Global Cement Newsletter

Issue: GCW340 / 14 February 2018

Headlines


Lhoist’s Jean Marbehant pretty much summed up the bind the cement and lime industries face from the tightening COP21 climate agreement when he said, “We produce CO2… and our by-product is lime.” He made the comment at a ground breaking event that HeidelbergCement hosted this week for a new carbon capture pilot project at the CBR Lixhe cement plant in Belgium. The project with the Low Emissions Intensity Lime And Cement (LEILAC) Consortium will test Australian company Calix’s direct CO2 separation process at an operational cement plant for two years at a pilot level scale.

Previously the technology has been used by Calix in the magnesite calcining sector in Australia. Now it will be trialled at 10t/hr of raw material for cement production and 8t/hr of ground limestone in a 60m tall direct separation reactor that is about to be built next to the cement plant’s pre-heater tower. The process has a target to capture up to 95% of process CO2 emissions. Construction is scheduled to be completed in 2018 and then followed by two years of operation and testing until the end of 2020. At this point the Euro12m funding ends but the next steps, if agreed, would be to test the process at a commercial scale for lime production and a large scale demonstration at a cement plant by 2025. Full scale commercial application at a cement plant would then happen by 2030.

The Innovation in Industrial Carbon Capture Conference was built around the various carbon capture initiatives that HeidelbergCement is involved with. The other big pilot is the oxyfuel project it is running with LafargeHolcim and the European Cement Research Academy (ECRA). As ECRA’s Volker Hoenig explained, this project is now set to move to the pilot scale at two cement plants in 2020 at a cost of Euro90m. The plants, in Italy and Austria, have been chosen so that the testing can start at a ‘simple’ plant and then move to a more complicated one. The former site, Colleferro, has a spare unused kiln that doesn’t use alternative fuels, making the testing less complicated. The latter, Retznei, does co-process alternative fuels and it also has a kiln bypass system. It’s also worth noting that Calix’s direct separation process is intended to be compatible with an oxyfuel kiln. Other technologies were also previewed at the conference such as the Cleanker calcium looping project, the CO2MIN mineral carbonation project, the Carbon8 process to make aggregates from flue gas and HeidelbergCement’s experiences with growing microalgae.

The event to mark the start of the pilot was an optimistic one but the cement and lime producers like Jean Marbehant have no illusions about the cliff face-steep challenge that meeting the CO2 emissions reduction targets the Paris agreement potentially demands. One slide Marbehant discussed in his presentation placed the CO2 marginal abatement cost for carbon capture at Euro90/t. However, since the European Union (EU) Emissions Trading Scheme (ETS) currently places the cost of CO2 at Euro9/t the real question about the future of carbon capture is about who is going to pay the bill. Albert Scheuer, a board member of HeidelbergCement, made it clear how his company thinks the cost should be divided when he said that its end product was concrete and he explained just how much cement and concrete everyone uses in their lifespan. He may not have said that we all need to pay but he certainly made it feel that way. The future of carbon capture it seems may be a bit like a group of friends awkwardly deciding how to split the bill after a meal.

One speaker at the LEILAC event used the phrase ‘no silver bullet’ to describe how industrial CO2 emissions could be cut and how Carbon Capture and Storage (CCS) might be used. Perhaps more tellingly though has been the emergence of a new acronym that seems to be doing the rounds at the European Parliament, of ‘Carbon Capture and Something.’ That ‘something’ here is of critical importance as it can either put up or decrease the price that CCS will add to cement production. So, whilst moving to Carbon Capture and Something might suggest that legislators are starting to get realistic about what carbon capture might actually be able to do, it might also indicate a naïve lack of understanding of how hard cutting CO2 emissions is from essential industries that produce CO2 from their core process.

The challenge for cement producers in this kind of environment is deciding how far they should go towards exploring CO2 reduction strategies whilst governments are not being precise about how they intend to meet their targets. Going first might bring an innovator advantages if the legislation toughens up, but the early cost is high. HeidelbergCement and others are definitely doing ‘something’ but commercial applications are at least a decade away at current funding levels. And that timescale doesn’t include rolling out the new technologies across the entire industry. Despite this it was reassuring to hear the director of the European Commission’s Directorate-General for Climate Action say that his outfit didn’t want to reduce cement production, only CO2 emissions. This was ‘something’ cement producers want to hear.


US: Plibrico, a single-source supplier of refractory products and solutions, has appointed Pamela Gaul as its director of marketing. She will be responsible for directing all activities related to the strategic development and implementation of marketing initiatives for the organisation.

