Global Cement Newsletter

Issue: GCW354 / 23 May 2018

Headlines


UltraTech Cement’s deal to buy the cement business of Century Textiles & Industries could see it become the world’s third largest cement producer by production capacity outside of China.

It announced this week that it had entered into an acquisition agreement to buy the cement subsidiary of BK Birla Group for US$1.26bn. If the deal completes then it will gain three integrated plants in Madhya Pradesh, Chhattisgarh and Maharashtra respectively with a combined production capacity of 11.4Mt/yr and a 1Mt/yr grinding plant in West Bengal. At this point UltraTech Cement will increase its production capacity to 106Mt/yr seeing it become the third largest cement producer in the world in Global Cement’s Top 100 Report.

This latest deal is subject to the usual regulatory approval from competition bodies and the like. Bustling past this step seems far from clear at this stage given that UltraTech Cement owns cement plants already in each of the four states the proposed purchases are in. It has described the purchase as giving it, …”the opportunity for further strengthening its presence in the highly fragmented, competitive and fast growing East and Central markets and extending its footprint in the Western and Southern markets.” Synergy savings from procurement and logistics are expected to follow with further benefits to be gained from the company’s distribution network. Local and national competitors may not see it the same way and the fallout from a price war could be damaging for smaller producers.

As covered previously, UltraTech Cement seems hell bent on winning its on-going fight against Dalmia Bharat to buy Binani Cement. Rightly or wrongly UltraTech Cement tried to muscle its way into buying Binani by making a bid directly to its owners after it lost an auction for it. Legal wrangling has followed as the insolvency process for Binani Cement has clashed against the auction process of the administrator. At the time of writing it is still far from clear which company will win.

Comparing the prices of the two latest acquisition targets by UltraTech Cement may offer some insight of its motivations. The Binani Cement assets roll in at just over US$125/t of production capacity. Although, as noted below, some of this is located outside of India. The Century Textiles & Industries assets are being purchased for a little over US$100/t. This is interesting as it is lower that the Binani cost, although the close links between BK Birla Group and UltraTech Cement’s owner Aditya Birla may help to explain this.

UltraTech Cement’s milestone as it surpasses the 100Mt/yr capacity level will mark a continuing change in the world’s cement industry as it moves away from Europe and North America to developing economies. As ever the classification is a bit of a fudge given that Global Cement’s top producers list excludes Chinese producers. Partly this arises from the difficulty obtaining reliable data on the Chinese industry. Partly this comes from top producer’s list looking at multinational companies over (extremely) large national ones. Due to this UltraTech Cement remains a regional player. Or it will at least until it (or if it) manages to buy Binani Cement. Some of the assets included in that sale include plants in both the UAE and China. At this point UltraTech Cement’s claim to be the third biggest cement producer in the world will be secure.


Australia: Martin Brydon plans to retire from Adelaide Brighton. No time scale has been specified but he intends to remain with the business while its finds a successor for him.

Brydon, aged 62 years, has been in post since 2014. He holds over 30 years of experience in the construction materials industry ranging from electrical engineering, operational and general management, sales and marketing and strategy and business development.

Others executive changes at the building materials producer include the appointment of Zlatko Todorcevski as chairman of the board. He succeeds Leslie Hosking, who has decided to retire. Todorcevski, aged 50 years, has been a non-executive director since March 2017 and he was named chairman elect in February 2018. A training accountant he holds 30 years experience in the oil and gas, logistics and manufacturing sectors gained in Australia and overseas with a background in finance, strategy and planning.

Graeme Pettigrew has also retired as a non-executive director of Adelaide Brighton after 14 years of service at the company. He had been a non-executive director since 2004. The former chief executive officer of CSR Building Products held experience in the building materials industry in South East Asia and the UK through former roles as the managing director of Chubb Australia and Wormald Security Australia.


Pakistan: DG Khan has completed the installation of its new cement grinding plant at Hub in Baluchistan. A new vertical cement grinding mill with a COPE drive has started trial operations together with cement siloes and a packing plant. Commissioning has also taken place of raw material crushing, transportation and storage units. Loesche, who supplied the mills for the project, said in 2017 that a 1050t/hr raw mill was the biggest raw material mill in the world.


