 emissions per tonne of cement by 2030, compared with 1990. HeidelbergCement says it intends to realise its vision of CO2-neutral concrete by 2050 at the latest.
Other figures of note in the report include an alternative fuels substitution rate of 21.7% in 2018 compared in 20.8% in 2017. NOx, SOx and particulate matter emissions all fell. However, total water withdrawal rose by 8% to 65.4Mm3 from 60.4Mm3 although water consumption fell.
UK: The Institutional Investors Group on Climate Change (IIGCC) has called on European building materials companies to take steps to fight climate change or face commercial extinction. Recommended changes from its new ‘Investor Expectations of Companies in the Construction Materials Sector’ report have been sent to the heads of LafargeHolcim, HeidelbergCement, CRH and Saint-Gobain. The report informs investor engagement with other construction material firms on the initiative’s global list of 161 focus companies. Investment bodies in the group represent US$2Tn in assets, assets under management and under advice.
“The cement sector needs to dramatically reduce the contribution it makes to climate change. Delaying or avoiding this challenge is not an option. This is ultimately a business-critical issue for the sector,” said Stephanie Pfeifer, the chief executive officer (CEO) of the IIGCC. “Major economies such as the UK and France are increasingly adopting economy-wide net zero emission targets. The cement sector needs to get ahead of the profound transformation their sector faces by addressing barriers to decarbonisation in the short- to medium-term if companies are to secure their future.”
Key details set out in the ‘Investor Expectations’ report include becoming carbon neutral by 2050. Companies are expected to set short, medium and long-term science-based targets to reach this goal. Building material companies should be public policy transparent and advocate for the Paris Agreement, they should implement a ‘strong’ governance framework assigning specific responsibility for climate change to a board committee or board member and they should provide enhanced corporate disclosure in line with the recommendations of the Task Force on Climate-related Financial Disclosures (TCFD).
The IIGCC recognised the steps HeidelbergCement in particular has taken in already having committed to meeting key aspects of the investor expectations it has outlined. CRH, LafargeHolcim and Saint-Gobain have been encouraged to follow suit, given the ‘significant’ role they play as European-based multinationals. The group also praised the ambitious targets set by India’s Dalmia Cement to become carbon negative by 2040.