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Cementos Molins has been celebrating the first anniversary this week of its alternative raw materials unit at its Sant Vicenç dels Horts plant near Barcelona. It has processed 75,000t of waste since September 2022 when the site started up. More is yet to come as the unit has a production capacity of up to 200,000t/yr. The facility receives waste in coarse, granular, powder and sludge formats. Waste from concrete plants is crushed and screened to produce recycled aggregate. Industrial and construction waste is dosed and homogenised to produce alternative raw materials for cement production.

Global Cement Weekly has covered construction and demolition waste (CDW) a couple of times already so far in 2023. A number of cement producers are investing in the sector - including Holcim, Heidelberg Materials, CRH, Cemex – by developing technology, buying up other companies, setting up internal CDW divisions and so on. Holcim and Heidelberg Materials have been the more obviously active participants over the past six months based on media coverage. In September 2023 Holcim France commissioned the Saint-Laurent-de-Mûre alternative raw materials plant and Holcim Group invested in Neustark, a company promoting technology to sequester CO₂ in CDW. In August 2023 Lafarge Canada also completed the first stage of a pilot project to use CDW in cement production at its St. Constant plant in Quebec. Heidelberg Materials meanwhile announced in October 2023 that a forthcoming upgrade to its Górażdże cement plant in Poland would include a new CDW recycling unit and in September 2023 it launched a CDW division for its subsidiary Hanson UK.

Previously we have described how the European Union (EU) has set recovery targets for CDW. However, McKinsey & Company published research in March 2023 setting out the economic case for cement and concrete companies looking at CDW. It estimated that “an increased adoption of circular technologies could be linked to the emergence of new financial net-value pools worth up to roughly Euro110bn by 2050.” It is not a certainty and there is risk involved, but adopting circular practices is one way to reduce this risk. It then went on to predict that recirculating materials and minerals could generate nearly Euro80bn/yr in earnings before interest, taxation, depreciation and amortisation (EBITDA) for the cement and concrete sectors by 2050. The biggest portion of this could come from using CDW in various ways such as a clinker replacement or as an aggregate in concrete production, or the use of unhydrated cement ‘fines.’ Capturing and using CO₂ and increasing alternative fuels (AF) substitution rates would have a financial impact but not to the same scale.

Graph 1: CO₂ abatement cost via circular technologies for cement and concrete sectors. Source: McKinsey & Company.

Graph 1 above puts all of the McKinsey circular technology suggestions in one place with the prediction that all of these methods could reduce CO₂ emissions from cement and concrete production by 80% in 2050 based on an estimated demand of 4Bnt/yr. The first main point they made was that technologies using CO₂, such as curing ready-mix or precast concrete, can create positive economic value at carbon prices of approximately Euro80/t of CO₂. Readers should note that the EU emissions Trading Scheme CO₂ price has generally been above Euro80t/yr since the start of 2022. The second point to note is that using CDW could potentially save money by offering CO₂ abatement at a negative cost through avoiding landfill gate fees and reducing the amount of raw materials required. This is dependent though on government regulation on CO₂ prices, landfill costs and so on.

Cement producers have been clearly aware of the potential of CDW for a while now, based on the actions described above and elsewhere, and they are jockeying for advantage. These companies are familiar with the economic rationale for AF and secondary cementitious materials (SCM) in different countries and locations. CDW usage is similar but with, in McKinsey’s view, existing CO₂ prices, landfill costs, and regulatory frameworks all playing a part in the calculations. Graph 1 is a prediction but it is also another way of showing the path of least resistance to decarbonisation. It is cheaper to start with AF, SCMs and CDW rather than barrelling straight into carbon capture. The beauty here is that cement and concrete sold, say, 50 years ago is now heading back to the producers in the form of CDW and it still has value.

Denmark: FLSmidth has appointed Christopher Ashworth as the president of its Cement division. He succeeds Asger Lauritsen, who left the post in August 2023. Group chief financial officer Roland M Andersen has acted as the interim president of FLSmidth Cement in the intervening period. Ashworth was previously the vice president and managing director of Eurotherm, a subsidiary of Schneider Electric. Prior to this he worked for Invensys and Wonderware.

India: Sagar Cement has appointed J Raja Reddy as its company secretary and compliance officer with effect from 11 November 2023. He succeeds R Soundararajan in the post, following his retirement for health reasons. Reddy has worked for Sagar Cement since 2013 and is currently working as the company’s assistant company secretary.

China: China Shanshui Cement recorded sales of US$1.92bn during the first nine months of 2023, down by 15% year-on-year from US$2.25bn during the first nine months of 2022. Reuters has reported that the company made a US$25.7m loss during the period, compared to a profit of US$139m in the corresponding period of 2022.