Ecuador: FCT Combustion has won an order to supply a clay dryer to Cemento Chimborazo. The order includes a complete raw material drying system. It consists of a 41.2t/hr Triplex drier and a fluidised bed combustion system for petcoke and alternative fuel firing. No value or commissioning date has been disclosed.


Vietnam: The environment ministry has approved fly ash from the Formosa steel company for use in cement production. Sông Gianh Cement in Quảng Bình Province has been cleared for its use provided the materials meet current technical specifications and that the company has the responsibility to monitor the transport of ash, according to the Viet Nam News newspaper.

Sông Gianh Cement initially denied receiving fly ash from Formosa. However, the transport company carrying the by-product from Hà Tĩnh to Quảng Bình admitted to local media that it had been hired for the job. The Quảng Bình environment department then revealed that Sông Gianh had asked the government if it could buy fly ash from Formosa but that it had been denied due to poor public opinion regarding the steel producer.

Formosa received widespread public criticism when it was blamed for a chemical spill into the sea in 2016 that caused mass deaths of marine life and public outcry.


Laos: The Ministry of Industry and Commerce says that the value of cement exports rose by 25% to US$19m in the first quarter of 2018 from US$15.2m in the same period of 2017. However, imports fell by 14% to US$16.4m from US$19.1m, according to the Vientiane Times newspaper. Exports have risen as new production capacity has been commissioned in the country.

Laos exported a value of US$0.2m in 2016 but this grew to US$47.6m in 2017. Imports fell to US$68m in 2017 from US$84.3m in 2016. The country has 16 cement plants and other units are being built. At present the country has a capacity of 4.4Mt/yr. This is expected to grow to 6.7Mt/yr once all the current projects are completed. Local infrastructure projects are driving local demand including the several hydropower plants and the Laos-China railway.


Spain: FYM, a subsidiary of HeidelbergCement, is facing a potential legal battle to expand the quarry at its La Araña cement plant near Malaga. It has applied to the local government for a compulsory order to buy land at the site, according to the Diario Sur newspaper. FYM says that it has the authorisation to use up to 176 hectares near its plant for mineral extraction but that it is only using 43 hectares at present. The agreement in place allows the cement producer to buy land on a compulsory basis if an agreement can’t be reached with the land owners. However, the current land owner and FYM have disagreed over the price.


Cameroon: The Ministry of Finance forecasts that demand for cement will rise by 10% due to various infrastructure projects. The government department also indicated that some cement producers are increasing their production capacity, according to Business in Cameroon.

Cimencam, a subsidiary of LafargeHolcim, is planning to build a 0.5Mt/yr grinding plant at Nomayos in Yaoundé. It is expected to be complete in 2019. Dangote Cement plans to build a 1.5Mt/yr plant in Yaoundé and Ciments de l'Afrique (CIMAF) is upgrading its plant Douala to 1.5Mt/yr from 0.5Mt/yr. The CIMAF project is scheduled for completion also in 2019. Following commissioning of all the new projects, the market share of each cement producer is expected to be Dangote Cement with 45%, Cimencam with 30%, CIMAF with 22% and Medcem with 3%.


India: Larsen & Toubro has won an order to build cement plants in Odisha and Andhra Pradesh. The end client has not been named and no value has been disclosed. The cement plant orders were announced as part of a wider set of orders worth over US$590m, including government construction projects.


India: UltraTech Cement has won the Deora-Sitapuri-Udipyapura limestone mining block in Madhya Pradesh in a state auction. The block has a reserve of around 54Mt and it is spread over an area of 345 hectares. The company said that the block is near to the existing limestone quarry of its recently commissioned Dhar Cement plant. It added that the new limestone reserve would be useful in augmenting the capacity of the plant in the future.


India: Dalmia Bharat's subsidiary OCL India plans to build a new cement plant in Odisha. The new unit will have a production capacity of around 1.7Mt/yr and it will include a waste heat recovery system. It will bring the cement producer’s total cement capacity up to around 8Mt/yr in the states of Odisha and West Bengal. The project is estimated to cost around US$545m. The plant is expected to be completed by mid-2020.


