Global Cement Newsletter

Issue: GCW342 / 28 February 2018

Headlines


Algeria: ETHRB Group has ordered an integrated cement plant from FLSmidth for a site at Relizane. The order has a cost of over Euro100m and it includes engineering, equipment supply, construction supervision, commissioning, and training. The deal comes from a partnership between FLSmidth and Beijing Triumph International Engineering Company, a subsidiary of China National Building Material Group Corporation, which will be responsible for the construction of the cement plant. The plant will mainly supply cement to the North African market. Once completed, the cement plant will have a capacity of 12,000t/day. Commissioning is scheduled for late 2020.

“This order underlines FLSmidth's strength as the leading supplier of the most productivity-enhancing solutions and energy-efficient equipment and technology available in the market today. It marks the culmination of a close collaboration between the customer and FLSmidth and demonstrates our ability to work with contractors from anywhere in the world based on our experience and competencies from the cement industry, our global presence, and the know-how of our 12,000 employees," said Per Mejnert Kristensen, Group Executive Vice President, Cement Division.

The scope of supply includes: two EV 200x300 Hammer Impact Crushers; one additive crusher; two circular storages; one longitudinal storage; two ATOX raw mills; two CF-silos (Ø18m x 52m); two preheaters (two string ILC, five stages); two kilns (5.25m x 62m); two Cross-Bar coolers (16m x 50m); a clinker silo (Ø 60m x 46 m); three OK61-4 cement mills; four cement silos (ø22x52 m); and six packing lines.


Vietnam: Vicem (Vietnam Cement Corporation) Hoang Thach Cement has ordered a type LM 59.3+3 CS vertical roller mill for the Hoang Thach cement plant in Hai Duong province. The mill has a transmission power of 6200kW and it is able to grind 250t/hr of Ordinary Portland Cement (OPC) to a fineness of 3600 Blaine. Commissioning is scheduled for later in 2018.

The scope of supply also includes an external reject system, dedusting equipment, a material conveying system and multi-chamber silos with two packaging systems downstream. The system is equipped with a LOMA LF20 heater run on heavy oil, which produces around 30,000Nm3/hr of hot gas at a temperature of 450°C. In addition, Loesche is supplying the equipment for the power supply and distribution and the grinding plant control. A particular challenge of the project has been supplying new equipment for an existing plant with limited space.


The old saying goes that nothing is certain except for death and taxes. But maybe that should be cement and taxes. Paying your taxes is something most people and companies just get on with, perhaps with some grumbling or perhaps not, but certainly with little press. So two news stories popping up in the same week about cement plants with tax issues is out of the ordinary.

The first concerned Lucky Cement’s battle in Pakistan to keep one of its plants open following accusations of underpaying its taxes. The local tax office tried to shut the Pezu plant down for not paying its property tax. The cement producer hit back with a restraining order from the provincial high court. The second detailed efforts by the Ethiopian authorities efforts to claw back US$10m from a local cement producer accused of deliberately understating its profits. In both cases it’s hard to tell if there is an obvious right or wrong party. Yet if these kinds of stories are hitting the local press headlines then either something has gone wrong or both parties are digging in for a fight.

Looking over a longer time frame two major stories about tax have been doing the rounds over the last year in the industry news. India’s Goods and Services Tax (GST) is a classic example of how cement producers sometimes have to deal with changes to existing regulations. It received another outing this week in the form of the credit agency ICRA’s latest forecast. It explained how the introduction of the new tax, a consolidation of other existing indirect taxes, had slowed production in the second quarter of the Indian financial year in 2017 - 2018.

The other example from a large cement producing country was US President Donald Trump’s cut to federal corporate tax in December 2017. The tax cut was expected to particularly benefit companies that produce materials, like building materials manufacturers. It prompted HeidelbergCement to say in early January 2018 that it expected to see a boost to its profits in 2019. Warren Buffet, the chairman of Berkshire Hathaway and owner of insulation producer Johns Manville amongst other companies, put it bluntly when he said in his 2017 annual report that nearly half the gain of his company’s net worth came from the changes to the US tax system.

