Displaying items by tag: Upgrade

Saudi Arabia: Sinoma Overseas has marked the construction of the preheater tower as part of a relocation and upgrade of Yamama Cement’s production line. The previously 10,000t/day line now has a capacity of 12,500t/day. The placement of the final structural element on the preheater tower was attended by representatives from both companies.

Sinoma posted on social media that the company had “overcom[e] significant engineering and logistical challenges – from dismantling and moving massive equipment to integrating new technology.”

With the preheater tower now complete, the company looks ahead to the plant’s commissioning and final delivery.

China: Hebei Wushan Cement has completely dismantled a 1000t/day clinker line formerly used to support its 3000t/day clinker line. The line will not resume production.

The producer also dismantled the original rotary kiln of a 2000t/day line and upgraded it to a 3000t/day new dry-process clinker line using a rotary kiln (Φ = 4.3m, L =  60m).

Russia: Kavkazcement plans to spend US$224m on equipment modernisation after cement production costs rose by 30–34% in 2024, according to local news reports. The producer recorded a production increase of 11% year-on-year to 2Mt in 2024 and aims to grow output by a further 10% in 2025.

General director Sergey Bogomaz said “Cement from Kavkazcement is in demand in many regions of Russia. The main deliveries go to the Rostov Region, Volgograd Region and Krasnodar Krai. In our region, we see an increase in construction volumes. New infrastructure projects are emerging, such as the construction of the first airport in Karachay-Cherkessia.”

Boral announced this week that it had secured around US$15m from the Australian government towards decarbonisation upgrades at its Berrima cement plant in New South Wales. The funding will go towards the company’s own investment in a kiln feed optimisation project. A new specialised grinding circuit and supporting infrastructure at the site is intended to increase the proportion of alternative raw materials (ARM) from 9% to 23% to decrease the amount of limestone the kiln uses. The use of more ARMs should also enable the unit to reduce its energy intensity. Boral plans to use ARMs including granulated blast furnace slag, steel slag, cement fibre board, fly ash and fine aggregates from recycled concrete. Commissioning and full operation of the changes are scheduled for 2028.

The Berrima plant officially opened its last set of changes, including a chlorine bypass unit, in December 2024. This was done to allow the plant to reach a thermal substitution rate (TSR) of 60% by the end of 2027. At the end of 2024 the company said it had a TSR of 30% having risen by 20% from 2023. Another similar decarbonisation project at the plant is a carbon capture and storage demonstration pilot trial involving the recarbonation of construction and demolition waste.

Parent company SGH said in its annual report for 2024 that Boral was continuing to advocate for a carbon border adjustment mechanism (CBAM) to prevent carbon leakage and that it had taken part in the ongoing government review on the issue. This lobbying was visible earlier in March 2025 when the Cement Industry Federation (CIF) publicly addressed the government on the issue ahead of its next budget. It asked that carbon leakage be addressed in the form of an import tax to protect the local cement and lime sector. Cement and lime imports from Thailand, Malaysia, Indonesia, Vietnam and Japan are particularly seen as an issue. The government review into carbon leakage started in 2023 and is due to report back at some point in 2025, most likely after the parliamentary election in May 2025.

Another big sector news story to note is the ongoing acquisition of the cementitious division of the Buckeridge Group of Companies (BGC) by Cement Australia that was revealed in December 2024. Unsurprisingly, the European Commission (EC) approved the deal in late March 2025. Cement Australia’s parent companies Holcim and Heidelberg Materials are headquartered in Europe, but the EC concluded that the planned transaction was unlikely to dampen competition in Europe. The verdict of the Australian Competition and Consumer Commission (ACCC) is likely to be far more telling. It closed taking submissions on the proposed deal in late February 2025 and plans to release an update in May 2025.

The ACCC’s market inquiries letter reported that Cement Australia wants to run BCG Cement. However, under the acquisition proposal, BGC Quarries and BGC Asphalt will be acquired and operated by a new 50:50 joint venture between Holcim and Heidelberg Materials, which will operate as a production joint venture in respect of aggregates. Holcim and Heidelberg Materials have suggested taking four ready-mixed concrete (RMC) plants each in the greater Perth area. Finally, one RMC plant at Wangara could be divested due to the close proximity of existing plants run by Holcim and Heidelberg Materials. Whether this is what actually happens remains to be seen.

