Displaying items by tag: Upgrade

We return to Brazil this week where Cimento Itambé has inaugurated a new kiln at its plant in Balsa Nova, Parana. The US$92m investment has added 0.6Mt/yr of cement production capacity to the unit, bringing its total to 3Mt/yr. Notably, the new kiln is intended to support the use of alternative fuels (AF) such as biomass and industrial waste. Local press reports that the new kiln can operate with a 50% AF thermal substitution rate (TSR) and in tests it has reached as high as 67%.

Local market leader Votorantim Cimentos has also embarked on an upgrade programme linked to increasing co-processing rates. In May 2025 it said that it had received and begun installing a new cement mill, supplied from China, at its Salto de Pirapora plant near São Paulo. Earlier in August 2025 it revealed that it was spending US$60m on upgrades at its Nobres and Cuiabá plants in Mato Grosso. A new cement grinding mill is to be installed at the Nobres plant. This should increase the site’s cement production capacity to 1.2Mt/yr from 0.6Mt/yr. At Cuiabá the company is installing a tyre shredding unit via its Verdura subsidiary to support increased rates of co-processing of AF. Work on these projects is set to start in 2025 with completion scheduled by the end of 2026.

These schemes are part of the group’s larger US$920m upgrade investment plans across the country. Announced in early 2024, this is intended to increase competitiveness and co-processing capacity and reduce CO₂ emissions. It will also add 3Mt/yr to the company’s production capacity. An investment of US$150m from the International Finance Corporation (IFC) in 2023 to Votorantim to support the uptake of AF is likely to have helped the decision to upgrade. The company currently has a target of a 50% TSR by 2030.

Of the other major producers, CSN is also aiming for a 50% TSR by 2030. It said in its 2024 sustainability report that all of its kilns were capable of processing AF. It also highlighted upgrade work at its Alhandra, Paraíba, plant in 2024 to handle, store and transport fuels, including biomass. InterCement reported some relatively high TSRs at individual plants in Brazil in 2023. For example, its Ijaci plant in Minas Gerais reportedly had a rate of 42%.

National Cement Industry Union (SNIC) data shows that the co-processing rate of AF reached 32% in 2023. The union says that this puts the sector ahead of its next target of 30% in the mid-2020s. The next one is to reach 35% by 2030. For reference, back in 2019 the country’s Cement Technology Roadmap reported that around 60% of cement kilns in the country were licensed by environmental agencies to co-process waste.

Graph 1: Sales of cement in Brazil, 2017 - 2025. Source: SNIC.

Looking at the domestic industry in general, SNIC reported growth in 2024 and the first seven months of 2025. Sales for the first seven months of the year grew by 4% year-on-year to 38.2Mt. This has been attributed to the real estate sector, boosted by the Minha Casa Minha Vida housing programme, and an expanding job market. Yet jitters remain, with fears of an economic slowdown in the second half of 2025 and uncertainty on how new US tariffs might affect the cement industry indirectly. Despite only exporting around 65,000t of cement in 2024 though, the association is wary of any indirect effects of tariffs.

It’s no surprise that cement plants in Brazil are prioritising AF usage. The market is buoyant and co-processing offers one of the cheapest routes to decarbonising cement production in the short-to-medium term. Increasing the use of AF can also potentially hedge against the cost of imported conventional fuels, such as coke, that are priced in US dollars. This is one example of SNIC’s concern over indirect effects on the cement industry from US tariffs via currency volatility. Expect AF rates to carry on rising.

The 18th Global CemFuels Conference & Exhibition on alternative fuels for cement and lime will take place on 17 - 18 September 2025 in Milan, Italy

Brazil: Cia. de Cimento Itambé has inaugurated a new kiln at its Balsa Nova plant in the Curitiba metropolitan region following a US$91.8m investment, according to the Curitiba government. Mayor Eduardo Pimentel and other members of the government were in attendance. The project reportedly increases clinker production capacity by 120% and adds 600,000t/yr of cement capacity, raising the plant’s total to 3Mt/yr.

The kiln will replace up to 50% of fossil fuels with renewable energy sources like biomass and industrial waste.

Belarus: Krasnoselskstroymaterialy is preparing a US$100m modernisation project at one of its cement plants and is seeking investment from Chinese companies. CEO Alexander Golda said “A large cement plant modernisation project is currently at its pre-investment stage. We are actively working with Chinese partners, and representatives of several large companies have already visited us with proposals.” He added that work will continue through 2025 ‘and the following years’ before a final decision is made.

The company reduced its net loss by 45% year-on-year to US$9.50m in 2024, while sales grew by 21% to US$139m.

Saudi Arabia: Qassim Cement has signed a US$298m contract with Sinoma International Engineering to build a fourth production line at its Buraydah plant. The new line will have a production capacity of 10,000t/day.