Multinational companies, including some cement producers, face issues when dealing with different rules and regulations between the various countries that they operate in. However, sometimes unfairly, sometimes not, large companies also hold a reputation for trying to avoid paying tax.

In this context it’s interesting to look at how LafargeHolcim says it approaches the issue. The company published its tax principles in 2016 where it talks about being responsible and that it, “…accepts tax as a necessary and required contribution to society.” It then talks about the necessity of transparency and good relationships with tax authorities. The same year it declared a total tax bill of Euro726m versus total sales revenue of Euro23bn. By contrast Cemex UK in its tax strategy talks about how it follows the US Sarbanes Oxley Act 2002, which applies a more stringent international accounting and auditing standard. It feels far more honest when it says that it aims to minimise the tax burden upon its shareholders by using methods outlined by the UK government. Taxes may be a certainty but nobody wants to pay a penny more in taxes than they have to.


Brazil: InterCement has appointed Paulo Eduardo Nigro has its chief executive officer (CEO). Paulo Nigro has acted as CEO in several countries including the US, Italy, Canada and Brazil. The company has also appointed Nicolas Fournier as a new non-executive member of its board of directors.

Nigro started his career as an engineering trainee at Philips in 1981, after which he joined Goodyear, working in industrial and automotive engineering. In 1991 he joined Tetra Pak as a sales manager for the Northeast region of Brazil, which he left to assume the vice presidency of the packaging division of its Canadian subsidiary. In 2001, Nigro was appointed president of Tetra Pak Italia, eventually taking on responsibility for Western Europe. In 2007, he returned to Brazil as president for the local and the Paraguayan markets, while at the same time leading Tetra Pak Latin America operations. He also took the leadership of Tetra Pak for the Americas, moving to Dallas, US where he joined the global top management team of the company. In 2014 Nigro was appointed president of Aché Laboratórios, in Brazil.

Nicolas Fournier holds 25 years of international experience in different industries in Europe, Asia, Africa, Latin America and Middle East. With 20 years of global experience on the cement industry, working for Lafarge Group, he acted as CEO of Lafarge Boral Gypsum Asia and was the regional president of Lafarge for Central Europe. More recently, Fournier served as the Managing Director for Energy Solutions Division at Aggreko, UK.


Saudi Arabia: Badr Jawhar has resigned as the chief executive officer of Najran Cement for personal reasons.

In a separate announcement, Najran Cement has appointed Turki Bin Ali Al Shanifi to its board of directors. Turki Bin Ali Al Shanifi holds a degree in Computer Science, specialising in Information Systems and has over 20 years of experience in working with private sector companies in leadership positions. His appointment follows the resignation of Abdulwahab Bin Saud Al Babtain as an independent member of the board.


US: CarbonCure has demonstrated an integrated CO2 capture and utilisation (CCU) process from cement for concrete production in January 2018 at Cementos Argos’ Roberta plant in Calera, Alabama. The consortium - comprising Carbon Cure, Sustainable Energy Solutions (SES), Praxair, Cementos Argos and Kline Consulting - says it is the world’s first project to collect cement kiln CO2 for subsequent utilisation downstream in concrete production and construction.

CO2 emissions from the Roberta cement plant were captured by SES’ Cryogenic CO2 Capture technology, transported by Praxair and reused in Cementos Argos' Glenwood, Atlanta concrete operations equipped with CarbonCure's CO2 utilisation technology. The concrete manufactured with the waste CO2 from the Roberta cement plant was then used in a local construction project in the greater Atlanta area. Design partners and fellow members of CarbonCure’s Carbon XPRIZE team such as LS3P Architects, Uzun + Case Structural Engineering, and Walter P Moore Structural Engineers completed the end to end integrated solution by creating demand for CarbonCure concrete products in the marketplace. Kline Consulting oversaw the commissioning and reporting of the industrial demonstration.