Gaul previously worked for RR Donnelley (RRD), where she served as a Senior Director of Marketing and Business Development. Much of her career has been spent with the marketing services division of RRD, where she held various marketing positions of increasing responsibility. Prior to RRD she held marketing positions with Riso and Canon Solutions America.


Morocco: LafargeHolcim has appointed George Michos as its new head of its Moroccan subsidiary. He succeeds Marcel Cobus, who moves to the LafargeHolcim executive committee in charge of the Europe region, according to Morocco World News. Previously Michos worked as the managing director of LafargeHolcim’s Heracles General Cement subsidiary in Greece.


Australia: Adelaide Brighton has announced the appointment of Vanessa Guthrie and Geoff Tarrant to the Adelaide Brighton Board as non-executive Directors, effective 8 February 2018. Company Chairman Les Hosking said that the appointments of Dr Guthrie and Mr Tarrant were part of Adelaide Brighton's Board renewal process.

Dr Guthrie has qualifications in geology, environment, law and business management, including a Doctor of Philosophy in Geology. She has more than 30 years' experience in the mining and resources industry across a variety of roles including operations, environment, community, indigenous affairs, corporate development and sustainability. She was previously CEO and Managing Director of Toro Energy Limited and Vice President Sustainable Development at Woodside Energy. Dr Guthrie is currently Chair of the Minerals Council of Australia and a non-executive Director of Santos Limited, Vimy Resources Limited and the Australian Broadcasting Corporation.
Mr Tarrant has a Bachelor of Business and is a finance executive with over 25 years' experience gained in Australia, the UK and Asia. He is currently engaged in a corporate finance consultancy role with Deutsche Bank, where he has held a number of senior roles since 2002, primarily in mergers and acquisitions and capital markets. Prior to this he held finance roles with Citigroup, National Australia Bank and Price Waterhouse.


Kenya: Bamburi Cement has announced the appointment of Seddiq Hassani as the new managing director of the company. Hassani will replace Eric Kironde who has been acting Managing Director and Finance Director for the past four months. Hassani joins Bamburi Cement from LafargeHolcim’s Middle East and Africa Region where he was the Head of Growth and Innovation since September 2015, based in Paris, France.

“We are confident that with his strong and wide experience in operational and functional positions, more specifically, in leading transformation and managing growth strategies at both country and international level, he will support the continued growth of the business to achieve its mid- and long-term strategic goals,” said the company board in a statement.

The board also announced the appointment of Nicolas George as a Board Director of Bamburi Cement Limited and Managing Director of Hima Cement Ltd, Uganda.

The cement maker plans to increase its production capacity from 2.3Mt/yr to 3.3Mt/yr in order to meet market demand in 2018, the first phase of its capacity expansion projects in both Kenya and Uganda. The US$38.5m expansion began in January 2017 with a new mill at its Athi River plant.


Colombia: Cementos Argos has reported a net loss of US$23.4m in the fourth quarter of 2017 due to lower prices and higher costs, primarily due to economic deceleration in Colombia. The net loss was a contrast to the US$21.6m profit made in the same period of 2016. Earnings before interest, tax, depreciation and amortisation (EBITDA) fell by 8.9% to US$126.7m during the quarter.

"The fall in income and EBITDA of Cementos Argos is best explained by the price of cement in Colombia, which reached its lowest level in the second quarter of the year," said the company in a statement. Imports from countries that subsidise industrial energy costs and exchange rate changes led to the fall in prices.

For the whole of 2017 Cementos Argos’ net profit slumped by 86.3% to US$27.0m, compared to US$196.9m during 2016. EBITDA for the full year 2017 was down by 15% to US$497.0m.


Australia: Boral Ltd has announced that its profit for the first half of the 2017-2018 fiscal year (from 1 July 2017 – 31 December 2017) rose by 13%. The company benefited from the 2017 acquisition of the US-based building products firm Headwaters Inc. and continued growth in its Australian business.

It reported a net profit of US$136.0m for the six month period, a rise of 12.7% compared to the same period of the 2016 – 2017 fiscal year when it made US$120.7m. Its profit before amortisation and significant items increased by 58% to US$$186.5m.

"These strong results confirm that our transformation strategy is on track," said Chief Executive Mike Kane. "The Headwaters acquisition has helped transform Boral into a construction materials and building products group with a greater geographic reach and improved prospects for growth."

Boral’s US business, which was only breaking even in 2015 – 2016, recorded a fourfold rise in earnings, despite adverse impacts from bad weather, including two hurricanes.

Kane also said Boral’s Australian arm, its largest divison, was ‘exceptionally strong’ during the half. Boral reported a 12% rise in earnings before interest, tax, depreciation and amortisation from that business.

