Global Cement Newsletter

Issue: GCW336 / 16 August 2018

Headlines


Costa Rica: Mexico’s Cemex has introduced its Cemex Go platform to the Costa Rican market. The new platform will enable customers to place orders, make payments, manage invoices and track deliveries in one place online. The new platform is available for mobile phones, tablets and computers. It has already been launched in nine countries and has over 13,000 users worldwide.


This week’s Plastics Strategy from the European Commission (EC) presents the cement industry with a narrowing target. If the Plastics Strategy is successful it will prevent plastics waste altogether. This will then eliminate the key calorific content of refuse-derived fuels (RDF) and disrupt co-processing supply chains at cement plants across the continent. If it is too lax then dumping plastics in landfill could become more economically viable, also changing the market dynamic. Neither extreme looks likely at this stage but the European cement industry needs to make its views known.

Cembureau, the European cement association, has done just that today with the publication of a position paper on the subject. It conveniently ignores the top two tiers of the waste hierarchy – prevention and re-use – but it does recognise that ‘high quality recycling’ is the preferred option. This is followed by the target of its lobbying: protecting co-processing. Make no mistake, this is supporting industrial behaviour change with solid environmental benefits. Its areas for policymakers to focus on include protecting co-processing: a ban on landfill; linking energy recovery to recycling; concentrating on the legislation; thinking about material lifespan sustainability benefits; and helping minimise the investment costs for processing facilities.

Providing cool heads prevail, the importance of co-processing plastics as part of any realistic plastics strategy seems unlikely to change any time soon. What’s more likely to be the real target for Cembureau is standardising measures on collection, sorting and material recovery across the European Union (EU). For example, as this column has reported twice in 2017 (GCW288 and GCW324), the issues with waste disposal legislation in Italy have led to various problems in the sector. Waste collectors found it easier to export RDF to Morocco from Italy rather than use it locally in 2016. The slag industry has also reported similar issues with reuse in Italy. The consolidation of the local cement industry following the takeover of Italcementi and Cementir by HeidelbergCement and of Cementizillo by Buzzi Unicem should present a more unified industry approach towards alternative fuels. Backup from the EC could solve the other half of the alternative fuels puzzle in Italy and help to deliver serious change. Ecofys data from 2014 showed the EU co-processing average rate as being 41%, with six countries – Ireland, Portugal, Spain, Bulgaria, Italy and Greece – having rates below 30%.

Vagner Maringolo of Cembureau outlined the market opportunities for waste uptake at cement plants at the 11th Global CemFuels Conference that took place in Barcelona in February 2017. He started by revealing that plastics represented over 40% of the total share of alternative fuels used in the EU in 2014. A ban on landfilling municipal waste was expected to boost the supply of RDF and a Cembureau/Ecofys study on the market potential of alternative fuels concluded that around 10Mt of waste was co-processed in cement kilns in the EU28 in 2015. This represented around 2% of total combustible waste each year but it represented 10% of all of the energy recovery from waste in the EU. In other words co-processing plastics waste offers a very attractive means for the EU to meet its sustainability targets.

However, before Cembureau and the cement industry starts popping the (reusable) champagne corks, consider the wider picture. China has banned imports of foreign waste in 2018 including RDF from the UK, a major exporter. Unless new markets are found this may impact the price of RDF in Europe. Brexit is another example how of European waste markets might be disrupted in the medium-term. Cement producers want a steady supply of cheap fuels but if the providers can’t make enough money from their products then the market will fail. The tightrope for Cembureau to walk with plastics is to promote RDF use and secure its supply. Persuading the EC to support this may involve some wobbling along the way.

The 12th Global CemFuels Conference on alternative fuels for cement and lime takes place in Berlin on 20 – 21 February 2018


Belgium: Stefan Borgas, the chief executive officer (CEO) of RHI Magnesita, has started working as the new president of the World Refractories Association (WRA). He succeeds François Wanecq, the former CEO of Vesuvius.

