Displaying items by tag: Upgrade

India: Ambuja Cement recorded sales of US$930m in the first half of 2021, up by 41% year-on-year from US$659m in the same period in 2020. Cement sales volumes grew by 36% to 13.5Mt from 9.95Mt. Its profit after tax was US$186m, up by 63% from US$114m.

“This performance resulted from strong growth in sales of premium products and successful execution of efficiency improvement programs which has partly been impacted by rising energy and raw material costs. Synergies under the master supply agreement have significantly benefited both Ambuja and ACC as we leverage our national footprint,” said Neeraj Akhoury, the chief executive officer of Holcim in India and the managing director of Ambuja Cement.

The company also announced that its board has approved a 1.5Mt/yr expansion project at its Ropar grinding plant in Punjab.

There has been a significant investment in the South Korean cement industry this week with the news that Hanil Hyundai Cement has ordered a steam-based waste heat recovery (WHR) system from Japan-based Kawasaki Heavy Industries. The 22.6MW system will be used on two of the production lines at the Yeongwol plant in Gangwon Province. The supplier says that installation is expected to generate about 30% of the energy the plant needs and save around 10,000t/yr of CO₂ in the process. Delivery is scheduled for late 2022.

This order may be the first investment following the announcement in late June 2021 that the state-owned Korea Development Bank had pledged around US$870m towards supporting the cement sector in making carbon reduction upgrades by 2025. These are intended to include moving away from burning fossil fuels in cement production and increasing the use of recycling materials. At the time of the agreement between the bank and the Korea Cement Association (KCA), Hanil Hyundai Cement noted that the local alternative fuels substitution rate was 24% compared to 46% in the European Union and 68% in Germany.

Graph 1: Cement production in South Korea, 2010 – 2020. Source: Korea Cement Association

By European or American standards South Korea kept its coronavirus cases under control in 2020. A robust testing and contract tracing regime (K-Quarantine) managed to prevent the country enforcing stricter measures until late in 2020. A fourth wave of infections, currently underway in July 2021, due to the more contagious Delta variant, has started to change this. Despite being able to keep its economy open though, the construction sector still took a hit although not as bad as initially feared.

Cement production fell by 6% year-on-year to 47.5Mt in 2020 from 50.6Mt in 2019 following a downward trend since 2017. The KCA expected worse after a poor third quarter in 2020 when it was preparing for shipments to fall below the level last seen in the midst of the International Monetary Fund (IMF) crisis in the late 1990s. On top of this the industry was also potentially facing a new tax on production towards the end of 2020. One large local producer, Ssangyong C&E, reported a 5% year-on-year drop in sales to US$864m in 2020 from US$910m in 2019. However, it managed to increase its operating profit over the same period. So far in 2021 the sector faced supply shortages in the spring. The KSA blamed the winter plant maintenance schedule and a lack of railway wagons and trucks.

The timing of the Korea Development Bank investment in the cement sector is interesting given the movement on the European Union carbon border adjustment mechanism. Cement exports seem unlikely to be affected but business lobbyists like the Federation of Korean Industries are well aware of the effects schemes like this might have upon commodities like steel and aluminium in the first phase and then the implications for car production later on. Target markets for cement exports such as the US, Peru, Chile and the Philippines might all become vulnerable should carbon-based trade restrictions become more prevalent. Of course export markets remain vulnerable to more usual hindrances. For example, in March 2021 the Philippines extended its safeguard measures on cement imports to various countries including South Korea.

Following a round of market consolidation in the late 2010s, the South Korean cement sector now appears to be entering a phase of sustainable realignment. In late May 2021 Prime Minister Moon Jae-in announced plans to hasten the country’s carbon reduction targets ahead of the United Nations Climate Change Conference scheduled for November 2021, including a carbon tax. With cement production on a downward trend since 2017 and the coronavirus crisis far from gone it will be instructive to see how far the intervention of the Korea Development Bank will go.

Brazil: Votorantim Cimentos has started operation of a new production line at its Pecém grinding plant in Ceará. The US$38m upgrade brings the production capacity of the site to 1Mt/yr from 0.2Mt/yr previously. The project was suspended temporarily in 2020 due to the coronavirus pandemic. The producer also operates the integrated 2.2Mt/yr Sobral plant in Ceará and a terminal in Fortaleza. The production sites the company runs in the state are connected by railway and a further line has been extended to connect the terminal.

