Analysis

Congratulations to Taiheiyo Cement Philippines (TCPI) this week for inaugurating its new 3Mt/yr production line at its Cebu plant. The US$220m line replaces the old line at the site that was closed in late 2021.

The plant was originally built by Grand Cement Manufacturing in the early 1990s. Japan-based Taiheiyo Cement took over in 2001 and later made the decision to upgrade the site in 2017. It then contracted China-based Anhui Conch and Sinoma (Handan) Construction for the project in 2021 and groundbreaking took place in mid-2022. Commercial operation of the new line was previously scheduled from May 2024. TCPI has also invested around US$140m in related projects such as its Jetty and Marine Belt Conveyor project, which links the Cebu plant to the coast via a conveyor. Other parts of this expenditure encompass the Luzon Distribution Terminal Project at Calaca in Batangas and general port development in San Fernando.

The Department of Trade and Industry (DTI) was keen to promote this example of a foreign-owned company investing in local manufacturing. DTI Secretary Fred Pascual pointed out that Japan is the country’s “second-largest trading partner and third-largest source of foreign investment.” He also linked the project to the national Build Better More infrastructure development programme and the Tatak Pinoy Act that was introduced in early 2024 to promote local industry. Along these lines, Republic Cement was awarded the Domestic Bidder’s Certificate of Preference this week. It is the first cement company to receive it. The initiative promotes the use of local manufactured materials in government projects as part of the Tatak Pinoy Act. As one might expect, the Cement Manufacturers Association of the Philippines (CEMAP) supports the Tatak Pinoy Act. It voiced its support for the legislation in June 2024 when the DTI started to implement it. It noted that cement imports were just under 7Mt/yr in 2023 despite the anti-dumping duties imposed on a number of Vietnam-based producers and traders. This compares to a local production capacity of nearly 50Mt/yr.

CEMAP mentioned that new production lines from both TCPI and Solid Cement were expected in 2024. The latter project is a new production line being built at Solid Cement’s Antipolo plant near Manilla in Rizal province. Cemex Philippines held a groundbreaking ceremony for the 1.5Mt/yr line at its subsidiary back in 2019. However, Cemex said it was selling its Philippines-based business to DMCI Holdings and related companies in April 2024. As part of this process Cemex sold its local cement brands to the Consunji family, the owners of DMCI Holdings, in June 2024. Regulatory approval of the divestment is still pending but the sale of the brands suggest that the transaction is progressing. Completion is expected by the end of 2024. Operation of the new line at the Antipolo plant is anticipated from September 2024.

Another forthcoming plant project was announced by PHINMA Corporation in June 2024. It signed a joint venture deal with investment company Anflo Group to build a 2Mt/yr cement plant in Davao del Norte. The project is scheduled to be operational by 2026. Cement from the plant will be marketed under the Union Cement brand. The sums involved suggest a grinding plant but PHINMA’s cement division, Philcement Corporation, is involved with both manufacture and importation. PHINMA also signed a deal to buy Petra Cement in May 2024. The latter company runs a 0.5Mt/yr cement grinding plant in Zamboanga del Norte. PHINMA re-entered the cement market in the late 2010s when it bought the Union Cement brand and built a cement processing plant at Mariveles, Bataan in 2020.

The battles between cement producers and importers continue to play out in the Philippines as the country’s infrastructure plans gather pace. Yet the balance seems to be tilting more towards the favour of the local manufacturers at the moment, as new capacity gets proposed and built. Anti-dumping duties on imports, particularly those from Vietnam, have now been followed up with local procurement rules in the guise of the Tatak Pinoy Act. Whether this is enough remains to be seen. This kind of environment and the departure of Cemex may also start to revive questions about whether any other foreign-owned cement companies might be considering their options too.

A battle over cement pricing in Ghana reached a new stage this week when the Chamber of Cement Manufacturers (COCMAG) hit back at proposed government regulation. Frédéric Albrecht, the chair of the association, told a meeting that about 80% of local production costs linked to cement manufacture are related to the local currency exchange rate. So fixing the price would do little to address the main cause behind rises.

