Displaying items by tag: Upgrade

Kenya: East African Portland Cement (EAPC) has contracted a technical audit from Denmark-based FLSmidth Cement with a value of just under US$70m. EAPC’s acting managing director Mohamed Osman said the findings would guide a pending plant upgrade, to be funded by some of the proceeds from the land sale, according to the Star newspaper. It hopes to double capacity at the unit by the late 2020s without incurring debt. The cement producer is also considering its options to use alternative fuels such as macadamia husks and other agricultural biomass. The 10-week audit process is expected to end in early December 2024.

Osman said “We have tapped FLSmidth to undertake a comprehensive technical audit of the plant, which will assess how to maximise the capacity and inform the design and cost of a new one,'' Osman said. “The audit by FLSmidth will also look at the reserves of raw materials that it has and inform whether it needs to acquire more land that has adequate reserves.”

Italy: Cementir Holding has blamed a fall in earnings in the first nine months of 2024 on “lower results achieved in all geographical areas except Egypt.” It added that sales had fallen due to a decrease in volumes in some places and negative currency effects in Türkiye and Egypt. The group’s revenue fell by 5% year-on-year to €1.24bn in the first nine months of 2024, from €1.30bn in the same period in 2023. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) dropped by 9% to €296m from €326m. Sales volumes of cement and clinker remained stable at 7.98Mt. It noted that volumes increases were reported in Türkiye and, to a lesser extent, in Malaysia and the US. However, volumes of ready-mixed concrete rose by 5% to 3.33Mm³ from 3.18Mm³.

Francesco Caltagirone Jr, chair and CEO, said “The results for the first nine months of 2024 are in line with our expectations and, after several quarters of contraction, signs of a market turnaround in some geographies are emerging in the third quarter of 2024. We are strengthening our competitive position through initiatives such as: the investment on Kiln 4 in Belgium, the restart of the second line in Egypt, the acquisition in concrete in Nordic & Baltic, a new limestone quarry in Malaysia, and the repurchase of a large part of the minority interest in our Egyptian subsidiary, to prepare ourselves for any upcoming market opportunities”.

Tanzania/Kenya: Amsons Group will build a US$320m cement plant in northern Tanzania's Tanga area with a production capacity of 5,000t/day, Bloomberg reports. The company also plans to implement a major upgrade at the recently acquired Mbeya Cement in Tanzania, including a new grinding mill, according to Capital News Kenya. Additionally, Amsons plans to invest US$400m in Holcim’s Kenyan subsidiary Bamburi Cement, contingent on its successful US$180m bid.

Edha Nahdi, managing director at Amsons Group, said "Thanks to the support of the Tanzanian and Kenyan governments, our regional expansion plans are now firmly on course. We plan to be one of the largest cement manufacturers in Kenya and Tanzania by 2030."

Philippines: Cemex Philippines has extended Aboitiz Construction’s contract to provide technical services for the commissioning of the upcoming Line 4 of its Antipolo City cement plant in Rizal. The Manila Times newspaper has reported that the new date on which the contract will conclude is in December 2024.

Aboitiz Construction chief operating officer Ramez Sidhom said "Our recent partnership with Cemex Philippines demonstrates our commitment to execution excellence and affirms our ability to provide reliable maintenance solutions while prioritising safety and quality of work.”

Energy has been the theme for a couple of cement news stories of note from Egypt this week. The first concerns the government’s impending plan to centralise distribution of mazut (heavy fuel oil) to cement plants to help them cope with ongoing power shortages. Earlier in the week Cemex signed a deal with the Assiut Governorate to operate a second municipal solid refuse processing unit in the country. The company’s first Regenera facility, in Mahala, started operations in May 2024. Another story from mid-September 2024, along the same theme, covered the inauguration of an 18MW waste heat recovery (WHR) unit at Heidelberg Materials Egypt's Helwan Cement plant.

The wider story is that the country has faced so-called load shedding, or power rationing, since mid-2023 due to falling gas production, rising energy demand and negative currency exchange effects making it harder to buy fuel imports. The power cuts were extended in duration in July 2024 due to a heat wave. The government then said in late September 2024 that it is making investments to prevent domestic power cuts in 2025.

