Global Cement Newsletter

Issue: GCW345 / 21 March 2018

Headlines


Lots of facts stuck out from the inaugural Global GypSupply Conference that took place in Brussels last week. One was that Spain exported 1.49Mt of raw gypsum to West Africa in 2016. The data point from Spanish customs popped up in a presentation by Mohamed El Moustapha, the managing director of a gypsum mining company based in Mauritania. He was using the figures to reinforce the opportunities for his company to supply the growing cement industry in West Africa. Yet the size of the market has implications for the oft-repeated claims of cement sector self-sufficiency that various countries in the region have cried out for.

Gypsum is used as a retarding agent to control the setting time of cement. It gets added whilst clinker is ground into cement. Roughly speaking, cement production requires about 5% of gypsum. So a 1Mt/yr cement plant would require around 50,000t/yr of gypsum. The crucial question for cement producers in West Africa is where is this gypsum coming from. Given that the Global Cement Directory 2018 places cement production capacity at just under 100Mt/yr in the region, this requires around just under 5Mt/yr of gypsum.

El Moustapha made out that there were no gypsum deposits in West Africa. This contradicts a study on Nigerian gypsum mining published in Global Gypsum Magazine in March 2016 estimated local reserves to be around 150Mt although to be fair to El Moustapha these appear to be relatively underused. This also doesn’t take into account sources of synthetic gypsum produced at coal-power plants although this is likely to be negligible at present.

Reserves in Mauritania appear to be much larger at 1.7Bnt. Instead, the problem here appears to be assisting the exploitation of mined gypsum by improving infrastructure and supply chain issues. El Moustapha’s company Samia reported that it exported 170,00t of gypsum to cement plants in West Africa, mainly via ship, but with a significant minority via truck overland to Mali. Another speaker at the conference from the Moroccan gypsum trader Cultura presented a snapshot of a more mature market with exports of 210,000t in 2017. However, similar issues with port infrastructure were also present. To this end the company was keenly looking forward to an upgrade project the Port of Safi due for commissioning in 2020 – 2022 that would allow larger ships to berth.

A market report on the gypsum and anhydrite market by Roskill in 2014 placed Egypt, Algeria and South Africa as Africa’s leading gypsum producers. In particular it singled out South Africa as the only sub-Saharan country producing more than 100,000t/yr of gypsum. In terms of usage of gypsum Roskill estimated that just over half of the world’s gypsum was used to make cement, followed by 38% for wallboard and plaster production and then 18% for agricultural usage. Although this compares to just over a quarter for cement production and most of the rest for wallboard production in the US, with its more developed wallboard market than the rest of the world, according to recent United States Geological Survey (USGS) data.

As the Global GypSupply Conference demonstrated plenty of raw gypsum is available around the world. However, since supply and price can vary considerably in the short term, cement producers are keen to secure steady sources. Developing gypsum sources in northern Africa are necessary to help build the West African cement industry, but the regions need to work together.

The 2nd Global GypSupply Conference will take place in spring 2020


China: Stephen Liu Yiu-keung has resigned as the chairman of Shanshui Cement. He will be succeeded by Li Liufa, according to the Hong Kong Standard newspaper. Other personnel changes include the resignations of Li Heping as an executive director and chief executive, of Han Yike as the chairman and legal representative of Shandong Shanshui Li Heping as vice chairman.


Malaysia: Lafarge Malaysia has appointed Mario Bastian Gross as its chief executive officer (CEO). He will take up his new post on 1 April 2018. He succeeds Thierry Legrand who has been in post since mid-2015.

Gross, a German national aged 39 years, joins Lafarge Malaysia from Sika. He started his career with Sika in 2000 and has global experience with roles across Germany, China, Thailand and Switzerland. He was Asia Pacific Head of Procurement from 2007 to 2011, after which he was appointed Managing Director of Sika in Thailand. In 2013, he took the role Head of Global Procurement, Quality & Sustainability of Sika based in Switzerland.

He holds an MBA from the University of Strathclyde in the UK and a Bachelor of Economics from the VWA Koblenz in Germany.


Burkina Faso: Assam Daoud has become the president of the Burkina Faso Cement Association. The director general of Ciments de l'Afrique (CIMAF) succeeds Hippolyte Guinguéré, the commercial director of Diamond Cement. Daoud will hold the post for one year. The association has also recently inaugurated its new headquarters.


Germany: Aumund Fördertechnik has appointed Reiner Furthmann as its Managing Director Technology. He started the role on 1 March 2018. His main responsibilities are Research & Development, Design & Engineering, Quality Assurance, Production, Materials Management and Purchasing. Furthmann joined Aumund in 1984. His previous role with the company was as its Technical Director.


