Displaying items by tag: Ghana

Ghana: FLSmidth has secured a contract for the supply of a clay calcination plant at CBI Ghana's 0.6Mt/yr Tema grinding plant in Accra. The supplier says that it will also install a complete grinding station to more than double the plant's production capacity. FLSmidth says that the entire project will reduce the Tema facility's CO₂ footprint by 20%. When commissioned, the new clay calcination plant will be the largest in the world, according to the supplier.

CBI Ghana chief executive officer Frédéric Albrecht said “Ghana is the perfect location for using clay as an environmentally friendly alternative to clinker. West Africa is traditionally a clinker and cement-importing region due to the lack of suitable limestone reserves. Developing countries with their young populations and a growing need for infrastructure and housing represent the future in cement consumption. Calcined clay cements are the most sustainable alternative to traditional clinker-based cement."

Türkçimento’s Volkan Bozay took to the airwaves last week to raise the issues that the war in Ukraine is causing for Turkey-based cement producers. The head of the Turkish Cement Manufacturers’ Association explained, to the local Bloomberg HT channel, that the dramatic jump in the price of Newcastle Coal posed a serious threat to the sector. The price jumped nearly US$100/t in a single day in early March 2022. Bozay said that the cost of cement from a plant using imported coal would consequently rise by around US$15/t. He added that the association’s members had an average of 15 – 20 days of coal stocks.

Graph 1: Price of coal, March 2020 – March 2021. Source: Trading Economics.

In a separate press release Türkçimento revealed that Turkey, as a whole, imported approximately US$1.5bn of coal from Russia in 2021. The cement industry imported about 5Mt of coal in 2021, from all sources, although the majority of this came from Russia. Coal shipments from Russia since the start of the war were reported as ‘very limited or even not possible.’ It was further explained that each US$10/t increase in the price of coal put up plant production costs by US$1.5/t of cement.

Naturally Bozay’s appearance on a television news show carried a lobbying aspect. He called for government import standards – such as the sulphur ratio, lower heating values and volatile matter limits - to be relaxed to allow coal to be imported more freely from sources such as Colombia, Indonesia and South Africa. There was also a push to let in more alternative fuels such as tyres and waste-derived fuels. The bit that Bozay didn’t mention though was how many of his members had long term coal supply contracts in place to cushion them, from short term price inflation at least. Yet, if coal shipments from Russia have simply stopped, then the price is irrelevant. A cement kiln configured to run on coal stops when it uses up its stocks.

Turkey was the world’s fifth largest cement producer in 2021 according to the United States Geological Survey (USGS). Türkçimento data shows that in 2020 it exported 145,000t of cement to Russia by sea. Overall it exported 16.3Mt of cement and 13.5Mt of clinker. The US, Israel, Syria, Haiti and Libya were the top destinations for cement. Notably, Ukraine was the sixth largest recipients of cement, with 752,000t imported, although anti-dumping legislation introduced in mid-2021 looked set to reduce it until the war started. Ghana, Ivory Coast, Guinea, Cameroon and Belgium were the principal recipients of clinker. Cumulative cement exports for the year to October 2021 were up by 3% year-on-year compared to the first 10 months of 2020. Clinker exports were down by 27% though. Overall domestic production and sales in Turkey rose by 9.5%, suggested an estimated production figure of 79Mt for 2021.

Other fallout in the cement sector from the war in Ukraine this week included Ireland-based CRH’s decision to quit the Russian market. It entered the region in 1998 through a subsidiary based in Finland and was operating seven ready-mixed concrete plants via its LujaBetomix joint venture. CRH says that all operations in Russia have now stopped. In 2021 it sold its lime business in Russia, Fels Izvest, to Russia-based Bonolit. Although selling concrete plants is not trivial, these are far cheaper assets than clinker production lines. Germany-based HeidelbergCement, Italy-based Buzzi Unicem and Switzerland-based Holcim each operate at least one integrated cement plant in Russia. So far these companies have publicly expressed dismay at the humanitarian crisis unfolding in Ukraine and made donations to the Red Cross.

Graph 2: European Union Emission Trading Scheme price, 2020 – March 2022. Source: Sandbag.

Finally, one more surprise this week has been a crash in the European Union (EU) Emission Trading Scheme (ETS) carbon price from a high of Euro96/t in early February 2022 to Euro58/t on 7 March 2022. As other commentators have stated, normally the carbon price would be expected to follow the energy market, but this hasn’t happened. Instead investors have pulled out, possibly to maintain liquidity for other markets.

With the US set to ban Russian oil, gas and coal imports and phase-outs to varying degrees promised by the UK and the EU in 2022, we can expect more turbulence from energy markets in the coming days. As the Turkish example above shows, all of this can... and will... have effects on cement production.

