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The power cuts in northern and eastern India this week will have presented citizens with a situation very familiar to Indian cement producers. With over half the country reported to be without electrical power after three power grids collapsed, industrial users are likely to have been shut down as the authorities try to bring back domestic supplies.

According to figures from the National Council for Cement and Building Materials, Indian cement producers used 79kWh/t of electrical energy in 2009 as production hit 181Mt. The Cement Manufacturers' Association placed these figures at 68-93kWh/t for a modern plant and 100-120kWh/t for older ones. In June 2012 the Central Electrical Authority reported the country's entire installed electrical capacity was 205GW.

It's difficult to estimate how much damage problems in power supply may have caused the Indian cement industry over the last few decades in either reduced volumes or increased running costs. The Cement Sustainability Initiative and European Cement Research Academy broke down the share of electrical power in a dry process plant as follows: 38% for cement grinding, 24% for raw material grinding, 22% for clinker production including grinding of solid fuels, 6% for raw material homogenisation, 5% for raw material extraction and blending and 5% for conveying, packing and loading. Generally speaking, interruption of power causes production losses and low capacity utilisation, idle running of equipment during stops and restarts of the plant, thermal losses during reheating, damage to refractory and other problems such as slowing down the train network.

Subsequently there has been a drive in India towards captive power generation and waste heat recovery (WHR) mechanisms, especially as input energy costs have risen. For example it has been reported that ACC's average cost of electricity per kWh from its captive plants is US$0.067 versus US$0.087 for grid power. Companies like Shree Cement have since gone into the electricity export market with their surpluses and, as shown by SP Ganeshan at the Global CemPower Conference in June 2012, interest in WHR is booming. Currently, the Indian cement industry has about 4000MW of installed captive generation capacity, including coal-based plants, diesel generating sets and wind turbines. Through various greenfield and brownfield expansion projects it is anticipated that another 2000MW of captive capacity will be added by 2016.

One sign of how well the Indian cement industry is coping with its energy requirements is the 74% rise in fourth quarter profit reported by Shree Cement in May 2012, in part due to savings made from captive power generation. Perhaps they could advise the Indian electricity board.

India: Birla Corporation has promoted BR Nahar to the managing director of the company. The decision was made at the board of directors meeting held on 28 July 2012. Nahar, a Fellow Member of the Institute of Chartered Accountants of India, holds more than 33 years professional experience. He became Birla's executive director and chief executive officer in 2006. He has served in diverse fields at senior positions in various large corporate houses.

Italy: Italcementi Group has released consolidated results for the six months to 30 June 2012, which show mixed results across its operations. Revenue and earnings were both down, as was the group's net profit, which was drastically down due to the absence of a major one-off receipt seen in the year-ago period. The company announced that it expected the second half of 2012 to be broadly in line with that of 2011.

The group's consolidated revenue for the first half of 2012 was Euro2.29bn compared to Euro2.42bn in the first half of 2011. Recurring earnings before interest, tax, depreciation and amortisation (EBITDA) came in at Euro328.7m compared to Euro371.7m in the first half of 2011. Italcementi's total profit for the period was Euro0.8m, compared to Euro187.8m in the first half of 2011. This apparent drop was due to the absence of a receipt from the sale of Turkish operations, which was conducted in the first half of 2011.

In the first half of 2012 consolidated cement and clinker sales totalled 23.5Mt, a drop of 7.5% compared to the first half of 2011. The reduction was largely due to the decline in central western Europe and, to a lesser degree, in Egypt. Sales in Asia continued to make good progress and sales volumes in North America and Bulgaria showed a strong recovery.

Italcementi said that its first half results confirm the upturn in North America and the recovery in prices in some markets, although demand was down in the Eurozone. Among emerging countries, it recorded positive market performances in India and Morocco, while the sales trend in Egypt remained negative, although better than expected. It added that its withdrawal from the Turkish market a and new strategic agreement in China had generated positive impact on its financial position.

Going forward, Italcementi said that the effects of efficiency measures, together with a positive dynamic in prices on a number of markets should enable it, in the absence of currently unforeseen events, to reach full-year operating margins broadly in line with those of 2011.

Germany: Price increases and cost cutting at HeidelbergCement have halted a slide in cement margins and put the German cement producer on track to reach its 2012 targets.

HeidelbergCement's operating income before depreciation (OIBD) for the quarter ending 30 June 2012 rose by 7% to Euro698m from Euro651m in the same quarter in 2011. Its revenue rose by 11% to Euro3.78bn from Euro3.39bn. The company's efforts to chip away at its cost base, easing energy costs and price increases pushed through in 2012 have all helped HeidelbergCement post a 0.2% improvement in cement margins following steady declines in 2011 and early in 2012.

"We will do everything in our power to continue this positive trend in the second half of 2012," said chief executive Bernd Scheifele in a statement.

