Global Cement Newsletter

Issue: GCW338 / 31 January 2018

Headlines


As readers in colder climes will understand: nobody likes a gas bill. Save some pity for LafargeHolcim Bangladesh then this week, as it faces attempts to hike the price it’s paying.

As reported by local press the government-run Jalalabad Gas Transmission and Distribution Systems (JGTDS) is trying to raise the rate for natural gas to the cement producer. Allegedly, LafargeHolcim Bangladesh is paying a lower unit cost for gas supplied to a power plant at its Chhatak cement plant than the fixed amount set by the country’s energy regulator. LafargeHolcim Bangladesh says the rate was set in a gas sales agreement (GSA) signed between JGTDS and its predecessor, Lafarge Surma Cement, in January 2003. The state body meanwhile has referred the issue up the chain of command to the Energy and Mineral Resources Division under the Ministry of Power, Energy and Mineral Resources.

JGTDS says that the plant is consuming around 450,000m3/day of gas. Of this, about a quarter is used to run the power plant and the remainder is used to power the cement plant’s kiln. The plot thickens though as LafargeHolcim Bangladesh is actually paying above the industry tariff for gas of US$0.09/m3. Commentators reckon the price of gas is set to rise in the future. Naturally the cement producer wants to stick to the pre-agreed price for the economic viability of the country’s main integrated cement plant. The Spanish embassy, representing Cementos Molins one of the owners of the company along with LafargeHolcim, has even gone as far as intervening in the argument.

The pressure is on LafargeHolcim Bangladesh because its sales revenue fell slightly year-on-year in 2016 but its fuel costs rose by 12%. As the country’s sole clinker producer it suffered from falling international clinker prices in a nation full of grinding plants. So far in the first nine months of 2017 its sales revenues have risen a little yet its profit has more than halved. Any change to its fuel costs would seem likely to damage the company at a delicate moment.

 

Graph 1: Energy costs and calorific ratio of cement technology in Germany. Source: Presentation given by Jessica Kuhnert, Clausthal University of Technology at Global CemPower Conference 2015.

Energy costs for cement plants are nothing trivial as the graph above shows. It uses data from the German cement industry but the key takeaways are that the calorific ratios of the different types of energy cement production uses don’t directly correlate to the cost. Hence, in Bangladesh and other countries where the electricity grid might be unreliable or expensives, running one’s own captive power plant makes sense both for cost and supply reasons. As an aside that may not be applicable to Bangladesh right now, the stark disparity between the energy produced by alternative fuels and their cost proportion is a great reason to use them if the necessary supply chains can be organised. LafargeHolcim launched local operations for its waste management wing Geocycle in December 2017 so this point has not been lost the company.

The situation in Bangladesh is reminiscent of the bind Dangote Cement found itself in towards the end of 2016 in Tanzania. A dispute over gas prices for its Mtwara plant led to company boss Aliko Dangote negotiating personally with President John Magufuli to protect his investment. Governments want inward spending in the form of new industrial plants and multinationals want assurances on some of their costs, like fuel supplies, before they reach for the chequebook. However, if one side is seen to be getting too good a deal then the relationship can break down. LafargeHolcim Bangladesh may have bagged itself a scandalously low gas deal and the Bangladesh government may also be breaking an agreement. Bear in mind though, that with sales of nearly US$28bn in 2016, LafargeHolcim took in revenue nearly one tenth of Bangladesh’s gross domestic product. If the two parties don’t reach an accord, the consequences for both parties could be negative.


India: Jorge Alejandro Wagner has been appointed as an additional director of Votorantim’s subsidiary Shree Digvijay Cement. Sven Erik Oppelstrupp Madsen has retired as a director following his departure from the role as chief executive officer (CEO) of one of Votorantim’s subsidiaries in Spain

Wagner holds a Master of Sciences in Management (MBA) from Pardue University Indiana in the US and a mechanical engineering degree from the Universidad Nacional de mar del Plata in Argentina. He started working for Votorantim Cimentos in 2002 in Brazil, later becoming the CEO for Spain in 2012. Prior to working for Votorantim he held roles with Esso Sapa, the Argentinean subsidiary of Exxon Mobil, and McKinsey & Company.