"Higher revenues and earnings were driven by increased spending on infrastructure, in line with our expectations that a large proportion of our work would gradually shift from residential to infrastructure projects, primarily in the eastern states," said Kane.


India: IDBI Bank has decided to withdraw the nomination of S K Mohapatra from the board of debt-ridden Jaiprakash Associates. In a BSE filing, crisis-hit Jaiprakash Associates informed that Subrat Kumar Mohapatra, the chief general manager of IDBI Bank, has resigned from the board. IDBI Bank has decided to withdraw the nomination of Subrat Kumar Mohapatra from the board of directors of the company with immediate effect, the filing said. Mohapatra thus ceased to be director of the company with effect from 13 February 2018.

Jaiprakash Associates, the flagship firm of the Jaypee Group, has interests in cement, construction, hospitality, power and real estate businesses. The company has divested a number of its assets, including cement plants, to reduce debt.


Peru: Cementos Pacasmayso has announced its financial results for the fourth quarter of and the full year 2017.

In the fourth quarter of 2017, sales volumes of cement, concrete and blocks increased by 7.3%, primarily due to increased sales volumes to the self-construction segment and to a pick up in public sector spending. The company’s cement-based earnings before interest, tax, depreciation and amortisation (EBITDA) increased by 13.9% to US$32.3m, but consolidated EBITDA decreased by 35.7% due to a write-off in a water-desalination project.

For the full year, sales of cement, concrete and blocks decreased by 0.8%, despite the significant decline in sales volume during the first four months of the year due to the effects of the El Niño. It is important to note that year-on-year sales volume has increased steadily every month, from May 2017 through to the end of the year. Cement EBITDA for the year reached US$114.9m, a decrease of only 2.2%, despite the aforementioned detrimental El Niño effects on both sales and costs.


France: The French cement industry union (SFIC), plus three other professional organisations, has announced that has committed to increase the amount of wood waste used in France’s cement plants. It has committed to increasing the amount used by 90% compared to 2015 by 2020.

90,000t of wood were used as fuel in cement production in 2015. The goal is to use 170,000t in 2020. Four cement plants will act as pilot sites. The wood used must be from the same region as the plant burning it. According to the SFIC, alternative fuels account for 41% of cement fuels used in France.


Paraguay: Industria Nacional del Cemento (INC) expects to begin March 2018 with a 30% production rise, following the opening of a new mill, according to its president Jorge Mendez. Production will increase to 1.4 million bags per month, from 1.1 million bags per month at present. Its market share will increase to 70%-75%, from 51% at present. This is anticipated to add an extra US$50m to the company’s turnover. The new mill is currently 90% complete and has cost the company US$11.5m.


UAE: Fujairah Cement Industries Co (FCIC) has reported a decline of 9% in its profits for the fourth quarter of 2017 compared to the same period a year ago. Earnings decreased to about US$2.7m in the fourth quarter of 2017 from US$3.0m in the fourth quarter of 2016.

During the 2017 fiscal year, the cement producer posted a drop of 35% in its profit to US$10.1m compared to US$15.4m in 2015. This was in part due to a 7% decrease in revenue and higher general and administrative expenses, which rose by 29% to US$6.4m.


Italy: The Board of Directors of Buzzi has approved the preliminary accounts for 2017, which see sales of cement at 26.8Mt, an increase of 4.4%, and consolidated revenues of Euro2.67bn, an increase of 5.1% year-on-year.

In Italy, Buzzi’s position benefited from the takeover of Zillo Group, which helped to raise clinker and cement volumes by 19.3%. However, average selling prices were down ‘siginificantly’ year-on-year. Overall consolidated sales were up by 14.0% year-on-year at Euro428m. Consolidated sales would have increased by 2% in the absence of the Zillo acquisition.

In Germany, cement sales were up by 4.5%, with total sales of Euro588m, a 2.7% year-on-year rise. In Luxembourg and the Netherlands, cement sales were also up by 4.5% year-on-year at Euro187m.

Sales were also improved in Poland (+0.7%), Czechia (+8.2%), Russia (+1.5%), the USA (+0.2%) and Mexico (12.7%), while they declined in Ukraine (-1.5%).


UAE: National Cement Company (NCC) has reported a decline in its profit to US$14.59m in the full year 2017 from US$24.24m in 2016. Revenues also fell to US$55.77m from US$64.11m.


Brazil: According to data from Brazil's national cement industry union SNIC, domestic cement sales in January 2018 were down by 0.1% compared to January 2017, at 4.33Mt. However, average sales per working day increased by 0.2% in the same comparison. Apparent consumption in the period stood at 4.4Mt, down by 0.5% from January 2017. The results for the period were in line with SNIC's expectations, with sales forecast to drop in the first quarter 2018, before seeing growth in the second quarter 2018.