Albrecht was speaking at a stakeholders’ forum organised by the Ghana Chamber of Construction. The group was convened to discuss the government’s proposed Ghana Standards Authority (Pricing of Cement) Regulations 2024 that were formally presented in the country’s parliament in early July 2024. The association argues that the cement sector has not been consulted properly over the proposal and that introducing it could have negative consequences for the construction sector as a whole. It says that imported clinker is subject to numerous taxes and that the average price of cement has actually lagged behind the rate of inflation.

The government is dealing with an economic crisis that forced it to default on its external debts in 2022 and ask the International Monetary Fund for support. This has led to depreciation of the local currency and high inflation. Around the same time the authorities have also been attempting to regulate the cement sector more closely. In 2022 the Ghana Standards Authority (GSA) took action against a brand of cement, Empire Cement, that appeared to be on sale without any of the required permits. Then in the autumn of 2023 the Ghana Revenue Authority (GRA) shut down Wan Heng Ghana’s grinding plant in Tema after the company failed to pay a major tax bill. Action by the GSA followed when it shut down three more plants in the Ashanti Region - Xin An Safe Cement Ghana, Kumasi Cement Ghana and Unicem Cement Ghana - for using inferior materials in cement production.

In April 2024 a nine-member committee was established to monitor and coordinate the local cement industry. Notably, cement producers have been required to register with the committee in order to secure a licence to manufacture cement. Kobina Tahir Hammond, the Trade and Indus¬try Minister, then said in late June 2024 that the government wanted to intervene in cement pricing to protect consumers from what he described as the ‘haphazard’ increment in cement prices by manufacturers. A legislative instrument doing just that was presented in parliament on 2 July 2024. Around the same time the GSA reportedly threatened to close down ‘several’ more cement plants for non-compliance.

The cement industry in Ghana is particularly vulnerable to currency exchange effects as it is dominated by grinding plants. One integrated cement plant, Savanna Diamond Cement, was launched in the north of the country in the mid 2010s. However, this compares to 14 licensed grinding plants in the country reported in the local media. This includes units run by Ciments de l’Afrique (CIMAF), Dangote Cement, Diamond Cement (WACEM) and Heidelberg Materials subsidiary Ghacem and its CBI Ghana joint-venture amongst others. This makes it one of the countries in Sub-Saharan Africa with the most grinding plants, along with places such as Mozambique and South Africa. When the Ministry of Trade and Industry started a consultation on regulating the cement sector in late 2023 it calculated that the country produced 7.2Mt of cement in 2021 and that the country had an overcapacity of 3.5Mt. This gives the country an estimated cement production capacity of just below 11Mt/yr.

Some sense of the growing costs that the cement sector in Ghana is facing can be seen in the Ghana Statistical Trade Report for 2023. Clinker was the country’s third biggest import by value at US$206m. It was only exceeded by diesel and other automotive oil products. The Ghana Statistical Service reported that most of the country’s imported clinker in 2023 came from Egypt, South Africa and its neighbours in West Africa. Both Dangote Cement and Heidelberg Materials flagged up the country’s economy as being hyperinflationary in their respective annual reports for 2023.

Argument and counter-argument over cement pricing is prevalent around the world especially in Africa. Fellow West African country Nigeria, for example, has endured plenty of very public dialogue and debate about the price of cement. In Ghana’s case it seems more likely than not that factors beyond the control of the local cement companies are driving the prices given the grinding-dominated nature of the sector with lots of different companies involved. Negative currency effects and inflation look more likely to be driving cement prices than anything else, although one should always be wary of the potential for cartel-like behaviour by cement producers. The economic crisis in Ghana certainly fits the bill for the conventional introduction of price controls on selected commodities but getting the fine tuning right could be difficult in practice. Fixed prices will reassure consumers in the short term provided supplies hold. Beyond this the actual causes of the high cement prices should emerge in time.