Ghana: The Chamber of Cement Manufacturers (COCMAG) has lobbied against the government’s decision to reduce the benchmark value to 30% from 50%. It says that a reduction in discounts on selected imports will result in higher production costs that could be passed on to the price of cement, according to the Business and Financial Times newspaper. Local limestone producers are also reported to be trying to increase their prices by over 60%, which could also put up prices. COCMAG has cited growing clinker, transport and fuel input costs as a potential source of higher production costs as well as negative currency exchange effects. COCMAG wants the government to maintain the benchmark value at 50% for input materials for cement production

The benchmark system was introduced in 2019 as a way of discounting the price of certain imports. Under the policy, certain commodities were benchmarked to world prices as a risk management tool.

Nigeria: Dangote Cement’s revenue grew by 33.8% year-on-year to US$3.33bn in 2021 from US$2.49bn in 2020. Its sales volumes rose by 13.8% to 29.3Mt from 25.7Mt driven by a strong domestic market, although international volume growth was strong. Earnings before interest, taxation, depreciation and amortisation (EBITDA) increased by 43.2% to US$1.65bn from US$1.15bn.

“Over the last two years, we have finalised the deployment of 6Mt new capacity in Nigeria. Looking ahead, we are now focused on a less capital-intensive expansion cycle, which includes building grinding plants across West and Central Africa to leverage and strengthen Dangote Cement’s regional integration. We are on track to deploy grinding capacity in Cote d’Ivoire and Ghana. In addition, our Alternative Fuel Project is at an advanced stage which aims to leverage waste management solutions, reduce CO₂ emissions, and source material locally. This year, we co-processed 89,000t of waste representing a 60% increase over 2020,” said chief executive officer Michel Puchercos.

The group noted that Cement demand in Nigeria was sustained by increasing housing infrastructure, commercial construction, and government projects including major highways, roads, and railways. In May 2021 it re-started exporting clinker from its Onne and Apapa terminals and delivered seven clinker shipments with a total volume of 197,000t in 2021. It also exported 706,000t in 2021 by road to Togo and Niger. Internationally, the group said that it performed well but it also faced challenges in Cameroon, Ghana and Sierra Leone, where freight costs had increased substantially, causing volatility in the landing cost of cement and clinker.

Ghana: Professor Karen Scrivener has paid a working visit to the Ghana Standards Authority (GSA). The visit was part of a tour by Scrivener to Ghana to discuss innovations in cement and cementitious products and to introduce Limestone Calcined Clay Cement (LC3) to the authority, according to the Ghana News Agency. The Head of Laboratory of Construction Materials at the Ecole Polytechnique Fédérale de Lausanne (EPFL) in Switzerland met with GSA management and staff of the Building and Civil Engineering Lab at the Authority's Head Office in Accra. Scrivener noted that she was interested in learning more and engaging with the GSA on standards and its testing capabilities as well as a potential collaboration in capacity building in cement and cementitious products.

Ghana: Daniel Asenso-Gyembibi, the director of the Building and Road Research Institute of the Council for Scientific and Industrial Research (CSIR-BRRI), has told parliamentarians that the institute’s Pozzolana cement plant needs US$4m to reopen. The unit at Gomoa Mprumem in the Central Region was forced to close due to a lack of private investment, according to the Ghanaian Times newspaper. Asenso-Gyembibi said that CSIR-BRRI had spent around US$250,000m on the project.

Commercial production started at the plant in 2011 with a capacity of around 5000bags/day. However, the unit stopped operation later in the same year due to poor sales and a lack of investment.

Ghana: The High Court of Ghana has ordered the Empire Cement Ghana to stop all activity related to building a new cement plant in the southern part of the McCarthy Hills. It has forced this until a hearing takes place for an injunction application by the McCarthy Hill Residents Association, according to the Ghana News Agency. The site was previously raided by Environmental Protection Agency (EPA) agents and the police in late June 2021 after a tipoff by local residents. The association alleges that the Chinese-run plant project has been misusing a temporary permit from the EPA to manufacture cement as a mandate to instead start installing equipment at the site.

Ghana: The district government of Shai-Osudoku in Accra has stopped the construction of an ‘illegal’ cement plant. The Daily Guide newspaper has reported that a China-based producer had been building the plant without a permit.

Ghana: George Dawson-Amoah, the executive secretary of the Chamber of Cement Manufacturers Ghana, has warned that mounting clinker costs are negatively affecting the cement industry. He said that the cost of clinker grew by 55% in the first half of 2021 and it is expected to nearly double, according to GhanaWeb. Cement prices have risen subsequently. Dawson-Amoah added that congestion at local ports is also adding to clinker import costs as importers potentially face demurrage fines.

Ghana: Ghacem plans to spend US$100m on building a new cement plant at Kumasi in the Ashanti Region. The new 1.5Mt/yr unit at Kumasi is intended to serve central and northern regions of the country, according to the Daily Graphic newspaper. The plant will use calcined clay as an additive. Construction is expected to take 18 months with commissioning planned for the first quarter of 2023.

The subsidiary of Germany-based HeidelbergCement is also planning upgrades to its grinding plants at Tema and Takoradi. The work at the Tema will include the addition of a new grinding and packing plant and an upgrade of existing equipment. It is expected to be completed by the end of 2021. Work at Takoradi will then follow afterwards.