The cement stories mentioned above show some of the ways cement companies cut their energy costs. Two potential ways of doing this are to increase the use of alternative fuels (AF), such as municipal solid waste, or to install a WHR unit. Titan Cement, for example, reported AF thermal substitution rates of above 40% in Alexandria and above 30% in Beni Suef in the first half of 2024. The local press hasn’t reported power shortages amongst the country’s cement producers, but the plans to control the distribution of mazut suggest that either ‘something’ has happened or the government is trying to avoid ‘something.’ Readers may recall that producers have periodically faced step changes in power supplies over the years. In the mid-2010s, for example, lots of plants switched from heavy fuel oil and gas to coal. The energy price fluctuations following the start of the Russia - Ukraine war in 2022 then saw the price of coal rise.

However, what the foreign-owned producers have complained about in the first half of 2024 is the declining exchange rate of the Egyptian Pound. Cementir, Cemex and Titan Cement all noted this. However, Titan reckoned that International Monetary Fund and European Union investment had actually eased the economic situation in the first half of the year leading to an increase in the number of large construction projects.

One effect of the currency problems upon the cement market has been a focus on exports. At the start of September 2024 the Federation of Egyptian Industries said that national cement consumption in 2024 was expected to drop by 4% year-on-year to 45Mt. However, exports were projected to rise to 15Mt. The first and second most popular destinations so far in 2024 have been the Ivory Coast and Ghana. Yet, exports to Libya, the third biggest external market, may have had the biggest effect. These have been blamed for creating a shortage of trucks that was causing delays to the local construction sector. The round-journey from Egypt to Libya can take up to 12 days. This has left building sites bereft of raw material deliveries because all the trucks are elsewhere! Vicat acknowledged the growing importance of imports for its business in Egypt in its half-year report for 2024. It said that ‘sluggish’ domestic market conditions “were more than offset by growth in cement and clinker volumes for export to the Mediterranean and Africa regions.”

The wider picture of the cement sector in Egypt remains one of overcapacity with integrated capacity estimated above 70Mt/yr. The government introduced cement production quotas in mid-2021 and this stabilised prices (and profits). The recent state of the local economy may have strained this, but the latest round of external investment appears to have buoyed things for now. Although the effects of the Israeli military action in Lebanon may have unforeseen consequences upon neighbouring markets. In the meantime, cutting energy costs and growing exports offer two ways for producers to raise their profits.

India: Union Steel and Heavy Industries Minister Haradanahalli Kumaraswamy has visited the Cement Corporation of India (CCI) plant in Bokajan, Assam, where he emphasised the potential of the facility to benefit local communities. During his visit, Kumaraswamy inaugurated a hot gas utilisation project at the plant's raw mills and laid the foundation for a 1MW grid-connected solar photovoltaic plant, reports the Deccan Herald. He also discussed important local issues, including the need for upgrades at the Bokajan cement factory and pollution control. CCI chair and managing director Sanjay Verma outlined plans to upgrade the plant’s equipment over the next three years and highlighted the employment of local labour as vital for regional economic growth.

India: RHI Magnesita India plans to invest approximately €442m to expand and upgrade its production capacity by the end of the financial year 2025, according to The Hindu newspaper. This follows a €331m investment over the past two years, which increased the company's refractory production capacity in India to over 0.5Mt/yr.

France: Eqiom has awarded Fives FCB a contract to upgrade its cement grinding plant at Héming. The project involves integrating an FCB TSV 4000 TSF Classifier and an FCB TGT Filter with the existing milling circuit at the unit operating by the subsidiary of Ireland-based CRH. The upgrade is intended to reduce the plant’s clinker factor, improve the quality of the cements produced, offer the option of manufacturing cements with higher fineness and reduce energy consumption. The new equipment is expected to be tied-in during the plant’s annual mill shutdown in 2025, with commissioning to follow.

US: GCC Pueblo has upgraded its OK™ 36-4 Cement mill with a new separator from FLSmidth, incorporating the addition of ECS/ProcessExpert's vertical mill application. This upgrades the plant's existing ROKS separator to the latest ROKSH technology.

Austria: Alpacem will invest €50m to modernise its Wietersdorf plant, including a new cement grinding plant, reportedly capable of saving up to 21,000t/yr of CO₂ and reducing electricity consumption, according to the Kronen Zeitung. The plant is scheduled for completion and commissioning in 2027. In the future, a new cement silo plant will also be built in the Görtschitztal valley, directly connected to the railroad.

Florian Salzer, technical director at Alpacem Zement Austria said "With this new project, we are investing in a sustainable future and laying the foundations for energy-efficient and environmentally conscious cement grinding."

Managing director Lutz Weber added "Alpacem has a clear goal: CO₂-neutral production by 2035. To achieve this ambitious goal, we need a package of measures and a concrete path."