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Vicat’s plans to buy another 42% stake in Sinai Cement became public this week. Once completed, the France-based company should own 98% of the Egyptian company, based on previously published ownership figures. The announcement heralds a rapprochement in the relationship between the cement producer and the Egyptian government.

Last year Vicat raised a case against the government with the International Centre for Settlement of Investment Disputes (ICSID) over an argument about how it could invest in Sinai Cement as a foreign company. All seems forgiven and forgotten now with a settlement agreement signed in March 2022 between Rania el Mashat, the Minister of International Cooperation on behalf of the Egyptian government, and Guy Sidos, the chairman and chief executive officer of Vicat Group. Local press reported that the government is trying to attract more direct foreign investment. Sinai Cement reported a loss attributable to its parent company of around US$19.1m in 2021, down from a loss of US$30.3m in 2020. However, its sales rose by 63% year-on-year to US$78m.

Sinai Cement has some specific operating issues related to its geographic position in the Sinai Peninsula and ongoing security concerns. Yet its mixed fortunes also sum up some of the continuing challenges the Egyptian cement industry is facing. After years of overcapacity, the government introduced reduced cement production quotas in July 2021 and this is mostly perceived to have improved prices in the second half of the year. Vicat described the arrangement as having capped the local market at 65% of its production capacity and it said that prices recovered ‘significantly’ as a result in the second half of 2021. Cemex’s regional chief Carlos Gonzalez told local press that the move had given plants “A glimmer of hope for the return of balance to the cement market.” The company has also announced a US$20m local investment backing up this view. Not all the foreign multinational companies entirely agreed, with HeidelbergCement reporting a ‘sharp’ decline in sales volumes although chief executive officer Dominik von Achten did describe the country as ‘coming back’ in an earnings call about his company’s financial results in 2021. Solomon Baumgartner Aviles, the chief executive officer of Lafarge Egypt, was also cooler about the production cap in a press interview in October 2021, describing it as too early to assess how well the cap was working and noting that the gap between supply and demand was still large.

Vicat said in its annual report for 2021 that, “Provided no further adverse geopolitical, health or security developments occur, the current climate is unlikely to jeopardise the prospects of an improvement in the subsidiary’s profitability, which should begin to gradually occur.” The geopolitical bit was timely given that Russia’s war in Ukraine started on 24 February 2022. It also targets the latest problem hitting Egyptian cement producers: energy costs. The head of Arabian Cement told Enterprise Press that initially some producers had opted to temporarily stop production and use stocks instead to attempt to try and wait until the energy price volatility ended. However, it stayed high so the cost of cement has gone up generally. Producers are now trying to switch to using a high ratio of natural gas, such as 10%, but this is dependent on the government letting them.

The Egyptian government, for its part, is facing a decision whether to supply subsidised gas for domestic industry or to export to Europe. The backstory here is that Egyptian cement producers are facing yet another step change in fuel supply. In the mid-2010s lots of plants switched from heavy fuel oil and gas to coal. High international coal prices could be heralding another change.

Alongside this the value of Egypt’s cement exports rose by 151% year-on-year to US$456m in 2021 from US$182m in 2020. The Cement Division of the Federation of Egyptian Industries has attributed this to growth mainly on the African market. This trend continued in January and February 2022 with cement exports up by 141% year-on-year to US$104m from US$43m. The main destinations were Ghana, Cameroon, Ivory Coast and Libya.

HeidelbergCement summed up the current state of the Egyptian cement market in its 2021 annual report as follows “The development of the Egyptian cement market continues to be determined by government intervention.” What happens next is very much in the hands of the state as it decides whether to extend the production cap, which fuels to subsidise, whether to allow exports and where to invest in infrastructure projects. One variation on this theme may be local decarbonisation targets. At the end of March 2022 the Global Cement and Concrete Association (GCCA) launched a series of Net Zero Accelerator initiatives, including one in Egypt. How a country that produces more cement than it needs reduces its CO₂ emissions presents another challenge for manufacturers and the government to grapple with.

Russia: Akkermann Cement, a subsidiary of USM Holding, has acquired Kaluzhsky Tsementny Zavod (Kaluga Cement Plant) for US$111m from state development corporation VEB.RF. VEB.RF provided a loan for construction of the plant in 2011 but the borrower was acknowledged bankrupt in 2018, according to Prime News. The plant is not yet fully built, but it is anticipated that the 3.5Mt/yr facility will create 400 jobs when commissioned.

“The asset is good,” said Akkermann Cement’s managing director Alexander Ivanov. “The dry process is one of the most efficient and budget-friendly technologies for production of cement, but the conclusion of the plant’s construction will need additional investment.”

India: UltraTech Cement says it has been declared as the preferred bidder for a limestone block in an electronic auction conducted by the Karnataka government. The block is situated in Tehsil Chittapur of Kalburgi district in Karnataka next to the company’s integrated Rajashree plant. It has a total cement grade geological resource of 530Mt of limestone over an area of 7.86km².

India: A shortage of limestone in the Jammu and Kashmir union territory since December 2021 has resulted in cement plant workers being laid off in Udhampur district. The local sector has lobbied the regional government to supply limestone from state-controlled quarries to fix the situation, according to Asian News International. One cement plant employee interviewed by the news agency said that his plant had laid off around 80 workers from a total of 200 due to the shortage.

Iran: Mehdi Dosti, the governor of Hormozgan Province, says that a new 3000t/day cement plant will be built in the region. Dosti met with the head of Cement Investment Holding to discuss the project, according to the Islamic Republic News Agency (IRNA). The project is intended to increase cement production and create jobs in the province. Currently, Hormozgan Province has a 6000t/day cement plant at the Port of Khamir but cement is also imported into the region.