The WRA was founded in 2014 by refractory industry associations and multinational companies. The WRA constitutes a forum to debate regulatory issues affecting global trade, circulate aggregated industry statistics, promote the interests of the worldwide refractory industry, and act as a counterpart to other world industry organizations such as the World Steel Association. The WRA is composed of continental associations including Europe (PRE), Latin America (ALAFAR) and North America (TRI) as well as national associations from China (ACRI), India (IRMA) and Japan (JRA). Multinational companies are also direct members.


India: Binani Cement has received six bids in its sale process. Offers were received from UltraTech Cement, JSW Cement, Ramco Cement, HeidelbergCement India, Dalmia Cements and a pair of Indian investors, according to the Daily News & Analysis newspaper. The bids ranged from around US$630m to US$940m. However, each bid came with various clauses that made the committee of creditors refer them to a consultancy for evaluation.


Colombia: Holcim Colombia plans to launch its new US$30m cement grinding plant in Buga in late 2018 or early 2019. Originally the plant was scheduled to start in the first quarter of 2018. The company also intends to focus on infrastructure projects such as the country’s fourth generation road development scheme, airport renovations and an urban train scheme in Bogota, according to La Republica newspaper.


Belgium: Cembureau, the European cement association, has published a position paper outlining its stance European Commission’s plastics strategy. The association wants policymakers to ensure any plastic waste that has a calorific value that can be recovered as a fuel source is not landfilled. At present there are differences in waste management policies across the member states of the European Union.

Other points that Cemburea wants to highlight include: a ban on landfill of recoverable and recyclable waste; recognition that cement plants can treat different waste streams such as plastics and simultaneously recycle them as material in the manufacturing process of cement and recover them as energy; the specific relevance that co-processing offers the unique opportunity of a simultaneous energy and material recovery; and the potential to minimise investment costs in dedicated facilities.

In January 2018, the European Commission published a dedicated Plastics Strategy as part of the Circular Economy package. The strategy indicates that there is currently a low rate of recycling or reuse of plastics with most of it going to landfill or used in incinerators.


India: Mamata Banerjee, the chief minister of West Bengal, has inaugurated JSW Cement’s plant at Salboni. The US$125m grinding plant has a production capacity of 2.4Mt/yr, according to the Press Trust of India. It started commercial production at the site in July 2017 with plans to manufacture Portland Slag Cement. The cement producer is already preparing upgrades at the unit including a US$15.6m captive power plant with a capacity of 18MW and a US$47m production capacity increase of 1.2Mt/yr.


Netherlands: The Damen shipyard at Oranjewerf in Amsterdam has upgraded the cement carrying capacity of the Lelie C owned by Cebo Marine. Eight new cement silos, with a capacity of 40m3 each, have been installed on the vessel alongside general maintenance.

The silos were previously fitted on the VOS Symphony prior to it going for scrap. Damen Shiprepair Oranjewerf removed the tanks, refurbished them and then installed them on board the Lelie C. The shipyard also built a silo foundation and fitted it in the vessel’s hold. 80m of stiffeners were welded into place in the double bottom tanks to provide the necessary support. Alongside this, approximately 100m² of grating walkway was fabricated and fitted on the deck to give access to the manifolds on each of the new silos. The supply and discharge and air pipe system for the two existing silos was also refurbished to accommodate the new capacity.

“Two years ago we installed the original tanks from the Ritske, a vessel belonging to the same client, and now we have repeated the process again, this time on a much larger scale. The Lelie C began her life as a general cargo vessel, but now her transformation into a cement carrier is complete,” said Jeen van der Werf, Commercial Manager at Damen Shiprepair Oranjewerf.


Kazakhstan: Steppe Cement’s revenue rose by 20% year-on-year to US$65.6m in 2017 from US$54.9m in 2016. Its sales volumes of cement rose by 4% to 1.63Mt from 1.57Mt. The cement producer says that its market share remained at 17% in the reporting period. Overall the country consumed 9Mt of cement in 2017. Steppe Cement’s exports doubled to 146,000t from 73,000t. Kazakhstan imported 0.7Mt of cement in 2017 compared to 0.5Mt in 2016. It exported 0.9Mt in 2017 compared to 0.4Mt in 2016.