South Korea: Hanil Hyundai Cement has placed an order with Japan-based Kawasaki Heavy Industries for the design and installation of a 22.6MW waste heat recovery (WHR) unit at its Yeongwol cement plant in Gangwon. The WHR plant will generate power from heat from two of the plant’s production lines when commissioned in December 2022. The supplier says that it will serve 30% of the plant’s energy needs. Kawasaki Heavy Industries says it has previously supplied WHR units to Japan, Germany, South Korea, Turkey, China, Vietnam, India, Pakistan and elsewhere.

Georgia: HeidelbergCement Georgia plans to invest in additional grinding capacity at both of its cement plants. The subsidiary of Germany-based HeidelbergCement says that it will complete expansion work at both plants by the 2022 production season. It is also contemplating the possibility of clinker capacity expansions.

In early July 2021, Georgia experienced a cement shortage due to the release of pent-up demand from infrastructure projects and reduced imports from Turkey and Azerbaijan.

Philippines: Holcim Philippines plans to invest US$4.18m in upgrades to its cement plants at La Union, Bacnotan, and Lugait, Misamis Oriental to improve business and sustainability performance.

The subsidiary of Switzerland-based Holcim held a ceremonial signing ceremony on 7 July 2021 to award the contract to Sinoma CBMIPH Construction to install a drying facility at the La Union plant. The project is intended to reduce the fuel consumption of the unit by reusing hot gases from operations to dry materials. The integrated plant was recently awarded an ISO 45001:2018 for Occupational Health and Safety Management System and recertified for ISO 9001:2015 (Quality Management System) and ISO 14001:2015 (Environmental Management System) by certification body TÜV Rheinland. Holcim Philippines has also contracted Sinoma CBMIPH to install a drying facility at its Lugait plant that will reduce moisture of raw materials to improve grinding operations. The La Union and Lugait projects are scheduled to be completed in the first quarter of 2022 and by the end of October 2021 respectively.

In January 2021, Holcim Philippines also started projects worth US$2.42m to raise the efficiency of converting qualified waste materials to alternative fuels of its cement plant in Bulacan, Norzagaray. These will enable its Geocycle subsidiary to support the Bulacan plant to increase its thermal substitution rate by using more post-consumer and municipal solid wastes as alternative fuels.

Portugal: Semapa subsidiary Secil is spending Euro86m on modernising its Outão cement plant in Setúbal. The Dinheiro Vivo has reported that the work will turn the facility into ‘the most sustainable cement plant in Europe,’ according to the company. It will reduce CO₂ emissions by 20%, end fossil fuel use and establish waste heat recovery to supply 30% of the plant’s electrical power needs. The government has granted the ‘Project of National Interest’ Euro14.5m in funding. The project will also expand the cement plant’s capacity by 30% to 1.3Mt from 1.0Mt.

Chief executive officer Carlos Abreu said "We have the ambition of reaching carbon neutrality in 2050 and this project is a step in that direction. Others will follow." He added "The Asian and American blocs are not always facing that direction, but the path is made by walking... and we will get there." Regarding the timing of the project, Abreu said "Secil was a very brave company here. The project was decided in 2019 before the pandemic broke out... We kept it, despite the fact that knowing that the pandemic was going to be, and is being, very difficult, but we believe that we had no other alternative."

Egypt: Redecam says it has successfully started up a project one line two at Lafarge Egypt’s Ain Al-Sokhna cement plant. The upgrade consisted of: converting the main kiln’s electrostatic precipitator (ESP) into a bag filter; enhanced the cooling system for the clinker cooler, including a partial ESP retrofit; and revamping the bypass the gas conditioning tower and dust transport system. The Italy-based engineering company previously carried out a similar project on line three at the plant in 2020.

Philippines: China-based Sinoma Construction will renovate Holcim Philippines’ La Union cement plant in Bacnotan, North Luzon. Seetao News has reported that the company signed a contract with the subsidiary of Switzerland-based Holcim in July 2021. The work involves a capacity expansion, renovation and de-bottlenecking. The aims of the projects are to promote the modular grinding station market and expand Holcim’s Philippines business and deepen its localisation.

Spain: Tudela Veguín says that an upgrade to a conveyor belt connecting its Aboño cement plant in Asturias to a terminal at the Port of El Musel will allow it to dispatch 5% more cement. The increase represents more than 100,000t/yr-worth of additional cement shipments, according to the La Nueva España newspaper. Ship loading time has also been reduced by nearly half. The Euro532,000 conveyor was completed in 2020. The El Musel terminal has shipped cement for export to several new countries, including most recently the US.