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The news from Sri Lanka this week is that Lanwa Sanstha Cement is preparing to commission a new 3Mt/yr grinding plant in January 2022. The timing is apposite given the current shortages in the country.

Some inkling of local problems can be seen in the cement news over the last few months. In August 2021 Insee Cement said that it was operating at full capacity utilisation across its network. Later, at the end of October 2021, the government intervened in the import market by opening up the use of Trincomalee Harbour. This was followed by the nation’s other main producer, Tokyo Cement, announcing that it too was operating its grinding plant at Trincomalee at full capacity. It also said that, at the government’s behest, it was going to increase its import rate.

The new Lanwa Sanstha Cement unit originally came to international attention when Germany-based Gebr. Pfeiffer revealed details in 2019 of an order of two MVR 5000 C-4 type roller mills from Onyx Group. Lanwa Sanstha Cement has since said that the plant will cost US$80m. Once operational the unit at the Mirijjawila export processing zone of the Hambantota International Port will manufacture ordinary Portland cement, Portland slag cement, Portland limestone cement and blended hydraulic cement. A further equipment order for the project was announced this week when the Chinese-run Hambantota International Port Group signed an agreement with Lanwa Sanstha Cement to build a conveyor from the port to the plant. The deal also includes two ship unloaders.

Other new cement units on the horizon include an integrated plant project from Nepalese businessman Binod Chaudhary that was announced in mid-2019. The US$150m plant was planned for Mannar in the north of the island. However, not much more has been heard since then. Chaudhary’s company CG Cement operates a grinding plant in Nepal. More recently, in October 2021, local press reported that the government had tentative plans to build a new plant at the old state-owned Kankesanthurai site, also in the north. The plant was originally built in the 1950s and production ran until 1990 when the military took over the unit amid the then on-going civil war. Earlier in 2021 the government agreed to sell off the machinery at the site. However, much of it has gone missing in the intervening period! Proposals to revive the plant have circulated since the mid-2010s.

Graph 1: Cement production and imports in Sri Lanka, 2015 – 2021. Estimate for 2021 based on January to August data. Source: Central Bank of Sri Lanka.

The Sri Lankan cement market has faced a tough time over the last two years. First, total local production and imports fell by 11% year-on-year to 7.2Mt in 2020 from 8.1Mt in 2019. Then, imports fell by 18% year-on-year to 1.83Mt from January to August 2021 from 2.24Mt in the same period in 2020. Local production has more than compensated though, leading to growth in the total so far in 2021. There have been general economic reasons for why the ratio of imports to local production has fallen in 2020 and 2019 and this is explained in more detail below. Yet, imports hit a high of 5.68Mt in 2017 and have been declining since then both in real terms and proportionately.

Insee Cement summed up the local situation in its third quarter results by blaming cement shortages on input cost rises, supply chain disruption and negative exchange rates effects. The first two problems are issues everywhere around the world as economies speed up again following the coronavirus lockdowns but the last one is more specific to Sri Lanka. The country has faced a recession in its economy because the pandemic shut down tourism. The government initially introduced import limits to try and control foreign currency reserves. It then imposed price controls on essential foods and commodities, including cement, in September 2021 to try and stop shortages but this plan was abandoned a month later. Focusing on cement, some idea of the input cost inflation facing the sector can be seen in Tokyo Cement’s latest quarterly financial results. Its cost of sales rose by 72% year-on-year to US$59.5m in the six months to end of September 2021 from US$34.5m in the same period in 2020.

Lasantha Alagiyawanna, the State Minister of Consumer Protection, said at the end of October 2021 that it would take three weeks to import the required cement into the country. Whether this is enough to end the shortage remains to be seen. Yet, whatever does happen, it is likely that more production capacity from the likes of Lanwa Sanstha Cement and others will be welcome in 2022 and beyond.

Bangladesh: The Bangladesh Cement Manufacturers Association (BCMA) has re-elected Alamgir Kabir as its president. Kabir is the vice-chairman of MI Cement Factory, which operates the Crown Cement band, according to the Daily Star newspaper. Md Shahidullah, the managing director of Metorcem Cement and chairman of Metrocem Group, and Zahir Uddin Ahmed, managing director of Confidence Cement, have also been re-elected as the first and second vice-president of the association respectively. The elections were held at the 20th annual general meeting of the BCMA in late October 2021.

