Displaying items by tag: Plant

Vietnam: ThyssenKrupp Polysius’ Asia Pacific division has secured an order for two Polflame-type main burners for an unnamed cement plant. The equipment supplier has highlighted the ability of its burner product to cope with low-grade coal and support high alternative fuel substitution rates as key selling factors. The order follows the purchase of an Impact Crusher by the same customer previously.

Lukas Schoeneck, the chief executive officer of Polysius Asia Pacific, said "We are very proud to add burners number 17 and 18 to our installed base in Vietnam which ensures our market leader position. Now we have to put our focus on the delivery and installation of the burner - in time and quality.”

US: Lehigh Hanson is preparing to start cutting jobs at the Glens Falls cement plant in New York from April 2023. The majority of the employees at the site will be laid off in April 2023 with some staff to be retained until later until 2023, according to the Times Union newspaper. It was previously reported in November 2022 that the subsidiary of Germany-based Heidelberg Materials was planning to close the plant in a phased manner in 2023. Production from the Glens Falls site will be covered in the future by the company’s new Mitchell plant in Indiana.

Morocco: NovaCim’s new 1.4Mt/yr cement plant at Ouled Ghanem near El Jadida has produced its first cement. Denmark-based FLSmidth supplied equipment for the unit including an OK type vertical roller mill, which it says is the first such installation of the product in the country. FLSmidth said in 2019 that it was going to build the plant for TEKCIM in conjunction with the Société Générale des Travaux du Maroc (SGTM). Full commissioning is scheduled for 2023.

US: Canada-based CEMSI Specialties, a subsidiary of Kontrol Technologies, has received an order for an emission analyser product from an unnamed global cement company. The analyser will provide real-time analysis of continuous emissions from the plant. The contract also includes ongoing annual preventative maintenance. Delivery and installation is scheduled for late 2022 and the first quarter of 2023. No value for the order has been disclosed.

Canada: Lafarge Canada’s Brookfield plant in Nova Scotia has switched to Portland Limestone Cement (PLC) production. The unit will now manufacture the company’s OneCem PLC product. It is the cement producer’s third plant to transition to PLC production in 2022 following the Bath plant in Ontario and the Richmond plant in British Colombia.

Andrew Stewart, the Vice President of Cement at Lafarge Canada (East), said, “We have been steadily moving the needle forward when it comes to cement decarbonisation and we will continue to honour our commitment in progressing our greener portfolio in Eastern Canada over the coming years.”

India: Adani Group has explained that truck drivers' unions are responsible for its subsidiaries ACC and Ambuja Cements' indefinite closures of their Gagal and Darlaghat cement plants in Himachal Pradesh. In a statement, the group said that the unions prevent cement truck drivers from operating at competitive rates.

The Hindustan Times newspaper has reported that Adani Group said "We are deeply aggrieved with the situation caused by the adamant stand of the truck unions in Himachal Pradesh. Such matters can be resolved only by understanding the issues faced by all the stakeholders."

India: Visaka Industries plans to invest US$15.7m in the construction of a new cement boards plant in West Midnapore, West Bengal. United News of India has reported that the plant will produce the company's Vnext fibre cement board product. When commissioned in August 2023, it will increase Visaka Industries' Vnext boards production capacity to 72,000t/yr. The producer will equip the plant with an ATUM Solar Roof integrated solar power unit, eliminating 840,000t/yr of Scope 2 CO₂ emissions. Visaka Industries plans to employ 500 people at the plant, and additionally support its host community in Shalbani Dakhinshole through its corporate social responsibility (CSR) initiatives.

India: Adani Cement has published its plans for the closure of two integrated cement plants in Himachal Pradesh. The Hindustan Times newspaper has reported the plants as ACC's 4.4Mt/yr Gagal cement plant in Bilaspur District and Ambuja Cements' 1.6Mt/yr Darlaghat cement plant in Solan District. The management of the Gagal cement plant said that losses ensuing from high operating costs, including transport costs, are the reason behind the decision to shut down that plant. ACC employs 1000 company staff and contractors at the site, and an additional 4000 truck drivers in its cement despatch operations. 3500 truck drivers also work in delivering cement from the Darlaghat cement plant. The Gagal cement plant alone reportedly despatches 5000t/day of cement for the Himachal Pradesh, Haryana and Punjab markets.

The Bilaspur District Truck Operators' Society said "The transport sector of Bilaspur is heavily dependent upon the Gagal cement plant. It's the source of livelihood for thousands of people, including operators, drivers and conductors. This decision should be reconsidered in the interest of the people." It added "Most roadside restaurants and mechanics' shops will also lose business. We never thought that this plant could ever stop functioning. It has been part of our landscape and economy for decades now."

