Displaying items by tag: Plant

India: Ambuja Cements will invest US$190m to establish a 6Mt/yr grinding plant in Warisaliganj, Bihar. The project is scheduled in three phases, with the first phase of 2.4Mt/yr costing US$131m, according to the company. The plant has secured environmental clearance and land allocation for potential future expansions, The Telegraph India reports. The project will reportedly create 250 direct jobs and 1000 indirect jobs and will contribute US$30m/yr to Bihar’s economy. It is targeted for completion by December 2025.

Pranav Adani, director of Adani Enterprises, said “This investment aligns with the state government’s development programmes and our growth plans. The cement industry is witnessing healthy volumes due to the government’s infrastructure thrust, and Ambuja Cements is well positioned to support sustainable infrastructure development in the country.”

Mexico: Cooperativa Cruz Azul has announced the upcoming construction of a new cement plant in Seybaplaya, Campeche, with an investment exceeding US$300m. The plant will occupy a site previously used for lime and cement production in order to minimise environmental impact. Construction started on 1 August 2024, with completion of the first production line anticipated by the end of 2026, Noticias Financieras News has reported. The plant will produce 3000t/day of cement. The project is expected to create 2000 temporary construction jobs and 350 permanent positions.

Nigeria: The Mangal Cement plant in Iluagba, Kogi State has successfully produced its first bag of cement. The plant is capable of producing 6000t/day of cement. The US$1.5bn facility aims to transform the local cement industry and will create 10,000 new direct and indirect jobs, Dateline Nigeria has reported. Mangal Industries has partnered with China-based Sinoma International Engineering for the plant’s construction, with a reported cost of US$600m.

Finland-based Wärtsilä has won a 10-year operations and maintenance agreement for a 50MW captive power plant to power the facility. Initially, the plant will use liquid fuel, but a pipeline will be constructed to allow it to use natural gas.

Chair Alhaji Dahiru Mangal said “This factory will employ the latest technology and adhere to the highest environmental standards. It is part of our ambitious programme to address Nigeria’s infrastructure and housing deficits, while demonstrating our confidence in the region’s economic outlook.”

Australia: The new Geelong grinding plant, situated near Lascelles Wharf in Victoria, has commenced operations. It has the capacity to grind 1.3Mt/yr of granulated blast furnace slag and clinker. It will utilise slag to reduce landfill waste and substitute cement in concrete products. According to Boral’s post on LinkedIn, the plant will provide direct and indirect job opportunities to help boost the Geelong economy.

Heidelberg Materials inaugurated a plant near Katowice in Poland this week for separating and sorting demolition concrete. This gives us the chance to catch up with the state of construction and demolition waste (CDW) for the cement and concrete sectors and consider the differences between the strategies of the multinational heavy building materials companies in Europe and the US.

The new CDW recycling unit has a capacity of up to 100t/hr. Heidelberg Materials says that it is the “first company in the industry to introduce high-quality, selective concrete separation at this scale.” The company is using its proprietary ReConcrete process to sort out fractions from the CDW including sand, gravel and, finest of all, recycled concrete paste (RCP). That last one is particularly valuable because it can either be used as an alternative raw material for clinker production by replacing limestone or as a secondary cementitious material. Heidelberg Materials is also promoting the potential use of RCP as a carbon sink over the lifetime of a concrete structure via ‘enforced carbonation.’ The RCP is exposed to raw exhaust gases from cement production allowing it to both mineralise CO₂ and act as a clinker substitute. To further explore this option Heidelberg Materials is building an industrial pilot at its Górażdże plant to test the concept with construction expected by the end of 2024.

Both Holcim and Heidelberg Materials have been visibly busy buying up more aggregate recycling companies over the last nine months since Global Cement Weekly last reported on CDW. Holcim acquired Germany-based Mendiger Basalt in January 2024, Switzerland-based Cand-Landi Group and UK-based Land Recovery in June 2024, and Belgium-based Mark Desmedt in July 2024. It also said at the start of the year that it aimed to conclude 15 - 20 new acquisitions in 2024 with a focus on CDW companies in Belgium, France, Germany and the UK. Heidelberg Materials bought UK-based B&A Group in May 2024 and US-based Highway Materials and Aaron Materials in July 2024. Holcim has set itself a target of recycling 12Mt/yr of CDW by 2030 by using its ECOCycle technology. It reported 8.4Mt/yr in 2023 and hopes to reach 10Mt/yr in 2024.

