Displaying items by tag: Ukraine

Russia: Switzerland-based Holcim has announced its upcoming exit from the Russian cement market in line with its corporate value ‘to operate in the most responsible manner.’ The Global Cement Directory 2022 records a total of four Holcim cement plants in the country, commanding a capacity of 9.2Mt/yr.

Holcim’s board of directors thanked all employees currently mobilising to provide shelter, essential goods and medical supplies and other support to Ukrainians.

The group had previously suspended new capital investments into the market on 15 March 2022.

Italy: Buzzi Unicem’s earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 1.8% year-on-year in 2021 to Euro795m. Despite this, its net profit for the year declined by 3.2% year-on-year to Euro542m.

In 2022, Buzzi Unicem forecasts a 10% full-year EBITDA decline due to the impacts of the Russian invasion of Ukraine.

Turkey: Members of Türkçimento produced 78.9Mt of cement in 2021, up by 9.2% year-on-year from 2020 levels. Capacity utilisation for the year averaged 71%. Cement sales also rose, by 8.2% to 60.2Mt. Exports fell by 1.9% year-on-year to 30.8Mt, with a value of US$1.26bn, 23% of total sales.

Türkçimento chair Fatih Yücelik said that the sector has ‘rapidly and heavily’ felt the effects of the Russian invasion of Ukraine on its operations. Yücelik said “We continued our activities in 2021 under difficult conditions, following 23% year-on-year growth in 2020. We predict 4% growth in our sector in line with the economic growth target in 2022.”

From the Nordics to the Mediterranean, European countries lead the field in reduced-clinker cement production using supplementary cementitious materials (SCMs). While consumers, faced with ever-greater choice, continue to opt for sustainability, projects to improve existing SCMs and develop new ones have won government backing and have become a matter of serious investment for other heavy industries beside cement. European cement producers’ decisions are steering the course to a world beyond CEM I. Yet, even in Europe, great untapped potential remains.

Companies generated a good deal of marketing buzz around their latest reduced-CO₂ cement ranges in 2021 and the first quarter of 2022: Buzzi Unicem’s CGreen in Germany and Italy, Holcim’s EcoPlanet in six markets from Romania to Spain, Cementir Holding’s Futurecem in Denmark and Benelux, and Cemex’s Vertua in Spain and several other countries. All boast reduced clinker factors through the use of alternative raw materials. This, however, is really a rebranding of a long-established norm in Europe.

Since 2010, cements other than CEM I have constituted over 75% of average annual cement deliveries across Cembureau member countries (all cement-producing EU member states, plus Norway, Serbia, Switzerland, Turkey, the UK and Ukraine). This statistic breaks down differently from country to country. CEM II is the norm in Austria, Finland, Portugal and Switzerland, with deliveries in the region of 90%. Portland limestone cement (PLC) makes up a majority of deliveries in all four. It has been central to Switzerland’s transition to 89% (3.72Mt) of CEM II deliveries out of a total 4.18Mt of cement despatched in 2021. There, the main types of cement were CEM II/B-M (T-LL) Portland composite cement, with 1.38Mt (33%), and two different classifications of PLC: CEM II/A-LL PLC, with 1.28Mt (31%), and CEM II/B-LL PLC, with 888,000t (21%).

A second approach is that of the Netherlands, where CEM III blast furnace slag cement with a clinker factor below 65% predominates, favoured for its sulphate resistance and the protection it offers against chloride-initiated corrosion of steel reinforcement in marine settings. By contrast, the UK has traditionally maintained a higher reliance on CEM I cement. This can be partly explained by the preference of builders there for adding fly ash or ground granulated blast furnace slag (GGBFS) at the mixing stage. Nonetheless, CEM II Portland fly ash cement held a 14% (1.43Mt) market share in the UK’s 10.2Mt of cement consumption in 2021.

The UK Mineral Products Association (MPA) has identified limestone as an underutilised resource in the country’s cement production. Together with HeidelbergCement subsidiary Hanson Cement, it has applied for a change to National Application standards to allow the production of Portland composite cement from fly ash and limestone or GGBFS and limestone. The association has forecast that Portland composite cement could easily rise to 30 – 40% of UK cement consumption, and that this has the potential to eliminate 8% of the sector’s 7.8Mt/yr-worth of CO₂ emissions.

