Displaying items by tag: GCW679

Bangladesh: Confidence Cement is building a new 1.8Mt/yr cement grinding plant at Narsingdi. The project has an investment of US$68m, according to the Daily Star newspaper. Germany-based Loesche is reportedly supplying equipment for the unit, which is scheduled to start operation in early 2025. Around two-thirds of the project cost is being supplied by loans with the rest coming from company equity.

Confidence Cement currently operates a 1.2Mt/yr grinding plant near Chattogram.

Energy has been the theme for a couple of cement news stories of note from Egypt this week. The first concerns the government’s impending plan to centralise distribution of mazut (heavy fuel oil) to cement plants to help them cope with ongoing power shortages. Earlier in the week Cemex signed a deal with the Assiut Governorate to operate a second municipal solid refuse processing unit in the country. The company’s first Regenera facility, in Mahala, started operations in May 2024. Another story from mid-September 2024, along the same theme, covered the inauguration of an 18MW waste heat recovery (WHR) unit at Heidelberg Materials Egypt's Helwan Cement plant.

The wider story is that the country has faced so-called load shedding, or power rationing, since mid-2023 due to falling gas production, rising energy demand and negative currency exchange effects making it harder to buy fuel imports. The power cuts were extended in duration in July 2024 due to a heat wave. The government then said in late September 2024 that it is making investments to prevent domestic power cuts in 2025.

The cement stories mentioned above show some of the ways cement companies cut their energy costs. Two potential ways of doing this are to increase the use of alternative fuels (AF), such as municipal solid waste, or to install a WHR unit. Titan Cement, for example, reported AF thermal substitution rates of above 40% in Alexandria and above 30% in Beni Suef in the first half of 2024. The local press hasn’t reported power shortages amongst the country’s cement producers, but the plans to control the distribution of mazut suggest that either ‘something’ has happened or the government is trying to avoid ‘something.’ Readers may recall that producers have periodically faced step changes in power supplies over the years. In the mid-2010s, for example, lots of plants switched from heavy fuel oil and gas to coal. The energy price fluctuations following the start of the Russia - Ukraine war in 2022 then saw the price of coal rise.

However, what the foreign-owned producers have complained about in the first half of 2024 is the declining exchange rate of the Egyptian Pound. Cementir, Cemex and Titan Cement all noted this. However, Titan reckoned that International Monetary Fund and European Union investment had actually eased the economic situation in the first half of the year leading to an increase in the number of large construction projects.

One effect of the currency problems upon the cement market has been a focus on exports. At the start of September 2024 the Federation of Egyptian Industries said that national cement consumption in 2024 was expected to drop by 4% year-on-year to 45Mt. However, exports were projected to rise to 15Mt. The first and second most popular destinations so far in 2024 have been the Ivory Coast and Ghana. Yet, exports to Libya, the third biggest external market, may have had the biggest effect. These have been blamed for creating a shortage of trucks that was causing delays to the local construction sector. The round-journey from Egypt to Libya can take up to 12 days. This has left building sites bereft of raw material deliveries because all the trucks are elsewhere! Vicat acknowledged the growing importance of imports for its business in Egypt in its half-year report for 2024. It said that ‘sluggish’ domestic market conditions “were more than offset by growth in cement and clinker volumes for export to the Mediterranean and Africa regions.”

The wider picture of the cement sector in Egypt remains one of overcapacity with integrated capacity estimated above 70Mt/yr. The government introduced cement production quotas in mid-2021 and this stabilised prices (and profits). The recent state of the local economy may have strained this, but the latest round of external investment appears to have buoyed things for now. Although the effects of the Israeli military action in Lebanon may have unforeseen consequences upon neighbouring markets. In the meantime, cutting energy costs and growing exports offer two ways for producers to raise their profits.

Türkiye: Çimsa Çimento has appointed Ozan Keskin as its Vice President of Operations. He will succeed Memet Metin Çalışkan in the role from the start of November 2024.

Keskin has worked in the cement industry for over 20 years. He started as a maintenance engineer at OYAK Adana Çimento in 2003. He later worked for Aslan Çimento, eventually becoming Technical Services Manager in 2015 and Investments & Project Manager in 2017. He then jointed Çimsa Çimento in 2018 as Project Manager. He subsequently became a Plant Manager and Investments and Maintenance Director. He is a graduate in mechanical engineering from the Middle East Technical University in Ankara.

