India: Wonder Cement, a part of the Rajasthan-headquartered RK Group, has announced that it will set up a 2Mt/yr clinker grinding unit in Dhule, Maharashtra at a cost of US$64.7m. The plan marks the company’s first foray into the state. This is in addition to the earlier-announced plan to invest US$359m by the end of the 2020 financial year.

“The Dhule plant will distribute cement mainly across Maharashtra, while a minimal quantity will be supplied to Madhya Pradesh,” said Managing Director JC Toshniwal, who added that the company is also in the process of developing a railway siding for the unit.

Following the commencement of the Dhule facility, Wonder Cement’s production capacity will increase to 8.75Mt/yr from the present 6.75Mt/yr. The clinker required for the unit will be supplied from Nimbahera plant in Rajasthan. Gypsum, another raw material used for manufacturing cement, will be procured from Gujarat and fly ash from a nearby thermal power plant.

In addition to the plants in Nimbahera and Dhule, Wonder Cement is in the process of setting up a third clinker facility of about 2.5Mt/yr in Nimbahera, Rajasthan. “The civil works for the third clinker unit is in full swing,,” confirmed Toshniwal. “We will commission it by mid-2019. This will help to increase our cement production capacity to 11Mt/yr.”

Under its expansion plans, the company will look at setting up two more clinker units. One will be in Madhya Pradesh, but the location for the other is yet to be finalised.

Azerbaijan: In the first seven months of 2018, Azerbaijan produced 1.92Mt of cement, a 21.6% increase compared to the same period of 2017. The country also produced 17,000t of lime (a 27.3% increase) and 811,100t of finished concrete (an increase of 2.2 times).

Indonesia: The sale of LafargeHolcim's Indonesian unit has sparked the interest of several potential buyers in the region. Names in the ring include Japan's Taiheiyo Cement, Malaysia’s YTL Corp and Indonesia’s PT Semen Indonesia, according to Bloomberg reports that cite unnamed sources. PT Indocement Tunggal Prakarsa is also reported to be interested. Bloomberg reports that LafargeHolcim could seek as much as US$2bn for the unit, which has 15.5Mt/yr of capacity across seven plants.

South Korea: Sungshin Cement will become the new owner of bigger rival Halla Encom Corporation, a ready-mixed concrete (RMC) manufacturer from Halla Corporation, by purchasing an 85% stake in it for US$49.3m.

Sungshin said that it had signed a share purchase agreement by forming a consortium with BCH Peregrine Investment, a private equity fund, to take over Halla Encom. It said that that the purpose of the sale was to improve its financial soundness and raise funds for new businesses.

Halla Encom ranked seventh among South Korea’s eight RMC producers in 2017, producing 3.44Mm^₃ of concrete. Sungshin Cement was eigth, with shipments of 1.91Mm³. The combined entity is expected to become the third largest producer of RMC in South Korea, larger than Ssangyong Remicon (5.34Mm³) Sampyo Industry (7.59Mm³) and Eugene Corporation (7.5Mm³).

Kenya: East Africa Portland Cement Company (EAPCC) properties are set to be auctioned to recover US$13.9m owed to workers following the firm’s failure to fully implement a collective bargaining agreement (CBA).

The Kenya Chemical and Allied Workers Union (KCAWU) has already obtained the services of an auctioneer, who will start auctioning EAPCC property upon expiry of the notice. The auctioneer will be seeking to recover the money for more than 400 workers covered in the 2013–2015 CBA.

The said CBA was the subject of a dispute before the Labour Court and the Court of Appeal. EAPCC was aggrieved that the court had directed it to increase wages for contract employees.

Court of Appeal judges GBM Kariuki, Fatuma Sichale and Sankale ole Kantai, held that upon the contract staff who were not part of management becoming members of KCAWU on payment of union dues, they were entitled to benefit from the negotiated CBA.

Turkey: Shanghai Triumph Energy Conservation Engineering Co Ltd has won a waste heat recovery (WHR) project at Bartin Çimento from Turkey’s Sanko Holding, which operates the plant. It will have a recovery capacity of 5MW from the 3700t/day facility. The project will be carried out on an Engineering, Procurement and Construction (EPC) basis.

Shanghai Triumph plans to install two boilers and one power generation system. It will use two boilers from Mitsubishi Corporation, with the power generator likely to be sourced from Kubota Corporation.

France: LafargeHolcim has announced a Euro3.5m investment in a new mixer for its clinker and slag mill located on the port of Dunkirk. The new equipment is intended to further increase the site's production, which has been steadily increasing since it was commissioned in 2012. The mill will manufacture of cement with 40% clinker and 60% ground iron slag. Commissioning is scheduled for January 2019.

Uzbekistan: Uzbekistan imported cement worth a total of US$79.8m during the first half of 2018, six times more than in the same period of 2017, according to the State Statistics Committee of Uzbekistan. It was reported earlier that Uzbek cement production had decreased from 4.2Mt in the first half of 2017 to 3.9Mt in the first half of 2018.