The project was an extension of Team CarbonCure's participation in the US$20m NRG COSIA Carbon XPRIZE Challenge, which incentivises and accelerates the development of integrated CCU technologies and new markets that convert CO2 emissions from coal and natural gas power generation into valuable products.


Mexico: Elementia’s sales benefitted from its Mexican cement business in 2017. Its net sales rose by 35% year-on-year to US$1.37bn in 2017 from US$1.02bn in 2016. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) increased by 24% to US$236m from US$191m.

Highlights of the company’s year included integrating Giant Cement’s assets into the company, the start-up and allocation of additional volume from the cement plant in Tula, Mexico and the expansion of the cement division in Costa Rica through the installation of a grinding plant that is expected to start operations towards the end of the first half of 2018.

Elementia’s Mexican cement division sales rose by 44% to US$236m from US$164m. However, the sales of its US division fell by 7% to US$231m from US$249m. The company blamed this on the year being a ‘transitional’ period where it conducted regular maintenance works that interrupted production.


Peru: UNACEM is considering buying local engineering company ARPL Tecnología Industrial, according to the Gestion newspaper. The plans will be discussed at a forthcoming shareholders meeting in late March 2018. ARPL Tecnología Industrial is an engineering company that specialises in the cement industry. It has operated for over 50 years. It offers consultancy services, and technical assistance, development and project engineering managing services, as well as analysis and physical chemical tests and computer services.


Ethiopia: The Ethiopian Revenues & Customs Authority (ERCA) says that Chinese company Inchini Bedrock Cement owes it US$10m for alleged tax evasion. The cement producer has declared a loss for five of the seven years it has been in operation, according to the Addis Fortune newspaper. However, ERCA’s Large Taxpayers Office (LTO) has refuted these claims and, following an audit, says that Inchini Bedrock had failed to keep records of the raw materials and finished products in stock. The investigation was triggered following the discovery of documents relating to Inchini Bedrock whilst ECRA was looking at another case.

Inchini Bedrock Cement employs 265 employees, including 22 foreign nationals. However, it appears to have no manager or representative at present, except for the head of the expatriate department, according to sources quoted by Addis Fortune. The manager of the company left Ethiopia in late 2017 due to medical reasons. The plant had a cement production capacity of 0.3Mt/yr when it opened in 2012.


Rwanda: Cimerwa plans to upgrade its Bugarama cement plant in Rusizi District of Western Province. The project is intended to increase the plant’s production capacity and to target demand locally and abroad, in particular infrastructure development, according to the New Times newspaper. However, the subsidiary of PPC has not disclosed how much it is spending on the project. Upgrade work will start in March 2018 and end in April 2018.

At present the 0.6Mt/yr plant has a 65% production utilisation rate. The company expects to reach full capacity in mid-2019, although it claimed in 2017 that it would be able to do this by mid-2018. In 2017 the company sold 0.38Mt of cement, with 10% exported to Democratic Republic of Congo and Burundi. The plant imports most of its coal from Malawi and Tanzania.


Burkina Faso: The Ministry of Mines and Quarries has signed a limestone mining deal with Sahelian Mining, a subsidiary of Diamond Cement Burkina. The deal covers mineral rights for the Sahel region, according to the Sidwaya newspaper. The agreement is intended to diversify the country’s mineral production. Diamond Cement Burkina oprates a cement grinding plant at Ouagadougou.


Thailand: Siam City Cement Group has hired US company Avaya and Thai technology company Loxley to upgrade its communication infrastructure. The project was intended to help the cement producer manage the transformation into a multinational company with operations in Thailand, Sir Lanka, Bangladesh and Vietnam and 1500 workers. Products from Avaya have enabled employees in different regions to connect via a range of devices and channels via varied internet connections in different territories. The project has also enabled employees to use video conferencing to collaborate and to reduce the need for travel.