Some of the recycling companies mentioned above are based in the US but the pace of CDW acquisitions have generally been faster in Europe. In the US, meanwhile, the heavy building materials producers have tended to buy more general aggregates companies. Heidelberg Materials announced on 30 July 2024 that it was buying Albany-based Carver Sand & Gravel. This followed the companies mentioned above and Texas-based Victory Rock, also in July 2024. Holcim said in its first half-year results for 2024 that it had ‘executed’ a bolt-on acquisition in the US that would strengthen its aggregate and ready-mixed concrete business. Cemex also revealed a joint-venture agreement with sand and gravel supplier Couch Aggregates and marine bulk product distributor Premier Holdings in July 2024. It said that the move was part of its “ongoing strategy to accelerate growth in the US and expand its aggregates business.” A big recent deal in the sector was the merger of the US-based operations of Summit Materials and Cementos Argos that completed in January 2024. Although at the time we concentrated on the cement-side of the transaction, it also gave the organisation just under 5Bnt of aggregate reserves.

It may be a stretch to call what’s going on here a trend. Yet the large heavy building materials companies do appear to be acting differently in the US and Europe with regards to aggregate companies and CDW recyclers. The main drivers here are the strength of the US market and the stricter environmental legislation in Europe. Higher population density in Europe compared to the US may also be playing a part in the differences in speed of adoption between the two markets. The ongoing Holcim spinoff demonstrates the differences between the two market regions in bold terms. In short, the company has decided to split itself in two in order to meet the different needs of each market. As for CDW, the trickle of acquisitions keep coming and momentum is steadily building.

UK: Aggregate Industries has appointed Tom Murphy as Carbon Capture Utilisation and Storage (CCUS) Project Manager at the Cauldon Cement Plant in Staffordshire. He will play a leading role in managing the introduction of a carbon capture unit at the site.

Murphy joins the subsidiary of Holcim from Tata Chemical Europe where he was the Plant Manager for a first-of-a-kind post combustion carbon capture plant. Prior to that, he worked as an Energy Chemical Engineer for Tata and as a Research Engineer for the Materials Processing Institute. He holds an undergraduate degree in chemical engineering from the University of Manchester.

The CCUS project at the Cauldon Cement Plant is part of the wider Peak Cluster partnership, which was formed by cement and lime producers around the Derbyshire Peak District region and aims to cut collective annual carbon emissions by 3Mt/yr by 2030. More than 0.6t/yr is targeted to be cut at Cauldon. The project is being led by Progressive Energy. It aims to capture and transport CO₂ emissions from Cauldon and other partner plants before sequestering them beneath the eastern Irish Sea in one of the storage options which the project has access to, including the Liverpool Bay CCS or the Morecambe Net Zero project.

Italy: Cementir Holding increased its sales volumes of cement by 0.3% year-on-year to 5.13Mt in the first half of 2024. Nonetheless, group sales fell by 3%, to €812m, and earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 4%, to €193m. The producer succeeded in raising its net profit, by 7% to €97m. During the half, it invested €24.7m in decarbonisation, primarily in upgrading the kiln line of its 2.5Mt/yr Guarain cement plant in Belgium.

Chair and CEO Francesco Caltagirone said "Results for the first half of 2024 were in line with our expectations. The adverse weather conditions in the first months of the year and a still weak residential market in the most important geographies, as well as a significant negative exchange rate impact, affected the results for the period, which nevertheless benefited from the reduction of main operating costs".

Cementir Holding confirmed its earnings guidance for the year of €385m (down by 6% year-on-year), but revised its revenues guidance downwards by 6% from €1.8bn to €1.7bn, in line with 2023.

Congratulations to Taiheiyo Cement Philippines (TCPI) this week for inaugurating its new 3Mt/yr production line at its Cebu plant. The US$220m line replaces the old line at the site that was closed in late 2021.

The plant was originally built by Grand Cement Manufacturing in the early 1990s. Japan-based Taiheiyo Cement took over in 2001 and later made the decision to upgrade the site in 2017. It then contracted China-based Anhui Conch and Sinoma (Handan) Construction for the project in 2021 and groundbreaking took place in mid-2022. Commercial operation of the new line was previously scheduled from May 2024. TCPI has also invested around US$140m in related projects such as its Jetty and Marine Belt Conveyor project, which links the Cebu plant to the coast via a conveyor. Other parts of this expenditure encompass the Luzon Distribution Terminal Project at Calaca in Batangas and general port development in San Fernando.