Egypt: Egyptian President Abdel-Fattah al-Sisi inaugurated a cement and marble production complex worth US$1.1bn to the south of Cairo on 15 August 2018. The 500-hectare industrial complex is located 12km north of the Upper Egyptian governorate of Beni Suef.

It took 21 months to complete the complex, which includes three cement plants with a combined annual production capacity of 12Mt/yr. Egypt, through the Armed Forces Engineering Authority, worked together with 20 local and international companies on the project.
During the unveiling ceremony, Sisi said that such industrial projects would help reduce imports, while saving foreign currency and offering thousands of job opportunities to local people.

There have been quite a few new cement plant project announcements in the past week, with expansions announced in Mexico, Nigeria, Bangladesh, Indonesia, India and Uzbekistan. 11.8Mt/yr of new capacity has been announced in just a week, mostly from a whopping 9.0Mt/yr project in Central Sulawesi, Indonesia, the first in that Province. Notable in this project, as well as two of the others, is the involvement, once again, of large Chinese-based cement plant manufacturers and / or finance and associated influence from Chinese parties.

Of course, this trend is nothing new. The rise of Chinese cement plant manufacturers, particularly into Africa and other developing cement markets, has been covered in previous Global Cement Weekly columns. However, it does appear to be stepping up a notch in 2018 compared to previous years. So far this year we have reported on 21 confirmed Chinese cement plants being built in 15 countries other than China, from the planning stage to ‘up-and-running.’ A total of 37.2Mt/yr, more than the capacity of Germany, is being built across Algeria, Cambodia, Cameroon, Indonesia, Kyrgyzstan, Namibia, Nepal, Nigeria, Pakistan, Russia, Tajikistan, Turkey, Ukraine, Uzbekistan and Zambia. That’s not including a similarly large number of news stories where the supplier is not explicitly stated. This is seen a lot in Indian projects, as well as in Vietnam, where the cement sector appears to still be expanding, despite the government’s pronouncements. In many of these cases, and elsewhere, these unidentified suppliers are likely to be Chinese.

The driver for this increase in Chinese-led cement sector investment is, of course, the severe overcapacity in China’s domestic cement sector. The government is currently undertaking its most drastic capacity reduction measures so far. The ongoing integration of Sinoma and CNBM is one example of the lengths it will go to to reduce the current inefficiencies in the sector. This week the Chinese government reiterated its strict prohibition on new greenfield cement plants. It also warned that any producer that wants to upgrade its plant with a new line must only install the same capacity as the line that will be replaced, amid concerns that some were flouting this rule. This comes as the profits of major producers have been rising. Presumably the government would like them to climb further still.

So where does this leave the more established (read ‘European’) cement plant manufacturers such as Fives, FLSmidth, KHD and thyssenkrupp Industrial Solutions, some of which are fully or partly-owned by Chinese companies? Well, with fewer full-line projects available in developing regions due to the rise of the Chinese, they have become increasingly specialised in specific areas. Those that want European equipment will increasingly specify a pyro-line from Supplier A, a mill or two from Supplier B, conveyors and storage from supplier C, and so on. Arranging this, as it turns out, is something that Chinese plant manufacturers are quite keen to do. Take, for example, FLSmidth working for Sinoma (China) alongside Atlas Copco (Sweden) and Kawasaki Heavy Industries (Japan) on a cement plant in Indonesia. Indeed, FLSmidth signed a framework with CNBM on future collaborations in July 2018. FLSmidth and CNBM already have an extensive ‘back catalogue’ of joint projects. FLSmidth has valuable expertise that Chinese firms need to complete these kinds of projects.

Of course, another European supplier, Germany’s KHD, is mostly owned by China’s AVIC. In a forthcoming interview in the September 2018 issue of Global Cement Magazine, KHD’s CEO Gerold Keune states that the Engineering, Procurement and Construction (EPC) scene is now ‘completely dominated’ by Chinese suppliers. KHD fits in by providing a wide range of equipment but, crucially, great expertise in pyroprocessing and crushing solutions. It itself relies on smaller firms to provide their knowledge to specific parts of a larger project, be it conveyors, feeding systems or silos. Everyone is getting better and better, but in a smaller and smaller area.

Also in the September 2018 issue of Global Cement Magazine will be a report from the VDMA’s Large Industrial Plant Manufacturer’s group (AGAB) in Germany, which highlights another advantage for the Europeans: Digitisation. According to a VDMA survey, the industry anticipates a positive influence from digitisation activities on sales and earnings and expects to see margins improve by up to 10% as a result of the efficiencies it offers over the next three years. In this regard they are ahead of the Chinese mega-suppliers.

The conclusion from this wide-ranging column? The integration of Chinese weight and European know-how is stepping up a notch and will only accelerate from here. Can everyone be ‘winners?’ The next few years may reveal some of the answers.