Both Limak Çimento and Cemento Yura revealed plans to work with hydrogen this week. Additionally, Lhyfe and Fives signed a deal to sell decarbonised products and services to industries, including cement, covering hydrogen production to combustion.

Türkiye-based Limak Çimento said that it had successfully conducted a hydrogen-enhanced alternative fuel test at its integrated Anka plant near Ankara. As part of the project it blended hydrogen with an alternative carbon-neutral fuel and then operated the plant’s kiln at a 50% substitution rate. The cement company says that the trial achieved a world first by feeding the hydrogen-enhanced fuel directly into the calciner instead of the main burner in the rotary kiln. According to local press, Air Liquide supplied grey hydrogen for the test, although this could be switched to green hydrogen in the future. As a reminder, ‘green’ hydrogen is produced by the electrolysis of water using renewable energy sources. ‘Grey’ hydrogen is made from steam reforming using fossil fuels.

Limak’s wider ambition is to use hydrogen-blended alternative fuels at all of its cement plants by 2030. By doing so it aspires to reduce its CO₂ emissions by 700,000t/yr. Its CEO Erkam Kocakerim remarked in mid-2023 that focusing on the carbon risks that energy-intensive industries might face exporting to the European Union (EU) paled in comparison to the potential payback from the green energy transition. At a climate change summit in mid-2023 organised by the United Nations and the Turkish government, he called for the Turkish Emission Trading System to be put into action as soon as possible, the creation of an updated renewable energy roadmap with renewable hydrogen, CCUS and renewable fuels, and the publication of a hydrogen and CO₂ country atlas. At the same time, he stated that the local cement sector could meet the EU’s 2030 emissions targets through the increased uptake of alternative fuels and blended cements.

Meanwhile in Peru this week Juan Carlos Burga, the general manager of Grupo Gloria subsidiary Cemento Yura, told the Gestión newspaper that its cement plant near Arequipa is preparing to start a green hydrogen trial in 2025. The catalyst for this is a solar power unit at the site that is currently scheduled for commissioning in early 2025. Once it is ready then the plant’s hydrogen project can use the renewable energy source to manufacture hydrogen and inject small quantities of it to stabilise the burning process and reduce the amount of coal used.

By contrast the memorandum of understanding that Lhyfe and Fives announced this week looks like the pair are marking their territory in the hydrogen supply and equipment chain for heavy industry. As part of the agreement the companies are targeting the metals, glass and cement industries and some other selected industrial heating processes and applications in Europe and North America. France-based Lhyfe develops, builds and runs green hydrogen production plants both for external clients and itself. It operates one plant at Bouin in France and is building other plants in France and Germany. However, the output of these sites is low. In spite of this, it says it is set to become the largest producer of renewable hydrogen in France in 2024. Fives, well known as a cement equipment supplier, says it has been a “technological leader in hydrogen for over 50 years” and that it sells “the widest range of hydrogen-proven burners available on the market to serve all industries.” The Lhyfe-Fives agreement follows a similar deal between Air Products and ThyssenKrupp Uhde Chlorine Engineers in 2020.

Projects in West Asia and South America such as those discussed by Limak Çimento and Cemento Yura are not necessarily where one might expect them to be. Typically all the sustainability news in the cement sector tends to be dominated by companies in Europe and North America. This is reflected in the continents that Lhyfe and Fives have targeted this week. Yet, the focus by Limak and Yura on hydrogen suggests that these companies are hunting for decarbonisation options that are cost effective ahead of potential legislative enforcement. Both appear to be using hydrogen as a fuel enhancer or additive rather than on its own.