The Department of Trade and Industry (DTI) was keen to promote this example of a foreign-owned company investing in local manufacturing. DTI Secretary Fred Pascual pointed out that Japan is the country’s “second-largest trading partner and third-largest source of foreign investment.” He also linked the project to the national Build Better More infrastructure development programme and the Tatak Pinoy Act that was introduced in early 2024 to promote local industry. Along these lines, Republic Cement was awarded the Domestic Bidder’s Certificate of Preference this week. It is the first cement company to receive it. The initiative promotes the use of local manufactured materials in government projects as part of the Tatak Pinoy Act. As one might expect, the Cement Manufacturers Association of the Philippines (CEMAP) supports the Tatak Pinoy Act. It voiced its support for the legislation in June 2024 when the DTI started to implement it. It noted that cement imports were just under 7Mt/yr in 2023 despite the anti-dumping duties imposed on a number of Vietnam-based producers and traders. This compares to a local production capacity of nearly 50Mt/yr.

CEMAP mentioned that new production lines from both TCPI and Solid Cement were expected in 2024. The latter project is a new production line being built at Solid Cement’s Antipolo plant near Manilla in Rizal province. Cemex Philippines held a groundbreaking ceremony for the 1.5Mt/yr line at its subsidiary back in 2019. However, Cemex said it was selling its Philippines-based business to DMCI Holdings and related companies in April 2024. As part of this process Cemex sold its local cement brands to the Consunji family, the owners of DMCI Holdings, in June 2024. Regulatory approval of the divestment is still pending but the sale of the brands suggest that the transaction is progressing. Completion is expected by the end of 2024. Operation of the new line at the Antipolo plant is anticipated from September 2024.

Another forthcoming plant project was announced by PHINMA Corporation in June 2024. It signed a joint venture deal with investment company Anflo Group to build a 2Mt/yr cement plant in Davao del Norte. The project is scheduled to be operational by 2026. Cement from the plant will be marketed under the Union Cement brand. The sums involved suggest a grinding plant but PHINMA’s cement division, Philcement Corporation, is involved with both manufacture and importation. PHINMA also signed a deal to buy Petra Cement in May 2024. The latter company runs a 0.5Mt/yr cement grinding plant in Zamboanga del Norte. PHINMA re-entered the cement market in the late 2010s when it bought the Union Cement brand and built a cement processing plant at Mariveles, Bataan in 2020.

The battles between cement producers and importers continue to play out in the Philippines as the country’s infrastructure plans gather pace. Yet the balance seems to be tilting more towards the favour of the local manufacturers at the moment, as new capacity gets proposed and built. Anti-dumping duties on imports, particularly those from Vietnam, have now been followed up with local procurement rules in the guise of the Tatak Pinoy Act. Whether this is enough remains to be seen. This kind of environment and the departure of Cemex may also start to revive questions about whether any other foreign-owned cement companies might be considering their options too.

Gabon: President Brice Oligui Nguema of Gabon invited Aliko Dangote, President and CEO of Dangote Industries, to invest in Gabon's cement sector during a visit to the country. Discussions centred on potential cement plant investments to bolster Gabon's infrastructure development. President Nguema noted that the collabora­tion with Dangote Industries would bring significant ben­efits, including job creation, technology transfer and en­hanced industrial capacity. This potential investment aims to strengthen economic ties between Nigeria and Gabon and enhance Gabon's industrial capacity, with further discussions planned in the coming months to finalise the investment strategy.

Dangote said "We are excited about the opportunity to invest in Gabon. Our goal is to contribute to the country’s economic diversification and industrialisation efforts. By leveraging our expertise in cement production, we aim to support Gabon’s infrastructure sector."

Cameroon: Cimpor has inaugurated its new plant in Kribi, Cameroon. Following investments in Côte d'Ivoire, Cimpor embarked on this greenfield project in February 2020, integrating the ‘world's first’ operational flash calcined clay production line, launched on 29 October 2023.

Cimpor Cameroun now has an output of 1.2Mt/yr of cement and 0.4Mt/yr of calcined clay. Cimpor's calcined clay production technology - ‘deOHclay’ – reportedly saves up to 80% in CO₂ emissions, up to 35% in electricity consumption and up to 40% in thermal energy consumption per tonne. Compared to a plant with a similar capacity, this technology could reduce CO₂ emissions by around 0.2Mt/yr, according to the company. The new plant will reduce the country’s dependence on imports to meet local cement needs.