Metallurgical waste streams have long flowed into European cement production, primarily as GGBFS, but also as bauxite residue. In 2021, alumina production in the EU alone generated 7Mt of bauxite residue, of which the bloc recycled just 100,000t (1.4%) that year. Two projects – the Holcim Innovation Center-led ReActiv project and Titan Cement and others’ REDMUD project – aim to produce new alternative cementitious materials from bauxite residue.

By collaborating with other industries, cement producers’ investments can most effectively reduce the overall cost of using these materials in cement production. In Germany, HeidelbergCement and ThyssenKrupp’s Save CO₂ project aims to develop new improved latent hydraulic binders or alternative pozzolan from GGBFS by producing slag from directly reduced iron (DRI). The Save CO₂ team believes that GGBFS substitution for clinker has the capacity to eliminite 200Mt/yr of CO₂ emissions from global cement production.

Meanwhile in the world of mining, ThyssenKrupp and others’ NEMO project is investigating the recovery of a useable mineral fraction for cement production from the extractive waste of the Luikonlahti and Sotkamo mines in Finland and the Tara mine in Ireland, through bioleaching and cleaned mineral residue upcycling. This may give cement producers full access to Europe’s 28Bnt stockpiles of sulphidic mining waste, of which mines generate an additional 600Mt each year.

Denmark-based CemGreen, which produces the calcined clay supplementary cementitious material CemShale, is developing a shale granule heat-treating technology called CemTower. This consists of three pieces of equipment vertically integrated into cement plants’ preheaters, kilns and coolers, and brings the processing of waste materials – here oil shale – to the cement plant.

Lastly, cement producers are exploring the possible uses of waste made of cement itself. In Wallonia, HeidelbergCement subsidiary CBR’s CosmoCem project is investigating the production of alternative cement additives from large available flows of local demolition, soil remediation and industrial waste. Similarly, the Greece-based C2inCO₂ project seeks to mineralise fines from concrete recycling for HeidelbergCement to use in the production of novel cements in its Greek operations.

In Switzerland, ZND Portland composite cement (produced using fine mixed granulate from building demolitions) is the third largest cement type, with 178,000t (4.3%) of total deliveries – narrowly behind CEM I with 239,000t (5.7%).Holcim Schweiz developed its Susteno 4 ZND Portland composite cement with Switzerland’s lack of any ash or slag supply in mind, demonstrating the potential flexibility of a circular economic approach to cement production.

On 21 March 2022, the University of Trier reported that it is in the process of mapping mineral resources, waste deposits and usable residues ‘on a cross-border scale,’ in an effort to produce new materials for use in cement production. Industry participants include France-based Vicat, CBR, Buzzi Unicem subsidiary Cimalux and CRH subsidiary Eqiom. Vicat is preparing a kiln at its 1Mt/yr Xeuilley cement plant in Meurthe-et-Moselle to use in testing new alternative raw materials developed under the project.

For Cembureau and its members, work continues, with the goal of Net Zero by 2050 constantly in sight. This goal includes a reduction in members’ clinker-to-cement ratios to well below 65%. In this, the association and its members are working towards a world not just beyond CEM I, but beyond CEM II, too. What exactly this will mean remains to be seen.

Sources

CemSuisse, ‘Lieferstatistik,’ 11 January 2022, https://www.cemsuisse.ch/app/uploads/2022/01/Lieferstatistik-4.-Quartal-2021.pdf

WSA, ‘December 2021 crude steel production and 2021 global crude steel production totals,’ 25 January 2022, https://worldsteel.org/media-centre/press-releases/2022/december-2021-crude-steel-production-and-2021-global-totals/

MPA, ‘Low carbon multi-component cements for UK concrete applications,’ July 2018, https://prod-drupal-files.storage.googleapis.com/documents/resource/public/Low%20carbon%20multi-component%20cements%20for%20UK%20concrete%20applications%20PDF.pdf

European Commission, ‘European Training Network for Zero-waste Valorisation of Bauxite Residue (Red Mud),’ 16 July 2020, https://cordis.europa.eu/project/id/636876

European Commission, ‘Industrial Residue Activation for sustainable cement production,’ 16 February 2022, https://cordis.europa.eu/project/id/958208

