Global Cement Newsletter

Issue: GCW334 / 03 January 2018

Headlines


Just before the Christmas break one of the Global Cement editorial staff noticed how many solar projects have been popping up in the industry news of late. Looking at stories on the Global Cement website tagged with ‘solar’ five occurred in a six month period of 2017 out of a total of 13 since 2014. It’s not a rigorous study by any means but projects in the US, South Korea, India, Namibia and Jordan all suggest a trend.

All these new projects appear to be providing a supplementary energy source from photovoltaic (PV) solar plants that will be used to supply a portion of a cement plant’s electrical power requirements at a subsidised cost. Typically, these initiatives are preparing to supply 20 - 30% of a plant’s electricity over a couple of decades. These schemes are often supported by government subsidies to encourage decarbonised energy sources and a general trend in societies for so-called ‘greener’ energy sources in the wake of the Paris agreement on climate change.

Global Cement is familiar with this model of solar power in the cement industry from its use at the HeidelbergCement Hanson plant at Ketton in the UK. The project was realised by Armstrong Energy through local supplier Lark Energy and it provides around 13% of the cement plant’s electrical energy needs. Originally the array started off by supplying 10MW but this was later increased to 13MW in 2015. A key feature is that as part of the agreement with Armstrong Energy, Hanson receives 35% of the solar power generated for free and buys the remaining 65% at a fixed rate. Even at this rate the plant expects to save around Euro11m in energy costs over the lifetime of the solar array. In addition it will save 3500t/yr of CO2.

Most of the new solar projects announced in 2017 are of a similar scale and ambition to what Hanson Cement has done at Ketton. However, JSW Group’s plans are a magnitude larger. The Indian cement producer wants to build a 200MW solar plant next to its cement grinding plant at Salboni in West Bengal for US$124m. However, it has hedged its bets somewhat by saying that it might build a 36MW thermal power plant instead if its proposal fails.

LafargeHolcim and Italcementi have also experimented with concentrated solar power (CSP) plants for the cement industry. In 2007 LafargeHolcim and the Solar Technology Laboratory of the Paul Scherrer Institute and the Professorship of Renewable Energy Carriers at ETH Zurich started researching using high-temperature solar heat to upgrade low-grade carbonaceous feedstock to produce synthetic gas. The intention was to use the synthetic gas as a substitute for coal and petcoke in kilns.

Italcementi’s project at the Aït Baha plant in Morocco uses a CSP process that can be used with the plant’s waste heat recovery unit. Its moveable trough-style solar collectors follow the sun throughout the day to warm up a heat-transfer fluid during the day and store the heat in gravel beds overnight. In this way the CSP process allows for continuous operation over 24 hours. Before Italcementi’s acquisition by HeidelbergCement in 2016 the company had long-term ambitions to roll-out its CSP process across plants in the Middle East and North African region.

New battery technology of the kind backing the growing electric car industry may be further pushing the cement industry’s preference to PV over CSP power. The other renewable energy source slowly being built to support cement plants has been wind. Like PV it too suffers from cyclical disruptions to its power. Technological entrepreneur Elon Musk (of Tesla car fame) notably supplied the world's largest lithium-ion battery to Southern Australia to support one of its wind farms in late 2017. Around the same time local cement producer Adelaide Bighton announced in a separate deal that it had struck a deal to use wind power to part-power some of its facilities in the same region. At present it doesn’t look like solar power will be completely powering cement plants in the near future but perhaps a renewable fuels rate along similar lines to an alternative fuels rate might be a growing trend to watch.

The Global Cement CemPower conference on electrical power, including waste heat recovery, captive power, grinding optimisation and electrical energy efficiency, will return in January 2019.


Malaysia: Isaac Lugun and Goh Chii Bing have taken their new roles at Cahya Mata Sarawak (CMS) as Group Chief Executive Officer – Corporate and Group Chief Executive Officer – Operations respectively. They replace Richard Curtis who retired as Group Managing Director at the end of December 2017. Curtis will remain at the cement producer as a Non-Executive Director until the end of 2018.


US: Kent Webber has started his new role as president for Monarch Cement. He was appointed to the role in December 2017 following the resignation of Walter H Wulf, according to the Wichita Business Journal. Webber has worked for Monarch Cement since 2013, first as its subsidiary operations manager and then its executive vice president. Wulf will continue in his role as chairman of the board and as a director.


France: Patrick Debavelaere has been appointed as the director of LafargeHoclim’s Val d'Azergues cement plant near Lyon. He suceeds Thomas de Charrette who has been in post for six years, according to Le Pays Roannais newspaper. Debavelaere, aged 43 years, had been working as an industrial director for Lafarge France’s aggregate business. Prior to this he was the production manager at the Martres cement plant.