Mexico: GCC recorded US$1.02bn in sales during the first nine months of 2023, up by 16% year-on-year from US$880m in the first nine months of 2022. The producer’s cement volumes rose by 5.5% in Mexico, but fell by 8.1% in the US. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 31% to US$354m from US$271m.

GCC chief executive officer Enrique Escalante said “The ability of our teams to face market conditions allowed us to further strengthen our margins Throughout the third quarter of 2023, we continued to invest in the business and focus on commercial performance to offset cost inflation and increase margins, as well as strengthening our market position to build a stronger future for GCC.”

Indonesia: Semen Indonesia subsidiary Semen Baturaja reported sales revenue of US$91.3m during the first nine months of 2023, up by 10% year-on-year. Cement sales contributed US$89.5m towards the total (98%). The producer raised its net profit by 25% year-on-year to US$3.4m. It also distributed US$169,000 as part of its Social & Environmental Responsibility Programme Fund, up by 61%.

General director Daconi Khotob said “The increasing net profit was also supported by a decrease in interest expenses as a result of refinancing bank debt and accelerating principal payments on syndicated credit loans.”

Belgium: The municipal council of Evergem has advised planning authorities to reject Cemminerals’ application to expand it Ghent grinding plant to 1.6Mt/yr in production capacity. The Het Nieuwsblad newspaper has reported that the expansion will entail the construction of a new grinding unit and six storage silos. Cemminerals currently holds a licence to produce 700,000t/yr at the site.

Councillor Josse Verdegem said that 400 residents signed a petition against the planned expansion of the Ghent grinding plant. He said that dust from the plant ‘regularly’ covered solar panels, cars and garden furniture. Residents have also complained about its noise and vibrations.

UAE: The director of the World Cement Association (WCA), Ali Emir Adiguzel, told listeners at the association’s 6th Annual Conference in Dubai that the world has ‘enough cement for the next 25 years.’ Adiguzel addressed the issue of overcapacity by noting a ‘substantial’ drop in demand and pointing out that high input costs had led the sector to raise its prices, by as much as 15% in Europe. He also said that the primary challenge facing the cement industry was “meeting stringent emission targets and embracing carbon capture technologies.”

Adiguzel added "Despite our achievements, there is more work to be done in the years to come. To reach our net zero goal by 2050, we must significantly reduce carbon emissions. The technologies and mechanisms for this endeavour appear available, though currently minuscule and not economically fully feasible. Regulatory frameworks must evolve to minimise costs for end customers. Collaboration between the private and public sectors is imperative to facilitate carbon reduction."

Ghana: Wan Heng Ghana has issued a statement clarifying its position after the Ghana Revenue Authority (GRA) found that it had failed to pay US$60.6m in taxes. The company markets cement from its Tema grinding plant as Sol Cement.

The producer said “We acknowledge that we are indebted to the GRA for unpaid taxes. We are fully committed to resolving this matter in a responsible and timely manner. We want to reassure our valued customers, stakeholders and the public that we are taking immediate and proactive steps to address this issue. We are in discussions with relevant tax authorities to develop a structured repayment plan that aligns with our financial capabilities and ensures that our tax obligations are met.”

It continued “Sol Cement remains dedicated to its mission of contributing to the growth and development of Ghana. We understand that paying our taxes is an essential part of fulfilling this commitment. We apologise for any concerns or inconveniences this situation may have caused, and we promise to keep all our stakeholders informed throughout this process. We appreciate the trust and support that our customers and partners have placed in us over the years, and we are determined to rectify this situation while continuing to provide top-quality cement products and services. We thank you for your understanding and patience during this challenging period. Sol Cement remains committed to being a responsible corporate citizen and a reliable contributor to the Ghanaian economy.

Latin America: Denmark-based FLSmidth says it has been awarded a new service contract with an unnamed cement producer in Latin America. The new contract builds on an existing relationship between the two companies and will last a period of 18 months. It will cover the complete production process, from quarry to packing plant. FLSmidth says that will support the customer in improving overall equipment efficiency and thus plant productivity. The scope of supply also includes training and mentoring of plant personnel to ensure successful execution of a jointly developed strategy long after the initial period of the contract ends. No value for the deal has been disclosed.

Jose Gil, Head of Service Execution - USA and Canada, FLSmidth, said “This contract is the result of conversations inspired by a reliability audit in the third quarter of 2022. From that, an action plan was developed in which FLSmidth has responsibility for the execution of activities in operations and the customer takes care of other support areas.” He added “The result is a tailored solution, encompassing a range of factors, including maintenance, reliability and operations, that will ultimately deliver much more efficient and productive cement plants.”