Nigeria: Dangote Cement’s sales revenue rose in 2017 but its sales volumes of cement fell. Its revenue rose by 31% year-on-year to US$2.23bn in 2017 from US$1.70bn in 2016. However, sales volumes of cement in Nigeria fell by 15.9% to 12.7Mt from 15.1Mt. Altogether, its sales volumes rose by 8.4% to 9.37Mt in the rest of Africa and fell by 7% to 21.9Mt in total. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 50.9% to US$1.08bn from US$713m.

“Although Nigerian volumes were lower in 2017, our Pan-African operations increased volumes by 8.4% and now make up 42% of the Group’s total cement sales, demonstrating the robust diversification of our business,” said Joe Makoju, Acting Group Chief Executive Officer of Dangote Cement. He added that the cement producer had increased its footprint from eight countries to 10 during the reporting period with the opening of new facilities in the Republic of Congo and Sierra Leone, while its operations in Cameroon, Senegal and Ethiopia achieved ‘strong’ sales growth during the year.

Regionally, Dangote Cement said that its estimate for the total Nigerian cement market fell by 18% to 18.6Mt in 2017 due to a recession in the first half of the year and higher prices. It also noted that its Gboko plant in Benue State was mothballed for ‘most of the year.’ Elsewhere, it said that it exported 174,000t of cement from Nigeria to Ghana. In Senegal it introduced 32.5R cement to its product range. In Sierra Leone it opened a 0.5Mt/yr terminal and bagging plant in Freetown in early 2017. In Tanzania it said that its plant at Mtwara had lost earnings due to its reliance on temporary diesel generators. Gas turbines are scheduled to start operation in March 2018.


Indonesia: Indocement has inaugurated a 0.5Mt/yr at Palembang in South Sumatra. The terminal has two cement silos and a packaging plant, according to Warta Ekonomi magazine. The new unit will allow the cement producer to sell bulk cement and it is expected to increase its presence in Sumatra.


Egypt: Egypt Petroleum Technology (EGYPTCO) has received bids from US, Canadian and Saudi Arabian companies to finance two oil well cement production projects with a value of US$500m. An agreement is expected to be reached by mid-2018, according to the Egypt News Daily newspaper. The company is seeking to reopen an existing cement production line and build a new plant to produce both specialist cement and additives.


India: Vijaykumar Iyer, a resolution professional with Deloitte Touche Tohmatsu India working for Binani Cement, has alleged that fraudulent transactions have taken place involving the promoters of the company. Iyer made an application in mid-March 2018 to the National Company Law Tribunal (NCLT) in Kolkata asking the court to take action and ‘appoint an appropriate investigation agency to investigate the directors of Binani Cement and the counter parties,’ according to the Economic Times. Sources quoted by the newspaper say that the application is likely to receive a hearing imminently. Binani Cement has denied the allegations.

Iyer’s application said that he had appointed Haribhakti & Co as a ‘forensic consultant’ in November 2017 for reviewing and identifying ‘suspect’ transactions. He said that since the inception of the corporate insolvency resolution process, he had not been provided access to all the required information and documents. He alleges that Binani Cement made several payments to ‘potentially related and/or connected customers and entities,’ such as Saraswati Sales (SSPL) and US$75.4m was outstanding at the end of November 2017, suggesting that sales were made to SSPL despite the fact that corresponding payments were not made to the corporate debtor. Other inconsistencies were also found suggesting that money was being removed from the business without paying outstanding debts.

Dalmia Bharat beat UltraTech Cement in a bidding war to buy Binani Cement for US$974m in early March 2018 in an auction was run by the National Company Law Tribunal under insolvency proceedings. However, UltraTech Cement has since made a US$1.11bn bid directly to Binani Cement to stop the insolvency process. UltraTech Cement has said it is ‘shocked’ by the allegations by Iyer and that it was unaware of any pending investigations when it made its latest offer.


India: UltraTech Cement has made a new US$1.11bn bid directly to Binani Cement in order to buy it. Binani’s parent company Binani Industries is independently seeking to stop the insolvency proceedings of its cement subsidiary using the money offered by UltraTech Cement in a so called ‘comfort letter.’ In a statement UltraTech Cement said it had in principle agreed to buy 98.5% of the shares of Binani Cement.

However, a consortium led by Dalmia Bharat won an auction for Binani Cement with a bid of US$974m in early March 2018. The auction was run by the National Company Law Tribunal under insolvency proceedings. Binani Cement has since complained that the bidding process was not run on a transparent process, according to the Economic Times newspaper. It added that the ‘shortcomings’ in the insolvency process had prompted the company to look at other options. The on-going struggle by UltraTech Cement and Dalmia Bharat is expected to test local bankruptcy law.