France/Egypt: France-based Vicat has issued a mandatory tender offer to buy an additional 42% stake in Sinai Cement. The proposal follows a final settlement agreement signed between Vicat and the Egyptian government in late March 2021, according to the Daily News Egypt newspaper. Following the completion of the transaction Vicat should own a 98% in the Egypt-based cement producer based on its reported ownership at the end of 2021.

In 2021 Vicat raised a case against the Egyptian government with the International Centre for Settlement of Investment Disputes. Media reports at the time alleged that the cement producer was being forced to reduce its shares in its subsidiary Sinai Cement due to a law stopping foreign ownership of companies operating in the Sinai Peninsula on the basis of security grounds. Around the same time Vicat also announced publicly that it was keen to continue operating in the country.

Panama: Cemex exported 3000t of bagged Ordinary Portland Cement to Jamaica from the Bahía Las Minas Grain Terminal in Colón. Data from the Ministry of Commerce and Industries shows that the company started exporting cement in January 2021 and recorded sales of over US$17m in 2021. In the first two months of 2022 Panama exported OPC to countries including Jamaica, the Bahamas, Guyana, Bonaire, Cuba and Curaçao.

Canada: Jean Boulet, the labour minister of Quebec, has called for an end to a long-running labour dispute at Ash Grove’s Joliette cement plant that has been running since mid-2021. Around 130 members of the Unifor union were locked out by management, according to Postmedia Breaking News. In a message on social media Boulet invited the parties to "concentrate their efforts at the negotiation table with a conciliator." The union alleges that company owner CRH has been importing raw materials to make cement from Greece or Turkey whilst the workers have been excluded from the plant. Negotiations will continue in mid-April 2022.

Ghana: The Ghana Standards Authority (GSA) has reported discoveries of Empire Cement brand cement on sale on the open market despite neither it nor the Ghana Environmental Protection Agency (EPA) having issued permits for Empire Cement to produce cement. Graphic Online News has reported that the suspect products are wrongly labelled with certification marks. GSA director general Alex Dodoo warned that this constitutes an offence.

African cement producers have confirmed their interest in calcined clay over the last month with two new projects. The big one was announced last week when FLSmidth revealed that it had received an order from CBI Ghana. This follows the launch of a Limestone Calcined Clay (LC3) project in Malawi in mid-March 2022 in conjunction with Lafarge Cement Malawi.

FLSmidth says that its order includes the world’s largest gas suspension calciner system and a complete grinding station. The kit will be installed at CBI Ghana’s plant near Accra in the south of the country. The new clay calciner system is expected to substitute 30 - 40% of the clinker in the final product, resulting in a reduction of up to 40% CO₂/t of blended cement compared to Ordinary Portland Cement (OPC). Overall the equipment manufacturers reckon that the grinding plant will reduce its CO₂ emissions by 20% compared to its current output. There has been no indication of how much the order costs but CBI Ghana expects energy and fuel savings, as well as lower overheads from clinker imports.

The public announcement of the Ghana project was also foreshadowed by the visit of Professor Karen Scrivener to the Ghana Standards Authority in February 2022. This was significant because Scrivener is the head of the Laboratory of Construction Materials at the Ecole Polytechnique Fédérale de Lausanne (EPFL) and has been one of the key instigators of the LC3 initiative since the early 2000s. Other calcined clay cements are available such as Futurecem or polysius activated clay (see below) but LC3 is arguably the most famous given its promotion in developing countries.

The Malawi project is at a much earlier stage. The government launched the public private partnership LC3 project in mid-March 2022 in conjunction with Lafarge Cement Malawi and Terrastone, a brick manufacturer. The Ministry of Mining is currently developing a memorandum of understanding with the Gesellschaft für Internationale Zusammenarbeit (GIZ), a Germany-based development agency. India-based Tara Engineering has also been linked to the scheme.

One thing to note about the Malawi project is that it is the first calcined clay project in the cement industry based in East Africa. All the other African ones are based in West Africa. The other two projects in this region are run by Turkey-based Oyak Çimento and its subsidiary Cimpor. The first of these is a 0.3Mt/yr calcined clay and a 2400t/day cement grinding production line that was commissioned in mid-2020. This plant is based at Abidjan in Ivory Coast. The second is a new plant that Germany-based ThyssenKrupp Industrial Solutions is building for Oyak Çimento at Kribi in Cameroon. This unit has a 720t/day calcined clay and a 2400t/day cement production capacity and it will use the supplier’s ‘polysius activated clay’ technology. ThyssenKrupp’s involvement came to light in early 2020 and commissioning was scheduled for late 2021. However, no update on the state of the project has been issued so far in 2022.

As the above examples show, Sub-Saharan Africa has at least one live calcined clay plant, two plants are being built and there’s one more at the development stage. This puts the region neck-and-neck with Europe, which has a similar mixture of current and developing projects. This column has been covering the wider trend of the growing usage of various types of blended cements recently, particularly in Europe and the US, with slag cements, Portland Limestone Cement (PLC) and more. With PLC, for example, note the transition of another two North American cement plants to PLC this week alone. As for calcined clay cement, it is fascinating to see the focus move to a different part of the world. Several commentators have predicted that the future looks set to be dominated by blended cements using whichever supplementary cementitious material (SCM) is most available for each plant. The growth in calcined clay confirms this view.

Global Cement is researching clay calcination use in the cement industry for the next edition of the Global Cement Directory. Email This email address is being protected from spambots. You need JavaScript enabled to view it. with any information on new industrial and research installations.