Denmark: Virve Elisabeth Meesak has resigned from FLSmidth as its Group Executive Vice President for Human Resources. She had been in post since 2013. She will leave the company by the end of January 2018.


India: The Environment Ministry has approved a US$9.4m opencast limestone mine project by UltraTech Cement in Bhavnagar district, Gujarat. The cement producer has proposed to lease a 632 hectare site with a production capacity of 2.07Mt/yr, according to the Press Trust of India. The mine has total mineral reserves of 63.6Mt with a lifespan of 32 years. Conditions of the approval include relocating 147 families and a group of local farmers.

Limestone from the mine will be used to support a proposed cement plant in Bhavnagar district. It will also be sent to UltraTech’s other plants in the state.


UK: Nine cement and concrete companies have launched the Global Cement & Concrete Association (GCCA), a new association that intends to develop the sector’s role in sustainable construction. The association also wants to build innovation throughout the construction value chain, in collaboration with both industry associations and architects and engineers.

The GCCA will be led by international cement companies and headquartered in London, complementing and supporting the work done by existing associations at national and regional level. Membership of the GCCA is available for cement manufacturers from all over the world that share the organisation’s values, and partnerships will be developed with organisations that share its vision. GCCA’s founding members are Cemex, CNBM, CRH, Dangote, Eurocement, HeidelbergCement, LafargeHolcim, Taiheiyo and Votorantim. They represent 1046Mt of cement production capacity, according to the Global Cement Top 100 Report.


US: Turkey’s Çimsa has launched a new subsidiary in the US at the World of Concrete event in Las Vegas. The company has set up the Cimsa Americas Cement Manufacturing and Sales Corporation to target its products at the US market. It also promoted white cement products at the fair including its Super White, Crafta, Recipro and Resisto brands.


Bangladesh: LafargeHolcim Bangladesh has entered into a dispute with the government-run Jalalabad Gas Transmission and Distribution Systems (JGTDS) over the price of natural gas for a captive power plant at its Chhatak cement plant. JGTDS has argued that the cement producer is paying less than the rate fixed by the country's energy regulator, according to the Financial Express newspaper. However, LafargeHolcim claims that it is paying a tariff set by a gas sales agreement (GSA) signed between JGTDSL and Lafarge Surma Cement in January 2003. The row has been referred to the Energy and Mineral Resources Division (EMRD) of the Ministry of Power, Energy and Mineral Resources for clarification.


Nepal: Cement producers in the Parsa-Bara industrial corridor have started importing clinker from the Narayanpur railway station in Bihar. The change in the supply chain has followed disruption in clinker imports via the Raxaul- Birgunj border crossing on environmental grounds, according to the Kathmandu Post newspaper. The longer route has raised production costs due to higher transport fees.


India: Dalmia Bharat is the frontrunner to buy Kalyanpur Cement following an auction for the Bihar-based cement producer. The bidding process follows a debt resolution plan for Kalyanpur Cement, according to the Economic Times. Dalmia Bharat’s winning bid has been submitted by the creditors to the Kolkata bench of the National Company Law Tribunal for approval.

Kalyanpur Cement owes more than US$94m to its creditors and its was declared bankrupt in May 2017. It operates a 1Mt/yr cement plant at Banjari.


India: A contract worker has been killed in an accident at Ambuja Cement’s Maratha plant in Maharashtra. An apparent electrical problem in a wagon loading machine caused the incident that crushed the 32 year old worker, according to the IndustriAll union. The union says that mechanical problems had been reported previously in the plant’s packing unit. LafargeHolcim, the owner of Ambuja Cement, reported 86 fatalities at its sites in 2016.


