Displaying items by tag: HeidelbergCement

Well, it turns out that the European cement industry wasn’t kidding when it raised the risks of the climate mitigation on the sector. This week three (!) integrated plants have been earmarked for closure.

Cementa in Sweden said that it was considering closing its Degerhamn plant due to increased environmental regulations. Today, local press in Spain is reporting that Cemex España is planning to shut down two of its plants. These are plants in different parts of Europe with different local market dynamics but both are within the European Union (EU). That’s three plants closing out of 219 in the EU, or a loss of around 1% of production capacity.

Last week’s column on the United Nations’ (UN) Intergovernmental Panel on Climate Change (IPCC) report on Global Warming raised the way the cement sector is tackling climate change and the existing and impending legislation. President of the German Cement Works Association (VDZ) Christian Knell’s opening words at the VDZ Congress in September 2018 seem prescient. He said, “To be able to realise our efforts in terms of climate protection and at the same time not to lose competitiveness, we need research policy-related support for our investment in breakthrough technologies and the corresponding demonstration projects.” The add-on was that the industry needed to focus on how the development of carbon abatement technologies can meet the 2050 climate goals and, specifically, that suitable boundary conditions would have to be created. The press releases accompanying his speech emphasised that, “on-going trends in European emissions trading and the ‘rapidly increasing’ price of CO₂ were already today leading to considerable costs for cement manufacturers.”

These words are similar to the comments Albert Scheuer, a board member of HeidelbergCement, made at the Innovation in Industrial Carbon Capture Conference early in 2018 about dividing the mounting environmental costs of cement and concrete between producers and society in general. Considering how much cementitious building materials most people use throughout their lives compared to the relative low price of cement, this argument carries some weight. In addition, the sustainability credentials of concrete buildings through longer lifespan and durability through extreme weather events is another argument that industry advocates such as the Portland Cement Association (PCA) in the US have been hawking in recent years.

Cementa, a subsidiary of HeidelbergCement, blamed anticipated tightening of environmental regulations for its decision. Although it said that the plant had made improvements over the years, the expected difficulty (read: cost) to make further improvements was becoming too hard. Shifting production to the company’s other two plants in the region, Slite on Gotland and Brevik in Norway, will reduce CO₂ emissions by 260,000t/yr.

In Spain, the news from Cemex follows a half-year report from Oficemen, the local cement association, that predicted growth for the year but not as fast as previously expected. The problem was that continued declines in the export market, the 13th decline month-by-month in a row, offset the domestic growth. Oficement president Jesús Ortiz also took time to blame rising electricity costs, expected to rise by 20% year-on-year by the end of 2018.

Market issues in Spain aren’t in doubt, but the real question for both Sweden and Spain is whether EU CO₂ legislation right now is causing cement producers to shut plants. The CO₂ emissions allowance price hit a high of Euro22/t in September 2018, the highest price in a decade. Allowances have stayed below Euro10/t since 2011 and the price has more than doubled in 2018. Throw in the mood music of the IPCC and the trend seems irresistible. How many more plants in Europe are at risk to shut next? No doubt the European cement producers have charts marking the viability of their plants against the CO₂ price. This would be a very interesting graph to get our hands on.

The 2nd FutureCem Conference on CO₂ reduction strategies for the cement industry will take place in May 2019 in London, UK

Sweden: Cementa says it is considering decommissioning clinker and cement production at its 0.3Mt/yr Degerhamn plant due to increased environmental regulations. Production will be shifted to other local plants at Slite on Gotland and Brevik in Norway, and the site retained as a port terminal.

The subsidiary of Germany’s HeidelbergCement said that although the unit had made several investments over the years to reduce its environmental impact its production equipment was difficult to adapt to future requirements for lower CO₂ emissions. Concentrating production to the other plants would mean a reduction in CO₂ emissions of 260,000t/yr.

75 employees work at the plant at Degerhamn. Union negotiations will start immediately and upon their conclusion the cement producer will make a final decision about the future of the plant. If decommissioning goes ahead then clinker and cement production will cease in 2019.

Sweden: Cementa plans to electrify its cement plant at Slite in Gotland as part of its Cemzero project. The subsidiary of Germany’s HeidelbergCement plans to make its plant CO₂ neutral by 2030, according to Helagotland. However, the plan is limited by a lack of technology to fully electrify large-scale manufacturing at the site. The company also holds concerns about where it would source larger quantities of electricity.

Germany: HeidelbergCement is planning to expand the Atlas quarry of its Paderborn plant. The quarry area will be increased by nine hectares, according to the Neue Westfälische newspaper. The company says that the expansion is necessary to support the supply of raw materials to the plant. It has organised an information forum for local residents.

