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PPC revealed plans this week to build a new cement plant in the Western Cape region of South Africa. It has entered into a “strategic cooperation agreement” with Sinoma Overseas Development Company to put together a 1.5Mt/yr integrated plant for around US$160m. It is hoped that construction will start in the second quarter of 2025 with commissioning scheduled by the end of 2026.

CEO Matías Cardarelli described more details about the project during a tie-in webcast on 16 January 2025. Specifically, the new unit will be built at the company’s integrated Riebeeck Plant site due to the quality of the local limestone and the greater reserves. In addition, all the key environmental approvals and mining rights have already been obtained. Both this plant, and the nearby De Hoek Plant, will continue to run throughout the construction and commissioning period. A decision will then be made about required staffing. PPC did not explicitly say whether the two old plants would be closed but the new plant will “replace and increase the existing capacity” at the other sites.

Points to note from the announcement start with the low cost for the clinker production line. PPC’s 1Mt/yr line at its Slurry plant cost around US$75m when it was commissioned in 2018. Sinoma also built that one. However, negative currency exchange effects make comparisons tricky. In 2015 PPC said that the cost of the Slurry line was around US$115/t. It pointed out that the price was low as it was a brownfield investment. This compares to US$107/t for the Western Cape project, another brownfield project. Other recent integrated plant projects in Sub-Saharan Africa to consider include Cemtech’s clinker plant in Sebit, Kenya (US$170/t) or West International Holding’s forthcoming plant in Buikwe District, Uganda (US$150/t). Plans for a new PPC plant in the Western Cape go back to at least 2017 when the then CEO Johan Claassen said it was preparing for a ‘mega plant.’ At the time it was hoping to replace its Riebeeck plant with a ‘semi-brownfield’ facility that would use around 25% of the current plant’s equipment. The scheme had actually been around longer but Claassen remarked that insufficient domestic demand had held it back.

The next detail to consider is that PPC is planning to build this new plant within 100km of the coast. This was addressed directly with PPC saying that the new plant would be “extremely competitive” against imports. They say it will be able to produce cement, at least, to a similar cost to imports from Vietnam. It was also remarked that only 10 - 15% of the 1Mt/yr of imports, mainly from Vietnam, go to the Western Cape with the rest heading to KwaZulu-Natal via the Port of Durban.

PPC’s plans in Riebeeck are part of its ‘Awaken the Giant’ development strategy. For its six month financial results statement to September 2024 it said that it had “early positive and encouraging signs in all lines of our business.” In South Africa its earnings were up despite lower sales volumes. Dangote Cement’s local subsidiary, Sephaku Holdings, reported a similar picture with a small bump in revenue and earnings back up after coal and fly ash supply constraints a year earlier. PPC isn’t the only cement company developing capacity. Huaxin Cement-owned Natal Portland Cement was reportedly investing US$65m in the autumn of 2024 towards expanding its Simuma Plant in KwaZulu-Natal.

The cement sector in South Africa had a couple of ownership changes in 2024. As mentioned above, China-based Huaxin Cement bought Natal Portland Cement from InterCement at the start of the year. Then, Afrimat received approval to buy Lafarge South Africa in April 2024. Both of these incomers have clear ambitions to expand in the industry. In this context PPC’s decision to finally revive its Western Cape plans, before whatever its new competitors devise, makes sense. Expect more talk of capacity upgrades in the future.

Portugal: CBMI has signed an engineering, procurement and construction contract with SECIL Cement Group for the renovation of the 1800t/day clinker line at the Maceira plant.

The project includes the installation of a new firing system and a series of upgrades to improve energy and heat efficiency. The upgrade encompasses five decarbonisation measures, including a 100% alternative fuel design rate, with the aim to decrease CO₂ emissions by 30% compared to 2019 levels. This would reportedly reduce CO₂ emissions to 550kg/t of clinker.