In the 12 months ending January 2018 domestic sales saw an accumulated 6.2% drop, in comparison with the previous 12 month period, at 53.77Mt. SNIC forecasts a 1-2% increase in cement sales in 2018.


US: Eagle Materials has reported its financial results for the third quarter of the 2018 fiscal year, which ended on 31 December 2017. It recorded record revenues of US$359.4m, a rise of 19% compared to the same period of the 2017 fiscal year

Third quarter gross profit improved by 8%, reflecting the financial results of the recently acquired cement plant in Fairborn, Ohio and related assets (the Fairborn Business) and improved net sales prices across most of Eagle’s businesses. Cement, Concrete and Aggregates Cement revenues for the third quarter, including joint venture and intersegment revenues, totalled US$161.6m, 17% higher than the same quarter last year. Total cement sales volumes for the quarter were 1.3Mt, 12% greater than the same quarter a year earlier. Like-for-like average net cement sales prices increased by 4% and sales volumes declined by 2%, respectively, versus the third quarter of fiscal 2017. This comparison excludes cement sales from the Fairborn Business since its acquisition date.

Operating earnings from cement activities for the third quarter of the 2018 fiscal year were a record US$52.5m and were 16% greater than the same quarter a year ago. The earnings improvement was driven primarily by earnings from the Fairborn Business and improved average net cement sales prices offset by lower sales volumes from Eagle’s legacy facilities.


India: Birla Corporation has declared its results for the quarter and nine months that ended on 31 December 2017. The consolidated results include the financials of Reliance Cement Company Private Limited (RCCPL), a wholly-owned material subsidiary of the Company.

The corporation made 3.06Mt in the third quarter, a 22% rise compared to the same period of 2016-2017. In the nine months to 31 December 2017 it produced 9.1Mt of cement, a 11.9% increase year-on-year. It despatched 3.04Mt of cement compared to 2.49Mt in the quarter and 8.98Mt in the nine month period, a 12% rise year-on-year.

In financial terms it took in US$215m in gross sales during the quarter, a 12.7% rise year-on-year. In the nine month period it took in US$667m, a 27.8% rise. Earnings before interest, tax, depreciation and amortisation (EBITDA) for the three months were US$23.6m and for the nine months they were US$93.0m.


Mexico: Cemex’s operating earnings have fallen in 2017 due to a lower contribution from the US and South America despite growth in Mexico and Europe. Its operating earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 7% year-on-year to US$2.57bn in 2017 from US$2.75bn in 2016. Its net sales grew by 2% to US$13.7bn from US$13.4bn and its cement sales volumes remained stable at 68.5Mt. The cement producer also reported an unexpected loss in net income of US$105m in the fourth quarter of the year, which it blamed on taxes on other costs.

“Although 2017 was a challenging year… We had important headwinds during the year: underperformance in Colombia, Egypt and the Philippines as well as increased energy costs, mainly in Mexico. As we have done in the past, we focused on the variables we control to dampen these headwinds and we continued to deliver solid results,” said Fernando A Gonzalez, Chief Executive Officer (CEO) of Cemex.


Kenya: President Uhuru Kenyatta has inaugurated National Cement’s US$280m integrated plant in Kajiado County. The clinker plant has a production capacity of 1.2Mt/yr and it set to employ 700 workers, according to the Agence de Presse Africaine. The plant also includes a 15MW captive power plant.


Cambodia: Chip Mong Insee Cement has launched its new plant in Kampot province. Prime Minister Hun Sen in the Banteay Meas district of Kampot attended the event, according to the Phnom Penh Post. The US$262m plant has a cement production capacity of 5000/day or nearly 2Mt/yr. The plant is a joint venture between Chip Mong Group, which owns 60% of the shares, and Thailand’s Siam City Cement. The project is intended to meet growing demand for cement in the country.


US: Two LafargeHolcim US cement plants have been awarded the Environmental Protection Agency’s (EPA) Energy Star award. The EPA recognised the Holly Hill plant in South Carolina and the Devil’s Slide plant in Morgan, Utah.

“Receiving the Energy Star award this year at two sites is an affirmation of the hard work all our employees are devoting every day to meeting our environmental goals,” said John Stull, chief executive officer (CEO), US Cement.

This recognition is the eighth time the EPA has awarded both the Holly Hill and Devil’s Slide plants with the Energy Star award since 2009.