Russia: HeidelbergCement Russia has held an opening ceremony for a new despatch system at its Slantsev ‘Cesla’ plant in the Leningrad region. Mihail Polendakov, General Director of HeidelbergCement in Russia, Anton Hadjiiski, General Director of the plant, Mikhail Moskvin, Deputy Chairman of the Leningrad Region Government for Construction, and Deputy Prime Minister Leningrad Region - Chairman of the Committee for Economic Development and Investment Activities Dmitry Yalov attended the opening.

Following the upgrade the plant now uses an automated loading system for its trucks. The investment for the project was around Euro13m. The unit has a cement production capacity of 0.8Mt/yr.

More positive news emerged from the UK cement industry this week with the news that Cemex is planning to restart the second kiln at its South Ferriby plant later in 2018. This marks the full recovery of the plant after a disastrous flood in late 2013 and it is an all round good news story. Around the same time the local government in Scotland approved the planning application for an upgrade to Tarmac’s Dunbar cement plant. That project involves installing a new cement grinding mill, a new cement storage silo and a rail loading facility.

Graph 1: Domestic cement, imported cement and other cementitious sales in the UK, 2001 - 2017. Source: Mineral Products Association.

The timing is interesting given the general uncertainty in the UK economy ahead of the UK exit from the European Union (EU). However, data from the Mineral Products Association (MPA) shows that total cementitious material sales (cement plus products made from fly ash and ground granulated blast furnace slag (GGBS)) reached 15.3Mt in 2017 from a low of 10.3Mt in 2009 following the financial crash. This isn’t as high as the 15.8Mt figures recorded in 2007 but it does mark a recovery. This masks to an extent the change in the market since 2007. Cement sales in 2017 at 10.2Mt were still below a high of 11.9Mt in 2008. The recovery has been driven by higher imports, 1.9Mt in 2017, and higher use of fly ash and GGBS products, which reached 3.2Mt in 2017.

Cemex and Tarmac are not alone in announcing projects. HeidelbergCement’s local subsidiary Hanson is upgrading its Padeswood plant with a new Euro22m mill. Irish slag cement grinding company Ecocem opened its import terminal at Sheerness in mid-2017 and French grinding firm, Cem'In'Eu, has also expressed interest in building a plant, in this case in London.

As discussed earlier in the year, new upgrade projects in the UK appear to carry an element of risk given the unknown status of its departure from the EU. Supply chains may be affected, companies are delaying investment and the value of Pound Sterling is falling. The collapse of construction services company Carillion also had a knock-on effect in the industry and, with major work on the Crossrail infrastructure project finishing, the industry has no major infrastructure projects in support. A quarterly graph of UK construction industry output volume by Arcadis shows almost uniform growth since mid-2012 although this started to flatten in 2017. A badly-handled Brexit (UK exit from the EU) could undo this growth.

All of this presents a picture of risk-adverse capital projects in the UK. The MPA figures help to explain the focus on grinding at Padeswood and Dunbar. The market has changed since 2007, with a growing focus on imports and secondary cementitious materials. Hence spending money on equipment to process these inputs makes sense. The decision to increase production at South Ferriby meanwhile depends on reviving existing equipment. Regional cement sales figures to 2016 from the MPA appear to indicate static demand in counties close to the plant (Yorkshire and Humberside) but sales have increased in the East Midlands and the East of England.

Just compare the current UK approach to the situation in Egypt. This week the head of the cement division of the Chamber of Building Materials described the decision to build the Beni Suef cement plant to local media as “not based on precise information” and that it had harmed local production. In case you had forgotten, that plant is one of the biggest in the world with six lines. The commentator may well have been representing smaller local producers but opening a 12Mt/yr plant in Egypt in these turbulent economic times marks a different approach to risk than the modest plant upgrades in the UK. Let’s wait and see who has the best approach.

Morocco: Cement sales volumes at Ciment du Maroc have fallen by 2.6% year-on-year in the first half of 2018. This compares to a decline of 2.9% in national consumption, according to local media. Its operating turnover fell by 4.2% to Euro449m. The subsidiary of Germany’s HeidelbergCement also noted that it was happy with the progress of its Nador grinding plant project.

South Africa: A ship carrying clinker and gypsum has arrived at the Port of Ngqura. The raw material is intended for Osho Cement, a company setting up a grinding plant at Coega special economic zone, according to the Herald newspaper. The imported clinker and gypsum was transported by truck to the new plant.

The joint venture between South Africa’s Osho ventures and Germany’s Heidelberg Cement plans to market cement from its new unit to South Africa, Sub-Saharan Africa and islands in the Indian Ocean. The plant is scheduled to open the new plant in late 2018.

Sweden: Cementa has appointed Jenny Larsson as the district manager for its south region. She succeeds Lars-Åke Andersson, who has held the role for 20 years. Andersson will retire in the spring of 2019 and the pair will work together until this time.

Spain: FYM-HeidelbergCement has reached a record two years without an accident at its Malaga cement plant. The milestone also includes no accidents for subcontractors working at the site. The company has operated a ‘Zero Accident’ program since 2000 that has focused on improving the safety culture for all staff.