Egypt: Arabian Cement plans to increase its exports to Africa and Asia. A senior official said the cement producer is considering international expansion amidst strong competition at home, according to Daily News Egypt. At present the company has exported cement to Libya, Yemen, Kenya, Madagascar and Somalia.

Arabian Cement is a joint venture between Spain’s Grupo Cementos La Unión, the majority shareholder, and a group of local investors. It operates a 5Mt/yr cement plant in Suez governorate.


Oman: Raysut Cement’s revenue fell by 22% year-on-year to US$187m in 2017 from US$240m in 2016. Its profit after tax fell by 66.6% to US$18m from US$53.8m. In November 2017 the cement producer blamed its falling profit on lower sales due to competition locally and in export markets, disruption to its export market in Yemen resulting from the on-going civil war and increased energy prices.


Paraguay: The association of cement distributors in Vallemi has expressed its concern over low production levels at Industria Nacional del Cemento’s (INC) plant. The association says that the cement plant has been unable to guarantee clinker production or dispatches of cement, according to the ABC newspaper. Cement shortages are expected unless normal production is resumed.

The kiln at INC’s plant in Vallemi as reportedly stopped repeatedly since September 2017. It stopped operating on 27 December 2017 and has been waiting for engineers from ABB to carry out repairs. Parts were due to arrive in mid-January 2018. INC has denied reports that cement production and supply have been affected.


UAE: India’s Shree Cement has purchased Union Cement Company (UCC) based in the UAE for US$305m. Its board approved the acquisition of at least a 92.8% share in the company, according to the Press Trust of India. The transaction is expected to be completed by September 2018. Following the deal Shree Cement’s cement production capacity will rise to 33Mt/yr from 29.3Mt/yr. The acquisition is the company’s first outside of India.

UCC was established in 1972. It operates a cement plant Ras Al- Khaimah with a clinker production capacity of 3.3Mt/yr and a cement production capacity of 4Mt/yr.


Philippines: SM Group heir Henry Sy Jr has launched Big Boss Cement with a group of investors. The new cement producer plans to start selling cement in March 2018, according to the Manila Bulletin newspaper. Its first product will be called ‘Big Boss Cement Type 1P.’

It has nearly completed a cement grinding plant that will have a production capacity of 1.5 million bags/yr at Porac in Pampanga. The company hopes to capture 3% of the estimated market demand for cement of 25Mt/yr. Big Boss Cement operates a laboratory in Metropolitan Manila.


Canada: Lafarge Canada, University of Calgary, Queen’s University, and Pembina Institute have started a study on the environmental benefits of introducing lower carbon fuels at the Exshaw Cement Plant in Alberta. Eight lower carbon fuels will be researched, including construction renovation and demolition waste, non-recyclable plastic, carpets and textiles, shingles, treated wood products, wood products, rubber and tyre-derived fuels. These sources of fuel have been successfully used at other LafargeHolcim cement plants in Canada.

“Lab simulations, environmental studies, economics and logistics reviews are already underway. All research will be finalised by December 2019 with regular updates provided to the neighbouring communities via a Public Advisory Committee,” said Jim Bachmann, the plant manager of Exshaw .

Additional research by the partners will measure the environmental components associated with the sourcing, processing and full-scale commercial operation of each lower carbon fuel compared to fossil fuels. The project will also measure the benefits of diverting materials from landfills and determine optimal points in the cement manufacturing process to inject each fuel.

In addition to Lafarge’s support, research funding is being provided by Alberta Innovates, Ontario Centres of Excellence, Emissions Reduction Alberta and the Natural Sciences and Engineering Research Council of Canada. It includes research by Millennium EMS Solutions Ltd., Geocycle, and WSP Global Inc.