“With our rapid expansion across the region, we wanted a cost-effective solution that would enable us to meet our sustainable development objectives while driving our digital transformation journey,” said Khun Ittaya Sirivasukarn, chief executive officer (CEO) of Insee Digital, the IT subsidiary of Siam City Cement.


Australia: Adelaide Brighton’s revenue rose by 11.7% to US$1.22bn in 2017 from US$1.09bn. The building materials producer said that the boost, although aided by acquisitions in 2017, was due to ‘strong’ demand in east coast markets, improving demand in South Australia and stabilising demand in Western Australia. However, its net profit after tax fell by 2.2% to US$142m from US$145m. It blamed this on one off provisions, acquisition costs and restructuring expenses.

For its cement business, the company said that cement and clinker sales volume rose by 9% in 2017, assisted by a ‘particularly’ strong second half. Strong volume growth continued in 2017 in Queensland, Victoria and New South Wales.
Sales volumes in Western Australia and Northern Territory declined in the first half but stabilised in the second half to be modestly lower for the year. Cement sales in South Australia improved, supported by the ramp-up of major infrastructure projects in the second half.

The cement producer also reported that in April 2017 its Birkenhead plant experienced a temporary issue with the quality of cement that incurred rectification costs of US$2.8m during the first half of the year. The quality issue arose due to lower grade feed making its way into the cement milling process. Fixes to inventory management and quality processes were made to address the issue and production and quality returned to normal shortly after the incident.


India: The credit agency ICRA forecasts that cement demand will grow by 4.5% in the 2018 – 2019 financial year due to growth in the housing sector and higher infrastructure spending. Improved rural incomes, higher rural credit and increased allocation for rural, agriculture and allied sectors are also likely to increase the demand for rural housing, according to the Press Trust of India.

Indian cement production rose by 2.7% to 217Mt in the nine months from April to December 2017 from 211Mt in the previous year. However, the first three months of this period, from April to June 2017, saw production drop due to local issues across the country such as a sand shortage, the implementation of Real Estate Regulatory Authority (RERA) Act and a drought. The following quarter then saw a fall in production due to the introduction of the Goods and Services Tax (GST), continued sand shortages and inclement weather. ICRA predicts that cement demand will grow by 3% for the remainder of the 2017 – 2018 financial year due to a boost in production in December 2017.


UK: Claudius Peters has released information about an upgrade project at Breedon Group’s Hope Cement plant in Derbyshire. The work included upgrading and replacing the existing kiln feed equipment built with the plant in the 1970s, and increasing the accuracy and capacity of the system to 200t/hr of raw meal for Kiln 1, Kiln 2, and a standby unit. The contact was signed in October 2014 and completed in May 2017. It is one the largest capital expenditure projects undertaken at the site in recent years.

A key challenge on this project was installing new equipment while the plant remained in operation. Claudius Peters supplied and commissioned: three 300 screw pumps complete with pump inlet hoppers with de-dusting filters and modified pipelines; modifications to existing compressors; and three cyclone filters with collection hoppers transport and material transport to pre-heater inlet via rotary feeders.


Spain: Oficemen, the Spanish Cement Association, says that cement consumption grew by 11% year-on-year to 12.3Mt in 2017. The association expects it to rise by 12% to 13.7Mt in 2018. However, the cement consumed in 2017 is well below the high recorded in 2007. This has been due, in part, to a decrease in the amount of cement used in infrastructure projects. Cement used in civil works decreased by 75% to 5Mt in 2017 from 19Mt in 2008.

Exports of cement fell by 10% to below 9Mt, mainly due to a ‘loss of competiveness’ caused by growing local electricity prices. The association added that Spain is the largest exporter in the European Union and the eighth largest exporter of cement worldwide.