We have reported upon a steady stream of hydrogen projects for the cement sector in the last year. These include Heidelberg Materials' study looking at using ammonia as a hydrogen source for fuelling cement kilns at its Ribblesdale cement plant in the UK, Fives work with Holcim at the La Malle plant in France and much work by Cemex such as the increase of its stake in green hydrogen production technology developer HiiROC in late 2023. As with Global Cement Weekly’s previous reporting on hydrogen, the jury is still out on whether it is a ‘goer’ for heavy industry at scale. An executive at Mitsubishi Heavy Industries told a conference in March 2024 that the infrastructure investment to support the use of hydrogen would cost over US$1Tn in the US and Europe alone. The head of Saudi Aramco then pointed out at the same event that oil and gas, for now at least, cost far less than hydrogen. Despite this, the projects keep coming.

Saint-Gobain looks set to increase its presence in the construction chemicals market this week when it announced a deal to buy Fosroc. A definitive agreement has been set for the acquisition valued at just over US$1bn. The purchase will be financed in cash and is expected to close in the first half of 2025.

The light construction materials company has been growing its construction chemicals capabilities for several years now. In 2021 it acquired Chryso for Euro1.02bn and then it bought GCP Applied Technologies for Euro2.3bn in 2022. Acquisitions of smaller companies in the sector, including Duraziv and IMPAC, also took place. With regards to the proposed Fosroc transaction, Saint-Gobain highlighted in its press release that the deal was “supported by solid macroeconomic factors including the transition towards low-carbon concrete.” It also noted that Fosroc’s geographic profile would strengthen its own presence in emerging markets such as India and the Middle East. Chryso’s market share is mainly in Europe, Turkey and Africa. GCP’s is in North America, Latin America and Asia-Pacific.

As Riccardo Stoppa, Saint-Gobain’s Business Director of Cement additives related to Global Cement Magazine in our May 2024 issue, the Construction Chemicals Business Unit of Saint-Gobain’s High Performance Solutions (SGHS) division broadly produces two groups of products for the cement and concrete sector: additives and admixtures; and a wider range of more recent products using newer chemistry approaches. Saint-Gobain’s total annual revenue is around €48bn/yr with SGCC’s contribution weighing in at around €1bn/yr. Most of that latter revenue derives from the former businesses of Chryso and GCP. Finally, Stoppa highlighted SGCC’s strength in North America, Europe and China but also highlighted the potential in the Middle East for its products. That last point makes interesting reading in light of the current Fosroc deal.

India was flagged as a benefit of the proposed Fosroc purchase. If any further reminder of the growth and market consolidation taking place there were needed, UltraTech Cement revealed this week that it is in the process of buying a 23% share of The India Cements. This story ties into the rivalry between the country’s two largest cement companies. Both UltraTech Cement and Adani Group are mounting up production capacity at pace through both acquisitions and by building new plants. All of this is rosy news for a company selling additives and admixtures to the cement and concrete market.

Saint-Gobain latest acquisition is subject to the usual regulatory conditions as one might expect. Yet, what Saint-Gobain didn’t mention in its statement, was that it reportedly had one of its sites in Türkiye visited in late 2023 as part of an international investigation into anti-competitive behaviour in the sector. Switzerland-based Sika was also linked to the case at the time. The UK-based Competition and Markets Authority (CMA) announced in October 2023 that it had launched an investigation into suspected anti-competitive conduct in relation to the supply of chemicals for use in the construction industry. It said it was working with the European Commission and that it had been in contact with other authorities, including the US Department of Justice, Antitrust Division. At this time Sika confirmed to Construction News that inspections had taken place into “suspected antitrust irregularities in the area of additives for concrete and cement.” However, it is important to note here that these were merely information gathering activities and no accusations of any breaches of competition law have been made so far. All of this suggests that Saint-Gobain does not seem too troubled by the interest of the various competition bodies with regards to its expansion plans.