As part of its 2030 Sustainability Plan, LafargeHolcim aims to replace 30 - 50% of fossil fuel use at its Canadian cement plants with lower carbon fuels by 2020.


Pakistan: Shahbaz Sharif, the chief minister of Punjb, has approved summary legislation banning the installation of new cement plants in the province on environmental grounds. The summary will be passed to standing committees on legislation for deliberation and recommendations, according to the Nation newspaper. The region has 12 cement plants, of which eight are located in the Salt Range of hills, where local residents have become increasingly intolerant of new industrial plants due to damage to underground water tables and increased air pollution.

The summary will also examine expansion plans by existing cement plants in the province and it has hired a consultancy, Artelia, to study the situation. The Supreme Court of Pakistan also being looking at the issue separately. However, the local cement industry is in an expansion mode as it copes with resident and public sector construction markets and large-scale infrastructure projects driven by the China-Pakistan Economic Corridor initiative.


Switzerland: The IndustriALL Global Union and Building and Wood Workers’ International (BWI) have expressed their dismay at LafargeHolcim’s failure to sign a global framework agreement intended to support industrial relations. The company signed a memorandum of understanding committing to sign the agreement in July 2017. However, the unions’ say that LafargeHolcim backed out of the deal in late December 2017, saying that its current internal arrangements were sufficient.

The unions, together with other international and national partners, have called on LafargeHolcim to sign the agreement, stop poor treatment of sub-contracted and third party workers by the company and to prioritise the health and safety of all of its workers.

“This recent decision to break the agreement on building a social dialogue further damages the credibility of the company. We strongly believe that the shareholders, board of directors and all decision makers in LafargeHolcim must think carefully what the future will hold for LafargeHolcim if this destructive approach prevails,” said Valter Sanches, the General Secretary of IndustriALL.


China: Six workers have been killed at a BBMG cement plant in Zhuolu County in Hebei. They were cleaning a storage unit when concrete slabs fell on them. The workers died later at hospital.


Puerto Rico: Cemex Puerto Rico plans to stop clinker production at its Ponce cement plant. The site will move to grinding cement in January 2018, according to Sin Comillas. The cement producer has been unable to rule out job losses.

The changes come in response to poor cement sales that the company says are the worst in the territory since the 1950s. Cement sales have been falling since 2009 and Hurricanes Irma and Maria punished the market in the autumn with big declines in September and October 2017. At present Cemex Puerto Rico says that the local market only needs around a third of the country’s capacity. However, the Ponce plant has a production capacity of 1.2Mt/yr. The company has also cited high electricity costs as part of its decision.


Costa Rica/Latin America: LafargeHolcim has opened the 1000th store in its Disensa retail network in Latin America. The milestone store opened in Costa Rica in late December 2017. Since expanding its Disensa network beyond Ecuador in April 2017, the company has added around 500 Disensa-branded stores in Argentina, Colombia, Costa Rica, El Salvador, Mexico and Nicaragua. LafargeHolcim plans to continue its network expansion in Latin America by opening its first store in Brazil in early 2018.

“The roll-out of the group’s retail strategy in emerging markets such as Latin America is enabling us to get even closer to consumers,” said Oliver Osswald, Head Region Latin America at LafargeHolcim.

The Disensa network is intended to offer self-builders and smaller contractors access to LafargeHolcim’s own building solutions as well as other construction materials and services, including microcredit and technical help. The concept was developed in Ecuador as a franchise scheme. The group also launched its Binastore brand of retail stores in the Middle East and Africa in mid-2017, opening stores in Algeria, Lebanon, Morocco, Ivory Coast, South Africa and Zambia.


Brazil: The Brazilian cement association SNIC expects an ‘effective’ recovery in cement sales to come in the second half of 2018. The association forecasts sales to grow by 1 – 2% overall in the year, according to the Valor Econômico newspaper. However, it expects a few months of weak demand before the market starts to change. Cement sales volumes fell by 6.4% year-on-year to 53.8Mt in 2016. The market previously peaked at 71Mt in 2014.