Nepal: Palpa Cement Industries has ordered a MVR 3350 C-4 mill from Gebr. Pfeiffer for its plant at Sunwal, in the district of Nawalparasi. The vertical roller mill has a drive power of 2150kW and is designed to grind 130t/hr of cement at 3000 Blaine and 100t/hr of blast-furnace cement at 3800 Blaine. Commissioning of the mill is planned for mid-2019. It is the fourth vertical roller mill order from Nepal for Gebr. Pfeiffer over the last year.


India: Gujarat Sidhee Cement has commissioned a 5.5MW waste heat recovery plant at its Sidheegram plant in Gujarat. The project has a budget of US$10m. Power generated from the unit is expected save the plant US$2.6m/yr .


India: Asian Cement Group has launched a new 1.5Mt/yr grinding plant at Rajpura in Punjab. The project had an investment of US$62m. The site will operate under the Duraton Cement brand.

The plant consists of a grinding mill with a roller press and a separator. The unit also uses a robotic laboratory from Demark’s FLSmidth to automate cement sampling, sample transportation, preparation and analysis.

The cement producer will launch its Prime WR variant product in March 2018. This product will be sold in vacuum-packed waterproof packaging. The first consignments from the plant have been sent to religious sites in Rajpura and Chandigarh. Subsequent rollout will target Punjab, Haryana, Chandigarh and Himachal Pradesh.


India: ACC and Ambuja Cements, the two Indian subsidiaries of LafargeHolcim, have put their merger plans on hold. ACC said that its board was of the opinion that there were ‘certain constraints’ blocking its merger plans, according to the Press Trust of India. However, it added that a merger was its ‘ultimate’ objective. Ambuja Cements made a similar statement. Both companies joined Holcim in 2005, before becoming part of LafargeHolcim in 2015.


Pakistan: Lucky Cement has obtained restraining orders from the Peshawar High Court to prevent its Pezu plant being closed by the Excise and Taxation Department for not paying a US$135,000 property tax bill. A team from the Excise and Taxation Department attempted to close the site on 23 February 2018, according to the News International newspaper. The cement producer says that the plant continues to produce cement and despatch its products. The tax office has launched a drive to target tax defaulters in the region. It alleges that it has been chasing Lucky Cement’s tax bill for the past six years.


Iran: Austria’s Fronius Solar Energy has installed an inverter for the 1.5MW photovoltaic solar plant at Shahrekord Cement Company’s plant. The engineering firm supplied its Fronius Symo 76 product for the site situated at 2300m above sea level that experiences a wide variation in ambient temperature between -10°C and 50°C. Using this system, the cement producer has achieved a total yield of 2953MWhr/yr, which it feeds back to the grid. The operator is also able to monitor the system using the Fronius Solar web analysis tool and it is using the provider’s Service Partner programme for ongoing support.


Qatar: Qatar National Cement Company (QNCC) plans to open its fifth cement plant in the first half of 2018. The move will increase its cement production capacity of 5500t/day, according to the Qatar Tribune newspaper. However, its sales of cement fell slightly to 3.4Mt in 2017 from 3.7Mt in 2016.

The cement producer’s sales revenue fell by 9.6% year-on-year to US$283m in 2017 from US$313m in 2016. Its net profit decreased by 31% to US$90m from US$130m. The company blamed the falling profit on a poor local economy causing poor demand and a reduced selling price since April 2017.


Nigeria: Ashaka Cement plans to complete its 16MW captive power plant in early 2019. The subsidiary of Lafarge Africa and LafargeHolcim started the US$30.5m project in 2017, according to the Nigerian Guardian newspaper. Once operational the power plant will supply additional electricity to the national grid as well as supplying the neighbouring cement plant.


South Africa: Prudential Investment Managers, one of the largest shareholders of PPC, has demanded the resignation of the chairman Peter Nelson. The shareholder sent a formal request to the cement producer because it wants the company to improve its operations, according to sources quoted by Bloomberg. In response PPC issued a statement admitting that it was talking to major shareholders over board positions. However, it defended the record of Nelson, saying that he had, “successfully led the company through a period of significant headwinds.”