Spain: Votorantim Cimentos Spain will invest €3.2m in a new clinker cooler at its Málaga plant, according to Alimarket. The upgrade will reportedly reduce thermal and electrical energy consumption and avoid approximately 11,000t/yr of CO₂ emissions. The project will receive a €725,960 subsidy from the regional government of Andalusia.

Iraq: Iraq’s largest cement plant in Kirkuk has resumed operations after a shutdown in November 2024 due to environmental non-compliance and an issued fine of US$343,000. Upgrades include a new dust control system and pollution monitoring equipment. Residents of nearby Lailan have previously protested against the plant, stating that the pollution caused adverse health effects and poisoned local crops, according to Intellinews. Following inspections, the factory now reportedly meets relevant pollutant standards.

Mexico: Cruz Azul has inaugurated a new limestone crusher at its Oaxaca integrated cement plant in Lagunas in Oaxaca state. Construction of a new mill at the site has also started, according to the Herald of Mexico newspaper. It was announced in August 2024 that the new grinding mill has an investment of US$40m and it is scheduled for completion by October 2025. The company is also expanding a local hospital. The projects were presented as part of a ceremony linked to the community’s 493rd anniversary of the apparition of the Virgin of Guadalupe.

Jamaica: Caribbean Cement Company has reached a milestone in its kiln expansion project with the installation of a 160t-capacity surge bin and solid fuel equipment.

The development ensures a stable and increased fuel supply to the kiln during cement production, according to Loop News.

Jorge Martinez, managing director of Caribbean Cement, said “The successful installation marks a significant step forward in enhancing our production capabilities. This investment is a main milestone of the expansion project to be completed in the first half of 2025 with the aim of increasing the efficiency and stability of our operations. It also demonstrates our commitment to meeting the local demand for cement.”

Australia: Boral has launched upgraded ‘carbon-reducing’ technology at its Berrima Cement Works in the Southern Highlands region of New South Wales (NSW). The upgraded facility features a new chlorine bypass, which reduces the build-up of chlorides and other alternative fuel byproducts. This will reportedly enable alternative fuel usage to reach 60% over the next three years at the site, doubling its current substitution rate of 30%.

US: Zanini Renk has received a repeat order from St. Marys Cement for four additional gearboxes at its Charlevoix, Michigan plant. In 2016, St. Marys Cement's Charlevoix plant began a US$130m upgrade to expand the plant's infrastructure. The project scope included adding a new finish mill, an additional kiln and a new coal grinding system. The 2016 upgrade at St. Marys Cement expanded the Charlevoix plant’s cement capacity from 1.4Mt/yr to 2Mt/yr.

The initial order for a Zanini Renk gearbox was for installation in its vertical roller mill. Zanini Renk completed the gearbox installation in 2022. The first new gearbox has been in operation since January 2023 and the other two new gearboxes will be delivered at the end of November 2024. Installation is expected to be completed by March 2025 and by April 2025.

US: Eagle Materials has awarded thyssenkrupp Polysius a contract for the modernisation and expansion of its Laramie, Wyoming cement plant. The modernisation project will result in an expansion of the plant's manufacturing capacity to approximately 1.1Mt/yr of cement. The project also includes the installation of an alternative fuel substitution system. The modernisation of the cement plant is expected to deliver benefits such as cost reductions, achieved with lower-cost alternative fuels and natural gas, simplified maintenance and improved operational efficiencies. The production expansion from the new finish mill will supplement the grinding capacity of the existing plant, which already operates with an integrated polysius booster mill. The polytrack ECO cooler will facilitate heat recovery and clinker cooling while improving process reliability. The project, which has received primary regulatory approvals, is slated to commence immediately [in November 2024], with construction scheduled for completion by the second half of 2026.

Belgium: Holcim has selected the joint venture between BESIX and DENYS as the main contractor for the civil works of the upgrade at its Obour, Mons, plant. The GO4ZERO project will produce nearly 2.3Mt/yr of carbon-neutral cementitious materials by 2029. In a separate contract, BESIX’s subsidiary Franki Foundations is handling the deep foundations. Work began in August 2024 and will conclude in February 2025.