Ireland: Ernst Bärtschi has retired from the board of CRH. He was appointed to the board of directors in 2011. A Swiss national he was previously the chief executive officer of Sika and had worked for Schindler Group.


Denmark: FLSmidth has appointed Jan Kjaersgaard as a new Group Executive Vice President, Product Companies Division, and a member of Group Executive Management. Kjaersgaard, aged 51 years and a Danish citizen, will take up the position as head of Product Companies Division on 1 March 2018.

Kjaersgaard holds a Master of Business Administration from Aalborg University and comes from Bladt Industries where he currently serves as chief executive officer (CEO). His previous postings include various senior positions at Siemens Wind Power.


US: Ametek Brookfield has appointed Joseph Plante as Division Vice President and Business Unit Manager. He will have responsibility for managing the day-to-day operations while continuing to promote growth, customer satisfaction and innovation at Ametek Brookfield.

Plante holds a Bachelor of Science in Electrical Engineering from UMass Amherst, a Master of Science in Biomedical Engineering from Worcester Polytechnic Institute, and a Master of Business Administration from Babson College. Most recently, he was president of Diba Industries, a subsidiary of Halma.

Ametek Brookfield manufactures tools for viscosity measurement and control of liquids and semi-solids.


Germany: Wieland Hopfe has left Fritsch Milling and Sizing after 25 years with the company. He originally joined Fritsch in 1992 and helped the firm establish its distribution network in the former East Germany. Most recently he was working as an application specialist for Fritsch. The company is a manufacturer of application-oriented laboratory instruments for sample preparation and particle sizing.


Italy: HeidelbergCement’s subsidiary Italcementi has completed its acquisition of Cementir Italia following approval by the Italian competition authority. The competition body gave clearance to the acquisition in November 2017 subject to certain conditions, including the divestment of some plants. Italcementi will reveal which units it intends to sell by mid-2018. The acquisition cost Euro315m.

“For Italcementi, the acquisition is a unique opportunity to grow and consolidate its position in the Italian market. We see strong recovery potential in Southern Europe and especially in Italy over the coming years. With this acquisition we are very well positioned to create value through synergies, efficient processes, and the offer of high-quality and innovative products,” said Bernd Scheifele, Chairman of the Managing Board of HeidelbergCement.

Italcementi and Cementir Holding entered into an agreement to buy Cementir Italia, and its subsidies Cementir Sacci and Betontir, in mid-September 2017. Cementir Italia’s business includes five integrated cement plants and two cement grinding units with a total cement capacity of 5.5Mt/yr, as well as a network of terminals and concrete plants, all operating in Italy. Minimum annual run-rate cost synergies of Euro25m are expected to be achieved by 2020.


US: HeidelbergCement expects its profit to be negatively effected in 2017 following reforms to the US tax system. Following a change in the rules from 22 December 2017 the federal corporate tax rate has been reduced from 35% to 21% from the start of 2018. In addition, the regulations regarding the utilization of loss carryforwards were changed. This has affected deferred tax assets on losses and interest carried-forwards that are expected to reduce the group’s balance sheet by Euro200m in its annual report.

However, the company still expects a ‘significant’ increase of 2017 group share of profit before one-time effects. In addition in 2019 the major reduction of the effective tax rate in the US is anticipated to have a positive effect on group net profit and cashflow.


Namibia/China: Sinoma Energy Conservation has signed a contract with China’s Asia-Africa Business Management (AABM) to build a 4.5MW waste heat power plant. The power unit will support a 2500t/day cement production plant that AABM and local company Whale Rock Cement plan to build as a joint venture. The cement plant project was first announced in 2015.


Nepal: Production at 13 cement grinding plants have been distrupted by a restriction on Indian clinker imports at Birgunj. Imports at the border town stopped on 22 December 2017 following complaints by local residents about air pollution, according to the Kathmandu Post. Cement plants in the so-called Parsa-Bara industrial corridor have resorted to using inventory supplies or clinker sourced from alternative locations.


India: The Maharashtra Pollution Control Board has complained about a terminal operated by UltraTech Cement at Peth Naygaon near Pune. Local residents petitioned the pollution board with claims that the trucks to the unit have been carrying raw and packaged cement without any cover, according to the Pune Mirrow newspaper. Following a study the pollution board then made an official complaint under the Air (Prevention and Control of Pollution) Act 1981 and the Environment (Protection) Act 1986. Local police are investigating the matter.