PPC added that it has received nominations for Jabu Moleketi as successor to the chairman, and Anthony Ball and Noluvuyo Mkhondo to non-executive directorships.

Nelson was appointed as chairman of PPC in October 2016, shortly before it revived merger talks with AfriSam. Later in 2017 Canada’s Fairfax Financial Holdings made a bid for PPC on condition that it merge with AfriSam. Negotiations with LafargeHolcim, CRH and Dangote Cement but these were all abandoned.


Bolivia/Paraguay: Bolivia’s Fábrica Nacional de Cemento (Fancesa) is planning to build a new cement grinding plant and terminal near the border with Paraguay. The project is budgeted at US$16m and it may be built as a joint venture, according to the Correo del Sur newspaper. The cement producer is also about to deliver its first consignment to Paraguay.


Colombia: Grupo Argos and Mexico’s Grupo Calidra have inaugurated a new US$40m lime plant at Puerto Triunfo, Antioquia. The unit has a production capacity of 90,000t/yr, according to the El Colombiano newspaper. The plant is the only one in Colombia capable of producing pulverized limestone. Grupo Argos and Grupo Calidra will operate the plant under a joint venture named Caltek. The new plant is expected to create 100 jobs.


Pakistan: Fecto Cement plans to build a new 6000t/day cement plant at Palai in Malakand. The project will also include a waste heat recovery unit.


Malaysia: Cahya Mata Sarawak's (CMS) sales from its cement division have fallen in 2017 due to lower sales volumes of cement and concrete. However, the cement producer said that the average production cost per tonne of cement had fallen due to cheaper coal prices and cheaper imported clinker. Its sales revenue fell by 7.5% year-on-year to US$133m in 2017 from US$144m in 2016. Its operating profit fell by 3.5% to US$25.9m from US$26.8m. The division also benefitted from the opening of the Mambong grinding plant in late 2016.


Morocco: Germany’s ThyssenKrupp Industrial Solutions (TKIS) has won a contract from LafargeHolcim, to supply a new 3500t/day cement plant in Morocco. The project will cover the engineering, procurement and construction (EPC) of the new plant. The line will be built in the Souss Massa region near Tidsi. Start-up of the plant is scheduled for the first half of 2020.

TKIS will provide engineering, procurement and construction for the entire clinker production line, ranging from raw material preparation to clinker storage, and a grinding facility for solid fuels. The main components include a 1000t/hr primary crusher, a longitudinal additives storage facility, a circular stockpile with a storage capacity of 12,000t, a Quadropol QMR² roller mill with an output of 290t/hr and a blending silo of 4600t. The kiln system consists of a five-stage, single-string polysius preheating tower, a two-pier rotary kiln and a
Polytrack clinker cooler. The line is completed by a ball mill for solid combustibles and a clinker stock with a total storage capacity of up to 65000t.


US: The Portland Cement Association (PCA) has supported an infrastructure study by the American Council for Capital Formation (ACCF). It liked how the study highlighted the importance of life cycle cost analysis and competition in paving. “If federal and state decision makers took this report as a playbook, America would see tremendous taxpayer cost savings and stronger infrastructure built to last long into the future,” said PCA President and chief executive officer (CEO) Michael Ireland.


Mozambique: President Filipe Nyusi has inaugurated Limak Cement’s 0.7Mt/yr plant in Matola. Nyusi said he expected the plant to ‘contribute to stabilising prices in a scenario of high levels of demand for cement,’ according to the Mozambique News Agency. The unit will employ over 140 people.


Saudi Arabia: Najran Cement made a loss of US$5.8m in 2017 from a net profit of US$33.5m in 2016. It blamed the loss on lower prices, reduced sales volumes due to lower demand for cement and greater competition and higher production costs. Its sales revenue fell by 39% year-on-year to US$115m from US$189m.