Demand for cement has remained robust in North America and Asia, prompting HeidelbergCement to affirm its outlook for a third consecutive year of growth in sales and operating profit. HeidelbergCement has also benefited from a slide of the euro against the US Dollar in the second quarter, which helped boost group revenue growth by 5 percentage points to 11.4%. Net profit was up by 16% to Euro184m.

Cement sales volumes benefited from strong demand in North America and Asia but sales declined in Europe due to decline in infrastructure spending. In western and northern Europe cement and clinker sales volumes fell by 5.1% in the first half of 2012 to 10.2Mt from 10.8Mt in 2011. In eastern Europe and central Asia cement and clinker sales volumes increased by 3.0% to 7.8Mt from 7.6Mt. In North America cement sales grew by 16.7% to 5.4Mt from 4.7Mt. In Asia-Pacific cement and clinker sales grew by 9.5% to 14.8Mt from 13.6Mt.

HeidelbergCement predicts that cement volumes in North America will rise by 8-11% in 2012, compared with a previous forecast of 4-7%. Sales in western and northern Europe could decline by as much as 2%. The company has slashed its global outlook for volumes to 4-6% growth, down from 6-9%, as its assessment of eastern Europe and Africa deteriorated.

"The growth in sales volumes, due to the additional capacities and a more or less significant increase in demand in Russia and central Asia, is being somewhat muted by the latest decline in demand in Poland and the Czech Republic," said HeidelbergCement.

Egypt: FLSmidth has been awarded a contract by the Egyptian National Cement Company for operation and maintenance of two of their production lines located in Cairo, Egypt. The parties have agreed not to disclose the value of the contract which covers a period of seven years but the order will contribute beneficially to FLSmidth's earnings until 2019.

The contract which is the largest operation and maintenance contract awarded to FLSmidth to date includes supply of spare parts and consumables, development of a full operation and maintenance organisation, knowledge transfer to local employees and implementation of industry best practice.

FLSmidth is currently carrying out an upgrade of the two production lines, which were originally supplied by German KHD and have been in operation since the mid 1980s. When the upgrade is completed in early 2014 each line will rise in capacity to 5200t/day from 3800t/day at present.

"We are now for the first time also taking over the operation and maintenance of a plant, which was built by a competitor and consists of a competitor's equipment, and still FLSmidth is in a better position to meet production and quality targets and optimising the customer's earnings capacity," commented group CEO Jørgen Huno Rasmussen.

Nepal: Bishal Cement Industries (BCI) formally commenced operation on 28 July 2012. The factory based in Manahiya VDC-4 in the Rupandehi district, produces 300t/day of OPC and 400t/day of PPC brand cement.

"We are planning to use 70% and 30% of the total capacity to produce Pozzolanic Portland Cement (PPC) and Ordinary Portland Cement (OPC)," said Jayendra Chudal, executive director of the company.

Costing over US$5.6m the factory has an inbuilt dust controller and six dust bag collectors to control the emissions. The company has been sourcing raw materials such as gypsum from India, Pakistan and Bhutan but using locally produced clinker. Direct employment opportunities have been provided to 150 skilled and semi-skilled workers.

With the opening of Bishal the number of cement factories operating along the Bhairawa-Lumbini Industrial corridor has reached 11. Producers estimate that Nepal has been importing 30% of its cement from India to meet its total domestic demand for 25Mt.

South Africa: Lafarge is considering approaching the International Trade Administration Commission of South Africa to protect the local market from what it calls 'low-quality cheap cement' imported from Pakistan. The multinational is concerned that substandard products are being used for large infrastructure projects in the country, including the construction of hospitals, government housing and schools. Some importers are labelling cement as flour to dodge quality tests. Yet when the regulators do test imported product, they refuse to disclose the outcome, citing confidentiality.

"Imports are a concern for several reasons; sometimes the prices are very low, which affects us financially. We are looking at approaching the International Trade Administration Commission of SA to intervene in the market, but no decision has been made," said Lafarge South Africa CEO Thierry Legrand. He added that some cement sellers did not comply with the National Regulator for Compulsory Specifications, yet had import licences. Other domestic producers including AfriSam and Pretoria Portland Cement have also expressed concern at the situation.

In 2011 three companies importing from Lucky Cement, Pakistan's biggest cement exporter, were shut down. Cement and Concrete Institute (CCI) managing director Bryan Perrie said that 140,000t of cement were imported into South Africa in the first quarter of 2012 and that a substantial portion of it probably came from Lucky Cement. "People have struggled to keep accurate import statistics of cement but we know that Lucky is a major importer. People bring cement in as flour, so the statistics of how much comes in is often incorrect," he said.

Importers in South Africa are supposed to test samples for every 500t of imported cement. Yet when the CCI asked third-party regulators about the results of these checks, they were told this was confidential. The CCI had asked the regulator to publish a list of cement importers online, recording which products had letters of authority, but this has not happened.