Slovenia: LafargeHolcim has lost a legal battle for an environmental permit at its Trbovlje cement plant. The cement producer appealed against a decision by the Environment Agency to decline to issue its consent to the company in May 2016, according to the Slovenian Press Agency. The company has been attempting to increase its cement production capacity to 1250t/day by using petcoke as a fuel.


Cambodia: Chip Mong Insee Cement has started production at its new plant in the Tuok Meas district in Kampot province. The unit had a soft launch with a visit from Suy Sem, the minister of mines and energy, according to the Phnom Penh Post newspaper. The US$262m plant will have a cement production capacity of 2Mt/yr when it is fully operational.


Nepal: Investment Board Nepal (IBN) and Huaxin Cement have signed a Project Investment Agreement (PIA) for the Chinese company to build a cement plant. The agreement follows the Department of Mines and Geology’s decision to award a limestone mine in Dhading district to the Chinese cement producer, according to the Xinhua news agency. Huaxin Cement plans to spend US$140m towards building a plant with a cement production capacity of 3000t/day. The deal follows an agreement between the IBN and Hongshi Cement finalised in September 2017 to build a new plant for around US$360m.


Nepal: The Department of Mines and Geology has technically disqualified Nigeria’s Dangote Cement from applying for three limestone mine licences in an open bidding process. The Investment Board Nepal (IBN) had approved the investment in 2013 before passing the application to the mining department, according to the Republica newspaper. Department deputy director general Ram Prasad Ghimire claimed that Dangote's proposals lacked essential documents on the required skilled manpower and it was not considered qualified for the next financial proposal.

Dangote Cement had applied for three mines: two in Dhading and one in Palpa. However, China’s Huaxin and United Cements recently won two limestone mining licences. Previously, Dangote Cement purchased a limestone mine in Makawanpur that was later found to be a substandard. The Nigerian company has also faced opposition from local producers who have described the country as being self-sufficient in cement.


China: China Resources Cement has started a production line at a subsidiary in Hepu County in the Guangxi Zhuang Autonomous Region. The new line has a clinker production capacity of 1.6Mt/yr and a cement production capacity of 2Mt/yr. At present the company has a clinker and cement production capacity of 26.6Mt/yr and 33.2Mt/yr respectively in the region.


Egypt: Khaled Fahmy, the Minister of Environment, has recognised the work by subsidiaries of Suez Cement to reduce air pollution and so called ‘black cloud’ periods. The minister presented certificates of appreciation to the manager of Helwan cement plant, Ahmad Ragae, the manager of Tourah cement plant, Omar Khorshid, the manager of the Environment Department at Helwan cement plant, Ragheb Hammouda and the manager of Environment Department at the Tourah cement plant, Badry Ibrahim.


Canada/France: Pension investment management companies La Caisse de dépôt et placement du Québec (CDPQ) and the Public Sector Pension Investment Board (PSP Investments) have each purchased a minority stake in France’s Fives. CDPQ and PSP Investments will each acquire a ‘significant’ minority stake in Fives, which will remain controlled by its management, to support its next development phase. Ardian, an investment house, will continue to be part of the new shareholding structure, as a minority co-investor. The completion of the transaction remains subject to approval by relevant regulatory authorities. No value for the deal has been disclosed.

“We are very enthusiastic to enter a new phase of our development with CDPQ and PSP Investments. Their long-term approach to investment, their deep valuable industrial insights and their strategic vision aligned with that of the management team make them ideal partners for the group, allowing Fives to take advantage, at a global scale, of the full potential of our diversified operations,” said Frédéric Sanchez, chief executive officer (CEO) of Fives Group.

Founded in 1812, engineering company Fives designs and supplies machines, process equipment and production lines for industries including cement, minerals, aluminium, steel, glass, automotive, aerospace, logistics, energy and sugar. The group is located in over 30 countries and it has nearly 8400 employees.


Poland: BWF Envirotec Group has purchased Orwat Filtertechnik. Based in Mysłowice, Silesia, the company has been producing and distributing filter bags and filter pockets for dedusting and flue gas cleaning technology as well as pockets, cartridges and compact filters for air conditioning and ventilation technology since 1995. The company also has a sales office in Warendorf, North Rhine-Westphalia in Germany giving it a European presence. No value for the acquisition has been disclosed.

"Orwat Filtertechnik, with its technologically outstanding equipment, is an excellent addition to our line-up with a high level of benefit for our customers, particularly for plant builders and operators of flue gas cleaning systems,” said Stefan Offermann and Philipp von Waldenfels, managing partners of BWF Group. They added that the acquisition also strengthens its Offingen-based headquarters.