Belgium: HeidelbergCement has hosted a ground breaking ceremony for the Calix carbon capture pilot at CBR’s cement plant at Lixhe. The ceremony itself took place at the Liège Oupeye Water Treatment Plant near Liège as part of the inaugural Innovation in Industrial Carbon Capture Conference. The two-day event, which took place on 7 – 8 February 2018, was organised by the Low Emissions Intensity Lime And Cement (LEILAC) Consortium, a European Union (EU) Horizon 2020 backed research and innovation project.

Construction work on the pilot at the cement plant is scheduled to start imminently. The project will test Calix’s carbon capture technology for two years at an operational cement plant. The technology has previously been used in the magnesite calcining sector.

Over 130 delegates from industry, academia and government attended the conference. The agenda was designed to encourage discussion and knowledge sharing across key stakeholder groups with a strategic interest in innovation in carbon capture technology. As part of the programme, the wider challenges faced by the cement and lime sectors in Europe were also explored focusing on how EU industries can contribute to reaching climate change targets, the role of innovation and company entrepreneurship and a knowledge exchange fair on technology.

The LEILAC consortium, which consists of representatives from the lime and cement industries, technology and engineering providers and research institutes, has set up as an industrial project securing Euro12m in EU funding in order to demonstrate technology to reduce carbon emissions from cement and lime industries.


Ukraine: The share of counterfeit products on the cement market in Ukraine dropped to 8.0% in 2017 from a staggering 21.5% in 2014, according to a press release from the Ukrcement association of cement producers, with reference to a study by GfK Ukraine. Ukrcement believes that change was prompted by the signing of a memorandum on the quality of cement between Ukrcement, the Union of Consumers and large distributors of construction materials in 2017.


France: Access to the Calcia cement factory in Calvados was ‘blocked’ on Wednesday 7 February 2018 by protestors from the General Confederation of Labour (CGT). They were protesting the salary policy of the company, as well as job cuts taking place across France. The move followed the collapse of annual pay talks between the HeidelbergCement subsidiary and the CGT.

Bertrand Moreau from the CGT said that the unilateral 1.3% pay increase offer from Calcia was not sufficient and that workers had witnessed ‘deteriorating working conditions’ since HeidelbergCement took over the company in 2016. He also expressed disappointment at plans to cut 22 jobs at Calcia’s Cruas plant in the Ardeche. The company employs around 1300 people across 10 sites in France.


Denmark: Cement plant manufacturer FLSmidth has announced its financial results for 2017, which show, overall, its strongest order intake for four years. Total orders grew by 6% year-on-year in 2017, bolstered primarily by the company’s Minerals division.

Cement sector orders for the year were Euro611.0m, 1% lower than the Euro615.0m seen in 2016. Revenue from cement sector orders came to Euro547.9m, 5% lower than the US$576.0m orders received in 2016.

“2017 probably marked the trough of the business cycle and, based on our good positioning and strong life-cycle solutions, we expect our business to start growing again in the coming years. Our order intake increased and the momentum in the mining sector continues in 2018, while cement market conditions are expected to remain unchanged,” said CEO Thomas Schulz.

For 2018, FLSmidth anticipates an overall revenue from all activites of Euro2.42-2.68bn (2017 was Euro2.42bn).


Colombia: Cemex Latam Holdings, the subsidiary of Mexican cement company Cemex in Central and South America and Caribbean region, has confirmed that is ‘solving’ the legal issues that prevent the opening of its new plant in Maceo, Antioquia, Colombia. The inauguration of the facility was postponed in May 2017 after authorities stated that the plant had not obtained all the permits to start operations. Jaime Muguiro, president of Cemex Latam, expressed that the company was still awaiting authorisation for the expansion of the plant's installed capacity, which is currently artificially limited to 0.25Mt/yr. The plant has a design capacity of 1.3Mt/yr and has so far cost Cemex US$420m.


Japan: Taiheiyo Cement has released its financial results for the nine months to 31 December 2017. They show a 10.3% rise in revenue for the nine month period to US$5.96bn from US$5.40bn in the first nine months of 2016. Its operating profit was up by 10.1% from US$403m to US$444m over the same period but its net profit fell by 43% to US$297m from US$520.9m. For the full year to 31 March 2018, Taiheiyo Cement advises that it anticipates a revenue of US$7.9bn, an operating profit of US$611m and a net profit of US$347m.


India: Cement maker ACC Ltd has announced that its fourth-quarter profit for 2017 was more than double that of the same period of 2016. Its profit rose by 126% to US$32.1m in the quarter that ended on 31 December 2017, from US$14.1m in 2016. Its net sales for the quarter were 30% higher at US$531m.