Brazil: InterCement is considering listing its European and African operations on a stock market according to sources quoted by Reuters. The move has been discussed with investment banks and could take place in the second half of 2018. InterCement has refused to comment on the story. InterCement’s owner Camargo Corrêa was reported by local media to be looking for buyers for its cement business in 2017 to reduce its debts. Cement sales in Brazil dropped by 6.6% year-on-year to 53.8Mt in 2017.


Ghana: Ghacem has opened a 3000t cement terminal at Sefwi Dwenase in the Sefwi-Wiawso Municipality. The unit is the cement producer’s sixth terminal in the country, according to the Daily Guide newspaper. The subsidiary of Germany’s HeidelbergCement has also purchased new trucks to support the site.


Algeria: Biskria Cement has started the kiln on its second new production line at its plant in Biskra. The 6000t/day line was supplied by China’s Sinoma. The Chinese plant builder announced the US$267m order in 2015. It included two production lines from raw materials to despatch. The cement producer operates three cement production lines at its plant with a production capacity of 4Mt/yr.


Pakistan: Lucky Cement’s profit after tax fell by 2% year-on-year to US$77.6m in the half year to 31 December 2017 from US$79m in the same period in 2016. The cement producer said that its cost of sales had increased by 21% due to rising coal and other fuels prices. Its sales revenue grew by 5.2% to US$297m from US$283m. Its cement production rose by 5.4% to 3.68Mt from 3.49Mt.

The company completed a new 1.25Mt/yr production line at its Karachi cement plant in December 2017. It is currently seeking government approval to build a new 2.3Mt/yr plant in Punjab Province. However due to the delay it is considering expanding its Pezu plant by 2.3Mt/yr instead. The cement producer also expanded its grinding plant in Iraq by 0.87Mt/yr to 1.74Mt/yr.


Pakistan: The Industries, Commerce and Investment department of the Government of Punjab has confirmed that it is banning the construction of new cement plants and the enlargement of existing plants. The decision follows approval by chief minister Shehbaz Sharif, according to the Nation newspaper. It is in response to a number of environmental issues allegedly caused by cement production in the province including damage to water tables and increased air pollution. Final confirmation of the ban came in response to the Supreme Court enforcing a similar ban near the Katas Raj Temples in the state.


Peru: UNACEM’s profit in 2017 rose due to a higher selling price of cement. Its net profit rose by 47% year-on-year to US$143m in 2017 from US$971.1m in 2016. Its income increased by 2.5% to US$595m from US$580m but its cement production fell slightly to 5.01Mt from 5.14Mt. Clinker production and cement despatches also fell. The cement producer blamed poor weather in the first half of 2017 that affected shipping at its Condorcocha plant as well as a general slowdown in the construction sector. It also reported that clinker exports more than doubled in 2017 to 0.55Mt from 0.21Mt.


Austria/Germany/Italy: The European Cement Research Academy (ECRA) has launched its oxyfuel carbon capture pilot projects at HeidelbergCement’s Colleferro plant in Italy and LafargeHolcim’s Retznei plant in Austria. The two locations were chosen form a shortlist of five sites. The pilots will test oxyfuel technology on an industrial scale. The test phase of the research is expected to cost Euro80m and the cement industry has contributed Euro25m towards this. ‘Substantial’ funding from European or national research schemes is being sought.

“The technical feasibility of oxyfuel technology can only be proven in real-scale application, but we have sufficient information from our research to believe that we will obtain a positive result after the trials” said Daniel Gauthier, chairman of ECRA.


Russia: Siberian Cement reduced its cement production by 3% year-on-year to 3.1Mt 2017. Production at its subsidiary Topkinsky Cement fell by 4% to 2.06Mt and at Krasnoyarsk Cement by 10% to 0.65Mt, according the Kommersant newspaper. Production at its Timluysky cement plant rose by 26% to 0.34Mt. Siberian Cement’s vice-president Gennady Rasskazov forecast that demand for its products will remain similar to 2017 in 2018. However, demand is anticipated to fall in some regions of the Siberian Federal District.