India: After setting a precedent by fining 11 cement companies a combined US$1.13bn in June 2012, the Competition Commission of India (CCI) has now imposed a penalty of US$71.5m on Shree Cement for indulging in restrictive trade practices.

The CCI has imposed the penalty on Shree Cement while issuing final order in the case against cement manufacturers and their trade body, the Cement Manufacturers Association (CMA). "The commission has also imposed a penalty on Shree Cement at the rate of 0.5 times its profits for the years 2009-2010 and 2010-2011 aggregating to US$71.5m," said the CCI in a statement.

"We have not seen the CCI order. Let us first go through the order and then we will decide on the future course of action in consultation with our lawyers, " commented H M Bangur, the managing director of Shree Cement.

The CCI found 11 cement manufacturers, including Shree Cement Limited and CMA, in contravention of the provisions of the Competition Act, 2002 which deal with anti-competitive agreements including cartels. As the cement companies (except Shree Cement) were already found to be in cartel in Case No. 29 of 2010 and penalised by the CCI via its order dated on 20 June 2012, the CCI decided not to order remedies including imposition of penalty on such companies again for the same period of contravention.

It has been reported by local media that since the fine in June 2011 Indian cement prices have continued to rise, with Rayalaseema Rashtra Samiti president Kuncham Venkatasubba Reddy threatening an indefinite hunger-strike over high prices.

India: Birla Corporation has earned a profit after tax of US$15.3m in the first quarter of the current financial year (ending 30 June 2012) against US$20.2m in the same quarter of the previous year. This represents a more than 24% drop year-on-year. Birla's net sales from operations for the quarter were US$118.5m. 

Commenting on the results, Harsh V Lodha, chairman of the company, said that the profitability of the company continued to be affected due to the closure of limestone mining operations at its Chanderia units on account of an order from the high court of Jodhpur. It was also observed that higher coal and freight prices had caused reduced margins.

France: Lafarge has reported that its net profit fell in the first half of 2012 due to troubles in its European markets, mainly in central and eastern Europe, where the construction industry slumped Lafarge recorded an impairment of Euro200m on its Greek assets alone. The French cement group's net income fell from Euro260m in the first half of 2011 to Euro13m in 2012, a drop of 95%.

Sales rose by 5% to Euro7.61bn and earnings before interest, taxes, depreciation and amortisation (EBITDA) rose by 8% to Euro1.52bn, boosted by increases in emerging markets. In addition to the impairment on Greek assets, Lafarge also recorded a Euro148m charge related to the company restructuring in the first half of 2012.

"Economic conditions remain challenging in many parts of the world and we remain prudent on our outlook," said Lafarge's chief executive Bruno Lafont. "Even in a lower growth volume environment, our actions to generate sales growth and cash, and to improve returns, led to a third consecutive quarter of positive trends." He confirmed that he expects the cement industry to grow between 1% and 4% in 2012, mainly driven by emerging markets. Lafarge expects higher pricing for the year and cost increases to be slower than in 2011.

By region on a like-for-like basis, cement volumes increased in North America by 14% to 5.7Mt and sales increased by 16% to Euro1.4bn. In Western Europe volumes decreased by 11% to 8.3Mt and sales decreased by 10% to Euro1.62bn. Here sales decreased by 6% to 7% in France and the UK, where it was blamed on adverse weather and a slowdown in advance of the London 2012 Olympic Games, and by 28% to 30% in Spain and Greece.

In Central and Eastern Europe volumes decreased by 7% to 5.9Mt, yet sales remained stable increasing by 1% to Euro561m. In both Russia and Poland higher pricing counteracted a drop in volume. In Middle East and Africa volumes decreased by 2% to 23.4Mt and sales increased by 4% to Euro2.2bn. Notably, Nigeria saw a 49% increase in sales due to a new line started in 2011 and Egypt saw volumes fall by 11% due to limited gas supply. In Latin America volumes increased by 5% to 4.5Mt and sales increased by 12% to Euro474m. In Asia volumes increased by 5% to 21.9Mt and sales increased by 11% to Euro1.36bn. Notably, activity slowed in India yet sales still rose by 25%. In China sales were impacted by slower construction growth, with volumes remaining stable but prices decreased.

Lafarge said that its debt stood at Euro12.55bn at the end of June 2012, down from Euro14.26bn a year earlier. The company's debts peaked at Euro17bn in 2008 and they stem from a series of acquisitions culminating in the Euro8.8bn takeover of Egyptian rival Orascom Cement. Lafarge plans to raise as much as Euro1bn in asset sales in 2012, though it hasn't said which units it may sell.

Lafarge made Euro72m from divestments in the first half of 2012. The company has also cut investment and reduced the number of executives. In June 2012, the company announced it would cut its costs by Euro1.3bn by 2015.