India: Jaiprakash Associates’ sales have nearly halved following the sale of much of its cement business to UltraTech Cement in mid-2017. Its sales dropped to US$1.14bn in the year to the end of March 2018 from US$2.19bn in the same period in 2017. The company said that its annual results were not comparable due to the sale of six integrated cement plants and five grinding plants.


Nepal: Hongshi-Shivam Cement has started trial production at its new plant near Dumkibaas in Nawalparasi district. The joint venture between Nepal’s Shivam Holdings and Hong Kong Red Lion Cement No 3, a subsidiary of China’s Hongshi Group, plans to start commercial production by the end of June 2018, according to the Kathmandu Post. The Chinese company owns a 70% stake in the joint venture. The unit has a production capacity of 6000t/day.

In September 2017, the Investment Board of Nepal had signed a US$359m project investment agreement with Hongshi-Shivam Cement to build the plant. A 10km road was built to connect the site to the main local highway and another 22km road was built to link up a limestone quarry at Palpa. The company plans to double the unit’s production capacity to 12,000t/day by 2020.


Philippines: Holcim Philippines plants to spend US$45m towards increasing production capacity. Its new chief executive officer John Stull told The Manila Times newspaper that the company is looking to improve efficiency at its plants to improve logistics and cut energy costs. It is also planning to hasten its equipment maintenance schedule. The cement producer set a target to increase its cement production capacity to 12Mt by 2019.


Zambia: The Ventriglia family has been awarded full ownership of Zambezi Portland Cement by the High Court of Zambia. The resolution follows a 10-year battle between the Ventriglias and businessman Rajan Mahtani, according to the Times of Zambia. Mahtani’s company Finsbury Investments claimed a majority share in the cement producer but the Ventriglia family objected, asserting full ownership of the company.


Cuba: A new railway cement terminal is being built at Ciego de Ávila. The unit will have five silos with a total storage capacity of 1600t, according to the Invasor newspaper. The terminal should be compelted by the end of 2018. The site is intended to support hotel construction, infrastructure projects and general housing in the region.


Mexico: Germany’s Loesche has sold two coal or petcoke grinding mills to Cruz Azul. Both will be used on new production lines at cement plants in Hidalgo and Oaxaca respectively. No value for the deal has been disclosed.

Each mill will have a capacity of 65t/hr. Loesche will be supplying complete plant equipment, including process gas filters, mill fans, inerting units, explosion protection valves, kiln gas cyclone separators, feed screw and drag chain conveyors as well as the complete electrotechnical equipment. The scope of supply also includes engineering for steel and concrete construction.

Loesche previously delivered a LM 46.2+2 CS type mill to Cruz Azul’s Tepezalá cement plant, operated under the Cycna subsidiary, at the end of 2016.


Senegal: Cement production rose by 5.6% year-on-year to 1.8Mt in the first quarter of 2018 from 1.7Mt in the same period in 2017. The production rise has been driven by an increase in local sales, according to the African Press Agency. Local sales of cement grew by 50.6% to 1.28Mt from 0.85Mt. However, exports have fallen by 37% to 0.56Mt from 0.90Mt.


France: The Carlyle Group has started talks with HGH Infrared Systems to acquire a majority stake in the specialist provider of infrared technology products. The proposed acquisition will be subject to customary employee consultations and regulatory approvals. The deal is expected to be completed by the end of 2018. No value for the deal has been disclosed.

“This potential partnership with Carlyle is excellent news for our customers. It will also help HGH to move to the next level and to build on our strong international growth trajectory,” said Thierry Campos, chief executive officer of HGH Infrared Systems. He added that Carlyle’s international reach and its experience in aerospace and defence, oil and gas and energy markets would further help to develop the company.

HGH was founded in 1982. It develops and sells optoelectronic and infrared systems and software for surveillance applications, test and measurement and industrial thermography in different end-markets. The company operates two research and development and assembly sites in the Optics Valley near Paris, France and in California, US. The company provides solutions to clients across 40 countries through two recognised brands HGH Infrared Systems and Electro Optical Industries (EOI).


Algeria: Italy’s Cimprogetti says it is making progress on a lime plant it is building with Bedeschi for Algerian Qatari Steel. The project is to build a lime plant supporting a steel plant at Bellara in Jijel. It includes the design and supply of the entire lime plant, from the limestone receiving area to quicklime storage, which is directly connected to the Danieli steel mill. The design of power and control systems has been developed by Cimprogetti, including the supply of all electrical panels, medium and low voltage transformers, the diesel generator set and all cables. Cimprogetti is also working with Idom, a Spanish company, on the design and erection phases of the project.