Germany: Norway-based Capsol Technologies has won a feasibility study from a German cement producer to assess the implementation of its CapsolEoP (End-of-Pipe) technology at a cement plant. The technology aims to capture 400,000t/yr of CO₂.

CEO Wendy Lam said "Capsol continues to build a position as a preferred carbon capture technology provider for the cement industry."

India: JSW Cement has commissioned another 2Mt/yr of grinding capacity at its Vijayanagar plant in Karnataka, increasing the plant's total capacity to 6Mt/yr. The expansion, which cost US$55m, increases the company's overall capacity to over 20Mt/yr.  JSW Cement was set to raise US$476m through an initial public offering (IPO), but the Securities and Exchange Board of India has placed the IPO plans ‘in abeyance’ as of September 2024, according to the Economic Times. Funds from the IPO were earmarked for debt repayment and financing a new unit in Nagaur, Rajasthan.

Chief executive officer Nilesh Narwekar said "This new capacity at Vijayanagar is a significant step towards increasing our overall capacity to 40.8Mt/yr while maintaining our commitment to sustainability."

Saudi Arabia: Turboden, a subsidiary of Mitsubishi Heavy Industries, has announced its first project in Saudi Arabia — a 13MW organic rankine cycle (ORC) power plant at Riyadh Cement Company. This marks the first ORC plant in the Kingdom and the largest globally.

The plant will capture residual heat from the cement plant's clinker coolers and pre-heaters (2 kilns of 5000t/day each), offering high energy efficiency and eliminating water consumption. Sinoma Energy Conservation serves as the project's engineering, procurement and construction contractor.

General manager Andrea La Gioia said "Turboden is honoured to spearhead this groundbreaking project in collaboration with Riyadh Cement Company. With around 460 ORC plants in 52 countries, 50 in ‘waste’ heat recovery application, our ORC technology represents a game-changer in the global energy landscape, and we are proud to support the Kingdom of Saudi Arabia in its transition towards cleaner, more sustainable energy sources."

India: UltraTech Cement will procure an additional 7MW of wind-solar hybrid power production capacity from Continuum MP Windfarm, increasing total procurement from 14MW to 21MW. This power is supplied from its 100MW project in Ratlam District in Madhya Pradesh. To facilitate this, UltraTech has raised its shareholding in Continuum MP Windfarm from 3.28% to 5.46% by investing approximately US$2.9m. The acquisition is expected to complete within 120 days following amendments to the power purchase Agreement, share purchase agreement, and shareholders agreement.

Ghana: The Minister of Trade and Industry, Kobina Hammond, has directed cement manufacturers to secure licences or cease operations immediately, in compliance with the new Ghana Standards Authority's (GSA) Manufacture of Cement Regulation, 2023 (LI 2480). This regulation mandates re-registration and licensing of existing operations and bars unlicensed new plants. It came into law in 2024 and seeks to address consumer concerns over rising cement prices and promote quality assurance.

Director-General of the GSA, Alex Dodoo, stated that all current manufacturers are operating illegally without a licence. Dodoo said that none of the cement producers in the country had applied for a licence to operate in accordance with the law.

Czech Republic: Holcim Česko, owner of the Čížkovice cement plant, will construct a new calcined clay processing line with an investment of US$44m, marking the largest investment in its history. The project, beginning in January 2025 and aiming for completion by the end of 2026, aims to reduce energy use and end reliance on fossil fuels. The Czech Ministry of the Environment has contributed US$14.5m towards the construction.

Holcim Česko CEO Miroslav Kratochvil said "The new calcined clay processing line represents a revolutionary step in the cement industry. Calcined clays will become a key material in our company's new cement products and will have a significantly lower carbon footprint. This innovation will enable the company to make a significant contribution to environmental protection and emission reduction."

Austria: Holcim is set to significantly reduce its carbon footprint with the installation of a new clinker cooler system and a large-scale photovoltaic system at its Mannersdorf cement plant. The clinker cooler project is valued at approximately €10m, and aims to cut heat consumption and reduce CO₂ emissions by 18,000t/yr. Completion is expected in early 2025. The solar project will be fully operational by 2025, and will cover approximately 15% of the plant’s energy needs and reduce CO₂ emissions by an additional 12,700t/yr. 2.7MW of solar panels were erected at the site of the former chimney on the plant’s premises.

Plant manager Helmut Reiterer said "Sustainability requires decarbonisation, i.e. continuously reducing the CO₂ emissions from our production activities. We are placing an investment focus on energy-efficient production by modernising our machinery, but also on expanding green energy."