UK: Heidelberg Materials subsidiary Hanson has awarded a contract to Mitsubishi Heavy Industries subsidiary MHI Engineering for installation of a planned 800,000t/yr carbon capture system at its Padeswood cement plant in Flintshire. The producer plans to store its captured CO₂ in exhausted Irish Sea natural gas fields. MHI Engineering will carry out a pre-front-end engineering design study using its Advanced KM CDR solvent-based process. The supplier developed the process jointly with fellow Japan-based company Kansai Electric Power.

The project will be MHI Engineering's third of its kind at a cement plant, following similar commissions with Lehigh Cement in Canada and Tokuyama Cement in Canada.

Further consolidation of the Indian cement sector looked closer this week with the news that Dalmia Bharat’s cement subsidiary has agreed to buy the remaining cement plants from Jaiprakash Associates. The US$685m deal covers cement and power plants in Madhya Pradesh, Uttar Pradesh and Chhattisgarh. It includes clinker production capacity of 6.7Mt/yr, cement capacity of 9.4Mt/yr and 280MW of captive power capacity.

Chart 1: Map of Dalmia Bharat’s cement plants in November 2022 with region of proposed new plants highlighted in orange. Source: Adapted from Dalmia Bharat investor presentation.

The acquisition gives Dalmia Bharat the opportunity to draw level with Shree Cement in terms of cement production capacity. If the deal completes, then both cement companies will hold a capacity of around 46Mt/yr. This puts them behind UltraTech Cement and Adani Group nationally. In terms of the cost, the proposed acquisition works out at around US$73/t of cement capacity, although this doesn’t take into account the additional captive power generation capacity. This compares to US$119/t for UltraTech Cement’s purchase of Jaiprakash Associates plants in 2017 and US$97/t for Adani Group’s purchase of Holcim’s Indian-based business in September 2022.

Dalmia Bharat’s rationale for its move this week was that it wants to grow in the Central Region of the country and work towards a capacity target of 75Mt/yr by the 2027 financial year and at least 110Mt/yr by the 2031 one. It backed this up in an investors’ presentation by saying that cement consumption was around 170kg/capita locally and that the region represented about 15% of national demand at 54Mt/yr. This roughly checks out with regional integrated/clinker production capacity distribution analysis that Global Cement Weekly carried out in June 2022. Only the East region was lower, but this didn’t take into account grinding plants or new projects.

Completion of the agreement is planned by December 2023 and is subject to the usual regulatory approvals. However, readers may recall the difficulties UltraTech Cement had in the mid-2010s when it attempted to buy two plants from the subsidiary of Jaypee Group. Problems stemming from an amendment to the Mines and Minerals (Development and Regulation) (MMDR) Act caused the original proposal to be rejected by the Bombay High Court in early 2016. UltraTech Cement bounced back though with a deal to buy far more plants instead. This deal completed successfully in mid-2017.

Jaypee Group’s debts have also caused problems along the way. Indeed, this is the reason why it has finally decided to leave the cement business altogether. In early December 2022 it reported its latest default on interest payments towards some of its loans. Overall its outstanding debt was US$3.39bn. Due in part to this, there have been plenty of stories in the local press over the last decade on whoever was reputedly buying the Jaypee Group’s cements assets. In October 2022, for example, Adani Group was reportedly in advanced talks to buy Jaypee Group’s remaining cement business until it denied it publicly. One deal that did reach fruition was Dalmia Bharat’s purchase of Bokaro Jaypee Cement back in 2014 from a joint-venture majority controlled by Jaypee Group. That agreement gave it full control of the 2.1Mt/yr Bokaro grinding plant in Jharkhand. Looking at the current proposed acquisition, one commentator from HDFC Securities in the local business press noted that detail on the transaction is lacking, such as what will happen to existing limestone reserves. Another pointed out that the deal was probably 30 – 40% below the replacement cost because the plants were old, lack of interest from potential buyers and due to the “likely need for additional CAPEX to run operations.”

If the Dalmia Bharat - Jaiprakash Associates deal completes then it marks the end of an era for the Indian cement industry as one of the big players bows out of the sector. It shows once more that, despite the mounting fuel and raw material costs in 2022, companies are still seeing big opportunities. In its December 2022 report, the ratings agency ICRA found that cement sales volumes grew by 11% year-on-year to 187Mt in the first half of the 2023 financial year. The acquisition might also, hopefully, put an end to the endless speculation about who Jaypee Group might be selling its cement plants to! Although, of course, the question then becomes who else might be considering divesting cement assets.