CEO and board member of Qassim Cement Omar Al-Omar said that the project will replace ‘outdated’, low-efficiency production equipment while optimising the plant’s existing infrastructure. Al-Omar added that the project will support the company’s sustainable growth strategy, aimed at meeting domestic demand and diversifying products in line with Saudi Arabia’s Vision 2030.

Brazil: Votorantim Cimentos announced a US$54.5m investment in the state of Mato Grosso, covering expansions and modernisation at its Cuiabá and Nobres plants. Construction will begin in 2025 and finish by late 2026, creating over 150 direct and indirect jobs in the state while retaining more than 700 existing positions.

At Nobres, a new cement mill will boost capacity by 60% from 0.75Mt/yr to 1.2Mt/yr, and the expansion will also add a new storage warehouse and logistics infrastructure. Votorantim Cimentos’ sustainable waste management arm, Verdera, will install a used tyre shredding facility at the Cuiabá site, supplying its kilns with co-processed fuel.

Global CEO Osvaldo Ayres Filho said the investments will “Increase our competitiveness and our production and storage capacity, and improve our efficiency to better serve our customers and the consumer market, while also reducing CO₂ emissions.”

The expansions are part of a comprehensive investment programme by the company, focused on modernisation, capacity growth, competitiveness and decarbonisation. Announced in early 2024, the plan includes US$909m in investments to be deployed by 2028.

North Korea: The Sangwon Cement Complex has reported that it ‘successfully fulfilled its economic plan for July 2025,’ following an overhaul of its No. 1 cement production which is reported to have increased its capacity. This includes an upgrade to the microalloying process used to cast components for the plant, which has enabled longer service life for components and reduced costs.

Local press reported that the plant was ‘intensifying the drive for increased production to send more cement to the forefronts of socialist construction.’

France: Vicat’s sales remained stable at €1.89bn on a like-for-like basis in the first half of 2025. This was attributed to negative currency exchange effects in Brazil, Egypt and Türkiye, and a slowdown in activity in the US. Earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 2% year-on-year to €331m from €353m in the same period in 2024. Cement and concrete sales volumes dropped by 2.5% to 13.7Mt and 3.9% to 4.4Mm³ respectively. Aggregates volumes rose by 5.8% to 11.3Mt. By region sales revenue and earnings fell in France yet rose in the rest of Europe and the Mediterranean. It fell elsewhere.

“The group continues to implement its market plan, with the start-up of Kiln 6 in Senegal, a major driver of the group’s organic growth, development in the construction chemicals business with the merger between VPI and Cermix, and the acquisition of Realmix, which strengthens the group’s vertical integration in Brazil,” said Guy Sidos, Vicat’s chair and CEO.

Nigeria: BUA Cement’s sales revenue grew by 59% year-on-year to US$379m in the first half of 2025 from US$238m in the same period in 2024. Its profit after tax jumped to US$118m from US$22.4m. In its recent annual general meeting the company reported that it commissioned two new production lines at cement plants in Edo and Sokoto States in 2024 that increased its production capacity to 17Mt/yr from 11Mt/yr. It also started building a new 3Mt/yr line at Ososo in Edo State.

Germany: Vecoplan is investing over €5m to upgrade its manufacturing plant in Bad Marienberg. It has enlarged its Plant I by a total of 1900m² and purchased new production equipment. The engineering company is now adding assembly capacity and expanding its warehouse. Construction work on a new warehouse complex started in spring 2025 and is scheduled for completion in the second quarter of 2026.

“We are continuing to witness a high level of demand,” said Vecoplan’s CEO Werner Berens. “We’ve had to create additional space, especially in preassembly, to meet the growing need for our heavy machinery.”

Vecoplan manufactures machinery and plants for shredding, conveying and processing. It is headquartered in Germany and has subsidiaries in Austria, France, Italy, Poland, Spain, the US and the UK.

Portugal: Cimpor has reported the successful installation of a new KHD Pyrorotor combustion chamber at its Alhandra plant. It described the upgrade as a key milestone in the modernisation of Kiln 7 and in the company’s energy transition process.

The combustion chamber measures 3.4m in diameter and 10m in length, and weighs 146t. It will allow the replacement of fossil fuels with alternative fuels, enabling a thermal substitution rate of up to 80%. Its installation required a technically demanding operation, carried out using a 400t crawler crane. The work is part of a wider structural upgrade of Kiln 7, which also includes the modernisation of the existing kiln to a production capacity of 3600t/day, a new preheater tower with a five-stage cyclone, the installation of a Pyroclon calciner, a new clinker cooler and a new vertical raw mill.

Cimpor says that the investment will contribute directly to the reduction of the plant’s CO₂ emissions, fully aligned with the company’s decarbonisation goals and reinforcing the company’s commitment to the targets set out in its Recovery and Resilience Plan.