Displaying items by tag: Upgrade

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."

Lithuania: Akmenės Cementas has completed a €30m upgrade to its Akmenės cement plant. BNS News has reported that the upgrade will enable the plant to raise its alternative fuels (AF) substitution rate to 90%. The work included the construction of supporting infrastructure, including a storage facility. The Lithuanian Environmental Project Management Agency granted the project €4.3m under its Climate Change Programme.

Akmenės Cementas sold 1.1Mt of cement in 2023, 74% of it on the local Lithuanian market, with the remainder exported to other EU markets.

Italy: Cementir Holding increased its sales volumes of cement by 0.3% year-on-year to 5.13Mt in the first half of 2024. Nonetheless, group sales fell by 3%, to €812m, and earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 4%, to €193m. The producer succeeded in raising its net profit, by 7% to €97m. During the half, it invested €24.7m in decarbonisation, primarily in upgrading the kiln line of its 2.5Mt/yr Guarain cement plant in Belgium.

Chair and CEO Francesco Caltagirone said "Results for the first half of 2024 were in line with our expectations. The adverse weather conditions in the first months of the year and a still weak residential market in the most important geographies, as well as a significant negative exchange rate impact, affected the results for the period, which nevertheless benefited from the reduction of main operating costs".

Cementir Holding confirmed its earnings guidance for the year of €385m (down by 6% year-on-year), but revised its revenues guidance downwards by 6% from €1.8bn to €1.7bn, in line with 2023.

Zimbabwe: Khayah Cement plans to invest approximately US$25m in capital expenditure in 2024, focusing on a kiln refurbishment project at its plant in Harare. The investment aims to increase production capacity and sales volumes, NewsDay Business News has reported. Preparatory work has begun, with completion expected by the end of 2025.

Khayah Cement's CEO, Innocent Chikwata, said that the project will address issues with its current equipment and stabilise the company’s operations by ensuring a reliable supply of raw materials. He noted that the plant's current capacity utilisation rate is 60%, with a target of 70% by the end of 2024.

Congratulations to Taiheiyo Cement Philippines (TCPI) this week for inaugurating its new 3Mt/yr production line at its Cebu plant. The US$220m line replaces the old line at the site that was closed in late 2021.

The plant was originally built by Grand Cement Manufacturing in the early 1990s. Japan-based Taiheiyo Cement took over in 2001 and later made the decision to upgrade the site in 2017. It then contracted China-based Anhui Conch and Sinoma (Handan) Construction for the project in 2021 and groundbreaking took place in mid-2022. Commercial operation of the new line was previously scheduled from May 2024. TCPI has also invested around US$140m in related projects such as its Jetty and Marine Belt Conveyor project, which links the Cebu plant to the coast via a conveyor. Other parts of this expenditure encompass the Luzon Distribution Terminal Project at Calaca in Batangas and general port development in San Fernando.

The Department of Trade and Industry (DTI) was keen to promote this example of a foreign-owned company investing in local manufacturing. DTI Secretary Fred Pascual pointed out that Japan is the country’s “second-largest trading partner and third-largest source of foreign investment.” He also linked the project to the national Build Better More infrastructure development programme and the Tatak Pinoy Act that was introduced in early 2024 to promote local industry. Along these lines, Republic Cement was awarded the Domestic Bidder’s Certificate of Preference this week. It is the first cement company to receive it. The initiative promotes the use of local manufactured materials in government projects as part of the Tatak Pinoy Act. As one might expect, the Cement Manufacturers Association of the Philippines (CEMAP) supports the Tatak Pinoy Act. It voiced its support for the legislation in June 2024 when the DTI started to implement it. It noted that cement imports were just under 7Mt/yr in 2023 despite the anti-dumping duties imposed on a number of Vietnam-based producers and traders. This compares to a local production capacity of nearly 50Mt/yr.

CEMAP mentioned that new production lines from both TCPI and Solid Cement were expected in 2024. The latter project is a new production line being built at Solid Cement’s Antipolo plant near Manilla in Rizal province. Cemex Philippines held a groundbreaking ceremony for the 1.5Mt/yr line at its subsidiary back in 2019. However, Cemex said it was selling its Philippines-based business to DMCI Holdings and related companies in April 2024. As part of this process Cemex sold its local cement brands to the Consunji family, the owners of DMCI Holdings, in June 2024. Regulatory approval of the divestment is still pending but the sale of the brands suggest that the transaction is progressing. Completion is expected by the end of 2024. Operation of the new line at the Antipolo plant is anticipated from September 2024.

Another forthcoming plant project was announced by PHINMA Corporation in June 2024. It signed a joint venture deal with investment company Anflo Group to build a 2Mt/yr cement plant in Davao del Norte. The project is scheduled to be operational by 2026. Cement from the plant will be marketed under the Union Cement brand. The sums involved suggest a grinding plant but PHINMA’s cement division, Philcement Corporation, is involved with both manufacture and importation. PHINMA also signed a deal to buy Petra Cement in May 2024. The latter company runs a 0.5Mt/yr cement grinding plant in Zamboanga del Norte. PHINMA re-entered the cement market in the late 2010s when it bought the Union Cement brand and built a cement processing plant at Mariveles, Bataan in 2020.