India: The Central Pollution Control Board (CPCB) has issued a show cause notice to Parasakti Cement for processing hazardous waste like battery scrap and operating without permission. The CPCB also noted that the particulate matter emissions from clinker rollers and cement mill exceeded the revised standards, according to the Times of India newspaper. The cement plant, based at Guntur in Andhra Pradesh, has been given 15 days to remedy the situation. Previously in 2016 the company said it was complying with the emissions regulations.


Bangladesh: A cargo vessel carrying 1035t of clinker has sunk on the Rupsha River. Local police said that water started to enter the ship, MV-BB 134, whilst in the middle of the river when a crack opened in its hull, according to the United News of Bangladesh news agency. The vessel sank within an hour. No casualties have been reported.


Malaysia: Lafarge Malaysia has won a US$68.9m contract from China Communications Construction to supply cement for the East Coast Rail Link project. The contract will run until the end of 2019 with options for renewal by a further two years.


Turkey: Data from the Turkish Cement Manufacturers’ Association (TCMA) shows that clinker exports rose by 32.4% year-on-year to 4.93Mt in 2017 from 3.72Mt in 2016. Cement production rose by 6.8% to 80.6Mt from 75.4Mt. Production rose in all regions with the exception of the Aegean and Mediterranean.


Australia: FCT Combustion plans to launch its Turbu-Flex burner in April 2018. The pyro-processing engineering company says that the product will enable operators to switch between different fuels and optimise for each with the one burner. Switching between alternative and refuse derived fuels is intended to allow cement and other industrial plants to lower fuel costs and improve kiln performance. The burner also offers reduced maintenance, as it no moving parts are needed to change the air supply.

“We’ve now proven the burner’s benefits and ease of use in the field. Under testing for almost one year, and operating with over 80% fuel replacement using refuse-derived fuel (RDF), the results are very pleasing for the plant operator and FCT,” said Con Manias, the Managing Director of FCT International. He added that the company also focused on building its footprint in South East Asia.

The company says that it has projects running in six continents due to a ‘surge’ in burner orders. FCT Combustion is currently working on projects in the US, Canada, Brazil, Ecuador, Poland, France, Egypt, Belgium, Italy, China, Thailand, Malaysia, Algeria, Oman, Belgium, France, Ukraine, Turkey and Australia.


Philippines: Eagle Cement’s net profit rose by 4% year-on-year to US$82m in 2017 from US$79m in 2016. It attributed this to increased sales, which rose by 12% to US$286m.

“We have continued to beat our operational targets in terms of volume growth and cost efficiencies. Our efforts in upgrading and debottlenecking of our existing production lines allowed us to keep healthy margins despite the challenging market environment,” said president and chief executive officer Paul Ang.

The cement producer is currently expanding its production capacity with a third production line at its Bulacan plant, which is due to start operation later in 2018. The new line will increase the company’s cement production capacity to 7.1Mt/yr. In November 2017 the company broke ground on its fourth production line at its Malabuyoc plant in Cebu. The project is on track for completion in 2020, and it will add another 2Mt/yr to the company’s capacity. The work at Malabuyoc also includes a marine terminal.


Tunisia: Portugal’s Secil and Spain’s Cementos Portland Valderrivas have both submitted bids for Carthage Cement. Other bidders included local company Omnium des Industries et de la Promotion, Malta’s Eurocem and a consortium of Asamer Kurt, Petech and Melton Enterprise. The companies are bidding for a 50.52% stake in the Tunisian cement producer.


Algeria: Serge Dubois, the Director of Public Affairs for LafargeHolcim Algeria, says that the company is currently negotiating a ‘major’ export contract to a West African country. The deal to export ‘several hundred tonnes’ of Ordinary Portland Cement is expected to be concluded in March or April 2018, according to the El Mujahid newspaper. The subsidiary of LafargeHolcim is attempting to secure export deals ahead of an anticipated 22 – 24Mt/yr production overcapacity in the country by 2020.

It conducted two export deals to The Gambia in December 2017 and March 2018. However, Dubois added that Algeria needs to improve its transport infrastructure to be able to increase exports. To this end he mentioned a Euro13m upgrade project at the Port of Oran. He also spoke about the company’s Ardia 600 binder product and its negotiations with the Ministry of Public Works and Transport to improve local road infrastructure.