The lime plant will use two Flex Reversy 9 kilns with a daily production of 420t/day each, and will be operated with natural gas. The mechanical erection is almost complete and the electrical installation has recently started. The erection works are being checked by Cimprogetti site engineers in collaboration with the end user.


US: Panamint Valley Limestone (PVL) plans to build a US$45m lime plant at Trona in California. The site and air emissions credits have been acquired, the conditional use permit process has started, and studies and preliminary engineering have been initiated. Lime production is scheduled to start in early 2021.

The PVL Lime plant will be located on a brownfield site northwest of the existing Searles Valley Minerals and ACE Cogeneration industrial facilities. Limestone will be sourced from the company’s quarry in the Panamint Valley. The unit will produce 400t/day of quick lime and hydrated lime products for use in cement, soil conditioning, water treatment and industrial processes.

PVL says that its new plant will be the only producer of lime in California, where currently all lime used is imported from outside of state. The plant is expected to create 30 to 40 new jobs.


Ethiopia: Deep Kamara, the country manager of Dangote Cement Ethiopia, has been shot dead in an attack by unknown assailants. A driver and a secretary were also killed in the incident, according to the Addis Standard newspaper. The attack took place at Inchini, near to the cement producer’s Mugher plant.

A local government source that spoke to the newspaper said that Kamara had recently visited the plant as part of discussions between the company and local residents. Oromio state suffered riots in 2016 and 2017 with damage incurred to Dangote Cement’s plant on several occasions.


India: Birla Corporation has overcome sand supply issues to see its sales and cement volumes rise in its financial year to the end of March 2018. The group overcame a restriction on sand mining in Uttar Pradesh and Bihar in the first nine months of the year, according to the United News of India. Its sales revenue grew by 19% year-on-year to US$878m from US$736m. Its cement sales volumes rose by 23% to 12.4Mt from 10Mt. Earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 14% to US$128m from US$113m.


Philippines: Denmark’s FLSmidth has won mill orders from San Miguel Northern Cement, Ionic Cementworks Industries and Oro Cemento Industries Corporation. It will supply four OK 56-4 vertical roller mills for cement grinding for the clients at different locations in the country. In addition FLSmidth will also deliver planetary mill gear units and air pollution control filters. The mills are expected to be installed by mid-2019. No value for the orders has been disclosed.


South Africa: Gebr. Pfeiffer has started installing a MVR 3750 C-4 mill for a joint venture between Osho Cement and HeidelbergCement that is building a cement grinding plant at Port Elizabeth. The deal was agreed in 2017 and TCDRI is the general contractor. It is Gebr. Pfeiffer’s first MVR mill in the country.

The new mill will be grinding 110t/hr of Ordinary Portland Cement (CEM I) to a fineness of 3500cm²/g Blaine and 80t/hr of blast-furnace cement (CEM III-A) to 4500cm²/g Blaine. A SLS 3750 BC classifier with high-precision cut will be mounted on top of the mill. The mill will have an installed power of 2600kW. It is intended to start operation later in 2018.


Norway: The government has proposed continuing funding for Norcem’s CO2 capture and storage project at its Brevik cement plant. The announcement follows an assessment by the Ministry of Petroleum and Energy of local carbon capture, transport and storage (CCS) projects. The government has proposed to fund FEED studies (Front End Engineering and Design studies) with around Euro8m in 2018. The total funding for the demonstration project in 2018 amounts to Euro29m, including funds transferred from 2017. The proposed funds for 2018 will cover FEED studies of CO2 transport, storage and up to two capture facilities.

“Of the three CO2 capture projects evaluated, Norcem has the best conditions for a successful implementation. Norcem has demonstrated project execution abilities and relatively low cost per tonne CO2 captured compared to the other two capture projects. The cement industry is also a significant contributor to global greenhouse gas emissions,” said the government in a statement Norcem, HeidelbergCement local subsidiary, which sbeat other projects by Yara and Fortum Oslo Varme to the funding.