Recycling Portal, Zement der Zukunft – Forschungsprojekt „SAVE CO₂“ gestartet, 28 May 2021, https://recyclingportal.eu/Archive/65677

h2020-NEMO, ‘Project,’ https://h2020-nemo.eu/project-2/

European Commission, ‘Green cement of the future: CemShale + CemTower,’ 14 April 2021, https://cordis.europa.eu/project/id/101009382

CosmoCem, ‘Communiqué de Presse,’ https://cosmocem.org/

CO₂ Win, ‘C²inCO₂: Calcium Carbonation for industrial use of CO₂,’ https://co2-utilization.net/en/projects/co2-mineralization/c2inco2/

Les Echos, ‘Rendre le ciment moins gourmand en CO₂,’ 21 March 2022, https://www.lesechos.fr/pme-regions/innovateurs/des-substituts-au-clinker-rendent-le-ciment-moins-gourmand-en-co2-1395002

Malaysia: Sharuddin Omar Hashim, the managing director of Cement Industries of Malaysia Berhad (CIMA), says that rising input materials, especially coal, are driving up the cost of cement. He blamed the mounting price of coal on Indonesia’s export ban and the war in Ukraine, according to the Malaysian National News Agency. Sharuddin said that coal had previously cost up to US$70/t but it was now US$200/t, with the possibility of reaching US$400/t. Other raw material costs were also reported to have risen sharply due to logistic problems following the Covid-19 pandemic. Sharuddin added that his company is trying to optimise production and reduce production costs through the use of other alternative materials.

Spain: FYM-HeidelbergCement’s Málaga cement plant has temporarily ceased to produce clinker due to high electricity costs. The La Razón newspaper has reported that the effects of the Russian invasion of Ukraine have made clinker production economically unfeasible at the plant.

Russia: Austria-based Mondi says it is continuing to operate a paper mill and three paper converting plants in Russia. All the units serve the local market. The company said that its operations in Russia represented around 12% of the group’s revenue by location of production in 2021 and, over the last three years, generated around 20% of the group’s underlying earnings before interest, taxation, depreciation and amortisation (EBITDA). Mondi has operated in Russia for over 22 years.

Mondi operates across more than 30 countries. It reported revenue of Euro7.7bn and underlying EBITDA of Euro1.5 billion in 2021. It produces paper and packaging products including bags for industrial products such as cement.

Pakistan: Cement plants in North Pakistan are using 70% Afghan coal in their fuel mix, and may increase the figure to 90%. Afghan coal costs US$170 – 200/t, in line with local Pakistani coal prices. The News International has reported that fossil fuel supply disruptions ensuing from the on-going war in Ukraine have increased global coal prices. Additionally, Indonesian coal is subject to a ban on exports, while bad rains have disturbed Australian coal production. On 14 March 2022, the price of South African coal exported from Richard Bay, Umhlathuze Municipality, was US$460/t, up by 95% month-on-month from US$236/t on 10 February 2022. South Africa has previously been a major source of coal for Northern Pakistani cement production. Cement producers in the region have on average 4 – 5 months’ supply of coal in inventory.

Thailand: Siam Cement Group (SCG) says that it is reviewing its planned US$2.4bn investment programme for 2022 due to the changing conditions it faces following the Russian invasion of Ukraine and ensuing cost rises. The Bangkok Post newspaper has reported that the company has recorded a rise in raw materials and energy costs across its businesses.

President and chief executive officer Roongrote Rangsiyopash said "We will delay some new investment projects, especially greenfield investments, and consider increasing more investments under merger and acquisition plans to avoid possible impact on our long-term financial management." Rangsiyopash added "Prices of cement and building materials will also gradually increase."

Russia: Germany-based HeidelbergCement has suspended ‘all further investments’ in its operations in Russia following the country’s invasion of Ukraine. According to its website, the group supplies the Russian cement market from three local cement plants and two terminals. CEO Dominik von Achten said that a ‘large part’ of HeidelbergCement’s Russian production capacity is presently in winter shutdown.

Von Achten acknowledged the company’s responsibility towards its employees in the country, who he said have no part in the apparent Russian aggression and on-going war crimes in Ukraine. He said “We are in constant exchange with our local workforce to protect them and are closely monitoring the situation on a day-by-day basis.”