Africa/Asia: Holcim has agreed to sell Holcim Madagascar, Holcim Reunion, Lafarge Comoros, Lafarge Mauritius and Lafarge Mayotte to Cementis Océan Indien, a newly launched subsidiary of Mauritius-based Taylor Smith Investment. The Les Echos newspaper has reported that Cementis Océan Indien's acquisition of Lafarge Seychelles is on-going.

Cementis Océan Indien chair Colin Taylor said "The companies that have been bought are all financially solid.” He added "Cementis is positioned as the regional leader in the production and distribution of cement."

India: Sesa Mining Corporation has received approval to acquire a 100% stake in Desai Cement. Sesa Mining Corporation, a Vedanta subsidiary, says that the acquisition will enhance its cement portfolio and help it to develop additional synergies through vertical integration.

Iran: The Cement Industry Employers' Association has confirmed that cement plants will store heavy fuel oil to cope with a potential shortage of gas in the winter. The association told the Iranian Labour News Agency that plants had been granted permission to store up to 15 days worth of heavy fuel oil following negotiation with the Ministry of Oil. Fuel storage is a sensitive issue locally due to the potential for misuse in the black market. The cement sector faced gas and electricity shortages earlier in 2021.

Japan: Sumitomo Osaka Cement says it will raise the price of its cement from February 2022 due to rising coal and heavy fuel oil costs. It said that these mounting input prices were leading to ‘significant’ manufacturing and logistical overheads. The cement producer expects that these energy prices will remain high in the foreseeable future. It added that maintenance, labour and carbon neutrality goal costs were also growing.

Thailand: Siam Cement Group (SCG) says that a fire at its integrated Kaeng Khoi plant in Saraburi may affect exports on a temporary basis. The cement producer reported a fire at the site on 29 October 2021. The incident took place in part of a cable tunnel near to the control room at the plant. No injuries to staff were noted and the situation was stabilised quickly. The company said that the fire will not affect domestic cement sales as it has sufficient inventory.

US: The Environment Protection Agency (EPA) has awarded Cemex USA's Miami cement plant its 11th consecutive Energy Star or its on-going energy efficiency and sustainability efforts.

President Jaime Muguiro said "Sustainability and conservation are ingrained in our operations and our business, so we constantly seek opportunities to decrease our energy use and reduce environmental impacts." He added "Our team at our Miami cement plant is helping to set the standard for our industry, demonstrating what can be possible, and we are proud of their ongoing environmental performance and commitment."

US: LafargeHolcim US has revealed more information about a commercial-scale carbon-capture study based at its integrated Ste. Genevieve cement plant in Missouri. The project aims to deliver a front-end engineering design (FEED) study for a carbon capture retrofit that can separate up to 95% of CO₂ emissions at the plant. The captured CO₂ will be ‘pipeline ready’ for geological storage and analysis of the project socio-economic impact will also be part of the study. The US Department of Energy’s National Energy Technology Laboratory awarded US$4m to the Prairie Research Institute at the University of Illinois to work on the project in early October 2021. LafargeHolcim and Air Liquide are also making cost share contributions.

The design will use Air Liquide’s Crycocap FG system at the cement plant. LafargeHolcim US says that it combines pressure swing adsorption capabilities with cryogenic refrigeration technologies to achieve high CO₂ capture rates with high CO₂ purity rates. Notably, for a carbon capture project, the Ste. Genevieve plant has one of the largest single clinker kilns in the world.

US: Bruks Siwertell has received an order for two 5000 S type road-mobile ship unloaders for cement handling in North America. The first unit will be delivered to the US midwest in the summer of 2022 with commissioning scheduled for the winter of 2022. The second unit, for the southeast region, will be delivered in the summer of 2022 with commissioning by the spring of 2023. Both unloaders will have a rated cement handling capacity of 300t/hr for vessels up to 5000 dwt. Other features include technology for diagnostics and trouble-shooting. The customer for the order has not been disclosed.