Finally, Holcim flagged-up Australia this week as one of the regions it intends to derive ‘profitable growth’ from after the planned spin-off of the US business. This approach is in line with the hunt by the big building materials companies for new growth markets as the cost of merger and acquisition activity in the US has risen. CRH, for example, bought a majority stake in AdBri in mid-2024. Further merger and acquisition activity in the cement sector in Australia seems less likely given its relative small size. Yet the higher economic growth forecast for the country compared to Europe is likely to keep multinationals interested.

France: CBMI has completed installation of a new rotary kiln at Eqiom’s Lumbres plant for the ‘K6 Project’. The plant is now reportedly carbon-neutral and is equipped with an oxyfuel kiln to reduce CO₂ emissions. The supplier said via social media that its team ‘delivered precise execution despite tight space and complex challenges’.

Eqiom announced back in 2024 that it would upgrade the Lumbres plant to expand its capacity and reduce emissions by 20% by 2026.

Brazil: Votorantim Cimentos grew its revenue and earnings in 2024 but its net income dropped significantly due to interest rate volatility. It noted ‘positive performance’ in its Europe and Asia region and a stable market in Brazil. It attributed its mounting earnings to its balanced portfolio, revenue in Europe and Asia, operational efficiency, reduced costs and new business.

The group’s net revenue grew by 3% year-on-year to US$4.69bn in 2024 from US$4.53bn in 2023. However, revenue fell slightly in local currencies due to negative exchange effects, particularly in North America. Cement sales volumes rose by 1% to 35.4Mt from 34.9Mt. Adjusted earnings before interest, taxation, depreciation and amortisation (EBITDA) increased by 16% to US$1.14bn from US$0.99bn. Earnings rose in all regions except for Latin America due to a ‘challenging’ market in Uruguay and lower prices in Bolivia. Despite this, its adjusted net income dropped by 17% to US$383m from US$461m.

“We ended the year with record-high operating results, supported by our geographic, product and business diversification, in line with our strategic mandate,” said Osvaldo Ayres, the group’s global CEO. The company invested over US$550m in 2024 towards decarbonisation, competitiveness and new businesses. A further US$880m investment plan in Brazil to 2028 was announced in early 2024. Ongoing projects include upgrades supporting higher thermal substitution rates at the Xambioá plant in Tocantins state and the Salto de Pirapora plant in São Paulo. A new 1Mt/yr cement grinding unit is being built at the Salto de Pirapora site. Construction of this project is scheduled for completion in the second-half of 2025. A new 1Mt/yr cement grinding unit was also announced at the Edealina plant in Goiás. This project is expected to be completed in the first half of 2026.

Votorantim also revealed that it paid around US$190m to the Administrative Council for Economic Defense (CADE) at the end of 2024 in connection with an agreement to end all administrative and judicial litigation. It said “We definitively resolved all pending disputes with CADE. We did not acknowledge, at any time, having committed any unlawful act or engaged in any anticompetitive behaviour.”

US: MTR Carbon Capture says that St Marys Cement’s Charlevoix plant in Michigan will be the first cement plant in the world to deploy its Polaris polymeric membrane-based technology. The pilot project aims to capture 3t/day of CO₂ during a six month testing period. It intends to demonstrate that a 95% CO₂ capture rate is achievable.

US-based Membrane Technology and Research (MTR) specialises in the development and production of membrane-based separation systems for the petrochemical, natural gas and refining industries. The company was set up in 1982 and has its headquarters in Newark, California.

India: Star Cement has successfully commissioned a 7MW air-quenched cooler waste heat boiler at its newly operational cement plant in Lumshnong, Meghalaya. increases the plant’s total waste heat recovery (WHR) capacity to 19MW. The WHR project aims to improve operational efficiency and reduce environmental impact.

Ethiopia: Dangote Cement will invest US$400m to restart the second production line at its Mugher cement plant, doubling the capacity to 5Mt/yr. The plant became operational in 2015, but has since faced challenges, including recurrent violence in the region, according to Bloomberg.

Aliko Dangote said that the expansion project is expected to be operational ‘within the next 30 months’.

India: UltraTech Cement has commissioned an additional 0.6Mt/yr grinding capacity at its integrated Sonar Bangla plant in West Bengal. It said the upgrade would help it meet cement demand in East India and enable it to increase its blended cement ratio. The company says that its domestic cement production capacity is now 166Mt/yr with an additional 5Mt/yr overseas.