Egypt: France’s Vicat plans to invest Euro50m into its Sinai Cement subsidiary. Gianfranco Tantardini, the managing director of the local subsidiary, said that the cement producer wants to reduce the company’s losses by raising its stake in it, according to Mubasher. Vicat is waiting for the Egyptian government to approve a waiver to the 45% foreign ownership limits for the transaction to happen. In 2003 Vicat acquired a 40% stake in Sinai Cement.


China: The China Securities Regulatory Commission (CSRC) has approved the merger between China National Building Material (CNBM) and China National Materials (Sinoma). The approval by the CSRC for the merger between the leading Chinese producer and the equipment manufacturer follows approval by the Anti-monopoly Bureau of the Ministry of Commerce and shareholder approval in December 2017 and approval by the Fair Trade Commission in South Korea in November 2017.


Mexico: Cemex’s chief executive officer (CEO) Fernando González says that the company is nearly ready to start considering acquisitions after a decade of asset sales and debt reduction. He told analysts at a conference in New York that the company will seek shareholder approval in April 2018 to issue new shares to raise capital, which it could eventually use along with debt and cash, according to Dow Jones.

The building materials producer plans to focus on cement operations in large emerging markets and on aggregates in developed markets. Major markets where Cemex doesn't have operations include India and Brazil and it would be interested in targeted these regions. The company has also striven to regain its investment-grade credit rating it held until 2008 when its earnings fell following its US$15.5bn purchase of Rinker.


Honduras: Cementos del Norte has spent US$29m on upgrades for its Rio Bijao cement plant in Choloma. The project includes increasing the unit’s capacity for production, storage capacity and alternative fuels, according to the La Prensa newspaper. The cement producer is installing a new cement grinding mill at the site. This will enable it to raise its cement prouction capacity to 2.5Mt/yr from 1.5Mt/yr.


India: The Fly Ash Council of Maharashtra has asked state power generation company Mahagenco to plan how to give fly ash for free to industrial users. The initiative follows the decision by the state government to adopt its Fly Ash Utilisation Policy, according to the Indian Express newspaper. An official said that the power company would give away fly ash for free within 100km of the plant if it is affordable. The measure was introduced to encourage cement manufacturers and construction companies to use more fly ash by offsetting the transportation cost. At present smaller companies receive the fly ash for no charge.

In 2015 - 2016, Maharashtra used 69% of the fly ash generated in thermal power plants in the state. With an installed capacity of 20,976MW, the state generated 18.6Mt of fly ash during this period, of which 13Mt was used, mostly to make bricks and to build roads. With the new policy the government is targeting a 100% utilisation rate.


US: Mexico’s Cemex says that the US Department of Justice (DOJ) is investigating whether the cement producer violated the US Foreign Corrupt Practices Act (FCPA) in relation to a new cement plant being built by Cemex Colombia at Maceo in Antioquia. Previously, the cement producer received a subpoena from the US Securities and Exchange Commission in late 2016 as part of a probe also checking whether the FCPA had been breached.

Cemex says it is cooperating with both requests. However, it also said that it does not know how long either investigation will last or what impact the results of either investigation might have upon the company in terms of eventual sanctions.

In late September 2016 Cemex fired several senior staff members in relation to the Maceo project and its subsidiary’s chief executive resigned. This followed an internal audit and investigation into payments worth around US$20.5m made to a non-governmental third party in connection with the acquisition of the land, mining rights, and benefits of the tax free zone for the project.


Argentina: Germany’s KHD has been awarded a contract by Holcim Argentina for the upgrade project of a clinker production line at its Malagueño cement plant near Córdoba. Holcim Argentina intends to recommission its mothballed 1650t/day production line, which originally was supplied by KHD Humboldt Wedag in the early 1980s. Commissioning for the updated line is planned for mid-2019.

KHD’s scope includes the engineering and supply of mechanical equipment for raw material preparation and clinker production as well as electrical equipment in order to modernise and recommission the currently mothballed production line no 1.

Core equipment for the project includes: tertiary raw material crusher with a capacity of 250t/hr; ball mill drive for existing ball mill and new feeding equipment for raw meal preparation; separator for raw material grinding plant; kiln feed dosing system; four-stage preheater; rotary kiln 4.4m x 64m and drive system; revamping of existing clinker cooler with ‘fourth generation’ walking floor grate; main bag house for kiln/mill and clinker cooler; and main process fans.


Saudi Arabia: Al Baha Cement plans to build a 6000t/day plant that will manufacture sulfate-resisting Portland cement (SRPC). The company is looking for bids for a financial consultancy contract for the new plant, according to Inside International Industrials. The project is expected to cost US$100m, which will be raised from banks. The Minister of Commerce and Industry has approved the license for establishing the company. Tendering for engineering, procurement and construction is expected to occur in the second of half of 2018.