In his interview, Stoppa told Global Cement Magazine that SGCC’s products allow cement and concrete producers to reduce the amount of cement used in their concrete. This is almost heretical thinking to a world that produces too much clinker. Yet Saint-Gobain is betting on exactly this outcome through the expansion of its construction chemicals division. Its purchase of Fosroc is the latest stage in this line of thought. It’s not the only company doing this. In May 2023 Sika completed its purchase of MBCC Group, another admixture manufacturer. Further sector consolidation looks likely.

The Hillhead Quarrying, Construction and Recycling Show is in full flow this week, taking place near Buxton in Derbyshire. As one delegate marvelled on the panoramic minibus journey down to the quarry, “It’s like a music festival without the music and… other stuff.” Indeed. Of course what one doesn’t find at Glastonbury and the like is a near comprehensive range of suppliers, over 600 of them, to the industry all in one place… in a quarry! Where else can one get up close and see the new hydrogen-powered generators and excavating vehicles that are being piloted? The official attendance figures don’t get released until after the event but on the ground it looks as busy as ever. It’s truly the place to be this week.

The show gives us a reason to take a look at the UK cement sector. Like many other countries around the world it is an election year in the UK, with a General Election scheduled for 4 July 2024. The result of this should determine the next Prime Minister and the ruling party. So, naturally, the MPA, the trade association for the aggregates, asphalt, cement, concrete, dimension stone, lime, mortar and industrial sand industries, is taking the opportunity to remind the political parties what its priorities are. The quick version is: support for decarbonisation; a streamlined planning system; and better delivery of projects. This sounds familiar to priorities in other countries but one British spin on this includes the UK’s carbon border adjustment mechanism (CBAM).

Graph 1: Domestic cement sales and imports in the UK, 2017 – 2022. Source: MPA.

Edwin Trout’s feature on the UK cement sector in the June 2024 issue of Global Cement Magazine presents a good overview of the last 12 months. The general UK economy has faced shocks in recent years such as Brexit, Covid-19 and the war in Ukraine. However, this has been further compounded by a downturn and high interest rates since late 2022 when the then Prime Minister Liz Truss caused market turbulence in the wake of a badly received government financial statement. As Trout relates, sales of heavy building materials have been in relative decline since mid-2022 with more of the same expected in 2024. Production of cement in 2023 is currently uncertain given the reporting time lag from the MPA but up until 2022 domestic cement sales fell somewhat but imports grew. This has created a situation where overall cement sales in 2022 were 12Mt, not far behind the annual level in the early 2000s. However, the share of imports has nearly doubled since then. More recent MPA data on mortar and ready-mixed concrete sales throughout the first nine months of 2023 suggest that market activity has decreased and poor weather at the start of 2024 looks set to have made this worse.

Despite the apparent slowdown in building materials sales the cement companies have been conducting smaller-scale maintenance and upgrade projects at their facilities and supply chain schemes such as the cement storage unit for deep sea shipping lines that Aggregate Industries said in February 2024 it was going to build at the Port of Southampton. The news the cement companies want to show off has been a steady stream of information about ongoing decarbonisation projects in the cement sector. C-Capture started a carbon capture trial at Heidelberg Materials’ Ketton cement works in Rutland in May 2024, Capsol Technologies said in March 2024 that it had been selected to conduct a study on its carbon capture technology at Aggregate Industries Cauldon cement plant in Staffordshire, Heidelberg Materials' Ribblesdale cement plant in Lancashire announced in March 2024 that it was taking part in a study to assess the use of ammonia as a hydrogen source for fuelling cement kilns and Heidelberg Materials awarded Japan-based Mitsubishi Heavy Industries (MHI) a front end engineering design contract for a carbon capture installation at its Padeswood cement plant in Flintshire in February 2024. Finally, on the divestment front, CRH completed the sale of its UK-based lime business to SigmaRoc for €155m in March 2024. The business operates from sites in Tunstead and Hindlow with five permitted lime kilns.

That’s it for this short recap on the UK for now. For a longer look at the UK cement sector read Edwin Trout’s feature in June 2024 issue of Global Cement Magazine.

Hillhead 2024 runs until 27 June 2024