The battles between cement producers and importers continue to play out in the Philippines as the country’s infrastructure plans gather pace. Yet the balance seems to be tilting more towards the favour of the local manufacturers at the moment, as new capacity gets proposed and built. Anti-dumping duties on imports, particularly those from Vietnam, have now been followed up with local procurement rules in the guise of the Tatak Pinoy Act. Whether this is enough remains to be seen. This kind of environment and the departure of Cemex may also start to revive questions about whether any other foreign-owned cement companies might be considering their options too.

UK: Aggregate Industries has commenced civil construction at its new manufacturing facility and import terminal at the Port of Tilbury. This new grinding station and storage facility aims to be fully operational by 2026.

The project will allow the company to supply conventional, low-carbon and circular cementitious materials 24 hours a day from five loading heads, meeting growing demands for sustainable building materials. It includes investments in new plant equipment for manufacturing blended cements and lower carbon cement components, such as ground granulated blast furnace slag and materials from construction demolition.

The Hillhead Quarrying, Construction and Recycling Show is in full flow this week, taking place near Buxton in Derbyshire. As one delegate marvelled on the panoramic minibus journey down to the quarry, “It’s like a music festival without the music and… other stuff.” Indeed. Of course what one doesn’t find at Glastonbury and the like is a near comprehensive range of suppliers, over 600 of them, to the industry all in one place… in a quarry! Where else can one get up close and see the new hydrogen-powered generators and excavating vehicles that are being piloted? The official attendance figures don’t get released until after the event but on the ground it looks as busy as ever. It’s truly the place to be this week.

The show gives us a reason to take a look at the UK cement sector. Like many other countries around the world it is an election year in the UK, with a General Election scheduled for 4 July 2024. The result of this should determine the next Prime Minister and the ruling party. So, naturally, the MPA, the trade association for the aggregates, asphalt, cement, concrete, dimension stone, lime, mortar and industrial sand industries, is taking the opportunity to remind the political parties what its priorities are. The quick version is: support for decarbonisation; a streamlined planning system; and better delivery of projects. This sounds familiar to priorities in other countries but one British spin on this includes the UK’s carbon border adjustment mechanism (CBAM).

Graph 1: Domestic cement sales and imports in the UK, 2017 – 2022. Source: MPA.

Edwin Trout’s feature on the UK cement sector in the June 2024 issue of Global Cement Magazine presents a good overview of the last 12 months. The general UK economy has faced shocks in recent years such as Brexit, Covid-19 and the war in Ukraine. However, this has been further compounded by a downturn and high interest rates since late 2022 when the then Prime Minister Liz Truss caused market turbulence in the wake of a badly received government financial statement. As Trout relates, sales of heavy building materials have been in relative decline since mid-2022 with more of the same expected in 2024. Production of cement in 2023 is currently uncertain given the reporting time lag from the MPA but up until 2022 domestic cement sales fell somewhat but imports grew. This has created a situation where overall cement sales in 2022 were 12Mt, not far behind the annual level in the early 2000s. However, the share of imports has nearly doubled since then. More recent MPA data on mortar and ready-mixed concrete sales throughout the first nine months of 2023 suggest that market activity has decreased and poor weather at the start of 2024 looks set to have made this worse.

Despite the apparent slowdown in building materials sales the cement companies have been conducting smaller-scale maintenance and upgrade projects at their facilities and supply chain schemes such as the cement storage unit for deep sea shipping lines that Aggregate Industries said in February 2024 it was going to build at the Port of Southampton. The news the cement companies want to show off has been a steady stream of information about ongoing decarbonisation projects in the cement sector. C-Capture started a carbon capture trial at Heidelberg Materials’ Ketton cement works in Rutland in May 2024, Capsol Technologies said in March 2024 that it had been selected to conduct a study on its carbon capture technology at Aggregate Industries Cauldon cement plant in Staffordshire, Heidelberg Materials' Ribblesdale cement plant in Lancashire announced in March 2024 that it was taking part in a study to assess the use of ammonia as a hydrogen source for fuelling cement kilns and Heidelberg Materials awarded Japan-based Mitsubishi Heavy Industries (MHI) a front end engineering design contract for a carbon capture installation at its Padeswood cement plant in Flintshire in February 2024. Finally, on the divestment front, CRH completed the sale of its UK-based lime business to SigmaRoc for €155m in March 2024. The business operates from sites in Tunstead and Hindlow with five permitted lime kilns.

That’s it for this short recap on the UK for now. For a longer look at the UK cement sector read Edwin Trout’s feature in June 2024 issue of Global Cement Magazine.

Hillhead 2024 runs until 27 June 2024

Germany: Rohrdorfer has started operation of a new photovoltaic (PV) unit at its Rohrdorf cement plant near Rosenheim in Upper Bavaria. The rooftop PV installation comprises 1000 modules, covers around 2000m2 and has a peak output of 400kW. The construction time of the solar panels took five weeks. Modules supplied by Hecker Solar were installed by Elektro Ecker.

The cement plant has produced around one third of its electricity requirements via a waste heat recovery unit since 2011. Rohrdorf Group aims to generate 30% of its electricity from renewable sources as a whole by 2033.

India: Adani Cement is upgrading its facility in Himachal Pradesh by installing a new 7800t/day double-stage cooler grate. This upgrade aims to increase efficiency, lower power consumption and clinker temperature and enhance waste heat recovery system performance, according to the company. The project involves replacing the first and second grates of the existing IKN pendulum cooler.

Zambia: Chilanga Cement has commissioned a US$20m kiln upgrade project, known as the Phoenix Project, at its Ndola plant. This initiative will double the plant's cement production capacity from 500,000t/yr to 1Mt/yr.