Indonesia: Indocement Tunggal Prakarsa, a subsidiary of HeidelbergCement, plans to open a new 1Mt/yr terminal at Palembang in South Sumatra in the first quarter of 2018. The unit is in the final stage of construction and scheduled for commissioning in March 2018, according to Kontan News. The new unit will allow the cement producer to sell bulk cement and it is expected to increase its presence in Sumatra.


Tunisia: Carthage Cement’s turnover fell by 12% year-on-year to US$72.8 in 2017 from US$82.6m in 2016. Clinker production dropped by 17% to 1.3Mt and cement production by 12% to 1.4Mt. Local sales of cement decreased by 2% to US$52.7m and exports by 80% to US$1.9m. The cement producer blamed its poor sales on a decline in the export market.


Bolivia: Empresa Publica Productiva Cementos de Bolivia’s (Ecebol) new plant at Caracollo in Oruro is set to open by the end of 2018. Government minister Eugenio Rojas said that the 1.3Mt/yr plant would start testing in September 2018, according to La Jornada newspaper. The project had a budget of US$244m.


Venezuela: A cement plant at Valencia in Carabobo is only using 25% of its production capacity due to a lack of government investments. The plant was nationalised in 2017, according to the El Carabobeno newspaper. Reportedly it is the only plant out of four in the local area that is still operating.


US: Ed Sullivan, the Portland Cement Association’s (PCA) Senior Vice President and Chief Economist says that economic momentum supported by tax reform and federal infrastructure programs will play key roles in the demand for construction in the next few years. Sullivan made his comments at the World of Concrete event in Las Vegas, where he revealed details from his forthcoming spring forecast.

“There is little doubt that the near-term outlook for construction and cement consumption in 2018 and 2019 remains favourable,” said Sullivan. “Strengthening economic conditions, with the addition of fiscal stimulus, and in the context of already low unemployment could awaken inflationary pressures. Down the road, this could lead to an even more stringent monetary policy, leading to an acceleration in interest rate increases and an eventual cooling of construction markets. If this scenario plays out, it will likely take time to gestate and not materialise to a significant degree until after 2019.”

Sullivan noted the strong economy comes in context of continued strain to find skilled workers, including those needed for construction projects. Weather conditions and other economic factors prompted PCA to revise its 2017 Fall Forecast down slightly, though it says that its ‘fundamental’ assessments pertaining to the economy, construction markets, and cement consumption remain on target.

The PCA Spring Forecast will be released in early March 2018.


Belarus: The Belarusian Cement Company increased its exports of cement by 42.6% year-on-year to 1.4Mt/yr in 2017. The exported cement had a value of US$682.m, according to the Belarusian Telegraph Agency. The company has attributed the rise on an efficiency drive that it says has reduced the cost of production by 50%. The company mainly exports to the Commonwealth of Independent States region but it has started selling its product in parts of the European Union, including Poland and Latvia. It plans to increases its exports by 4% in 2018, partly by introducing 35kg bags.


Ukraine: Cement production rose by 2.3% year-on-year to 9.3Mt in 2017. In 2016 it rose by 7.1% to 9.1Mt, according to the Ukrainian News Agency. Despite the growth in 2017 production fell slightly in December 2017. 15 companies produce cement in the country with a total production capacity of 25Mt/yr.


Spain: LafargeHolcim’s subsidiary Holcim España invested over Euro2m in its cement plant at Jerez during 2017. The work included environmental improvements, changes to the despatch areas and health and safety upgrades such as fire detection systems in its fuels storage zones. The plant also introduced a sulphate-resistant cement product (CEM IV/A (V) 42,5 R/SR) in May 2017 targeted for marine applications.


Italy: Legal firm Eversheds Sutherland has suspended a Euro1.8m fine imposed by the Italian Competition Authority on Calme. Fines were made to a number of Italian cement producers in August 2017, according to the Il Sole 24 Ore newspaper. They were in relation to allegations of price fixing and market share coordination between 2011 and 2016.