Global Cement Newsletter

Issue: GCW365 / 08 August 2018

Headlines


The Global Cement and Concrete Association (GCCA) announced this week that it intends to take over the work done by the Cement Sustainability Initiative (CSI). This marks a change in how the cement industry as a whole approaches sustainability and in the wider context how the sector manages itself on the world stage.

The CSI was set up in 1999 with the aim of advancing a sustainability agenda for the cement industry. It has done this by laying out strategy for the industry to follow in the form of technology roadmaps and publishing its ‘Getting the Numbers Right’ (GNR) data on CO2 and energy performance information. By 2018 it had 24 cement company members composed of nine core members, 14 participating members and one affiliate member. It represents around 2.4Bnt/yr of global cement production capacity or over half of the world production, according to Global Cement Directory 2018 data.

The idea behind the membership was that the core members are all members of the World Business Council for Sustainable Development (WBCSD) and that the members would contribute ‘modest’ funds to run the organisation. That last point about WBCSD membership is worth noting because members need to stick to conditions such as publishing an annual sustainability report and agree to have the sustainability report reviewed and benchmarked by the WBCSD.

 Figure 1: Outline of selected current global cement organisations with a sustainability remit. Source: Association websites, Global Cement Directory 2018.

Figure 1: Outline of selected current global cement organisations with a sustainability remit. Source: Association websites, Global Cement Directory 2018.

The GCCA, which formed in early 2018, says it had formed a ‘strategic’ partnership with the WBCSD and that it will take over the work previously done by the CSI from the start of 2019. Although there’s no mention so far whether GCCA members have to actually become WBCSD members with all that this entails. At present the GCCA consists of nine major international cement producers, including over half of the world’s top 10 producers by production capacity, with a production base in every inhabited continent except Antarctica. Roughly speaking it represents just under 2Bnt/yr of global cement production capacity or about half of the world’s total.

Now where this starts to get confusing is that other cement associations exist with their own established advocacy roles and sustainability agendas. The established players include the various regional associations such as the Portland Cement Association in the US, Cembureau in Europe and so forth. The multinational ones also often represent national bodies.

Then there is the World Cement Association (WCA), which formed in 2016. This independent body is a private company run out of an office in London, UK with non-profit aims. It has 45 members but only three quarters are actual cement producers. Of these most are single-country cement manufacturers. The glaring standout is China National Building Material (CNBM) and its subsidiaries, representing over half of the association’s member’s cement production capacity. The production capacity of the WCA’s members is around 1Bnt/yr or a quarter of the global total. More than half of this comes from CNBM and its subsidiaries. Unsurprisingly then that Song Zhi Ping, the head of CNBM, is the president of the WCA. It too supports a sustainability agenda, saying that it, “seeks to co-operate with the WBCSD, CSI and regional and national Cement Associations.” What is noteworthy is how few of the current members of the WCA joined the CSI previously.

There is definitely a need for a global organisation advocating sustainability issues for the cement industry and by taking over the work of the CSI and the GCCA has cornered this part of what a global cement association might do. However, the GCCA represents less cement production capacity than the CSI did. The main omissions are the Indian producers, led by UltraTech Cement, as well as others. It seems likely that they will join the GCCA following the end of the CSI but there is no guarantee.

The other point arises when looking at these various cement associations is: who does what exactly? The CSI’s focus on sustainability gave it a purpose that it did well with a genuine appearance of independence. Its narrow focus also gave it a complimentary role to the existing national and regional associations. Global bodies like the GCCA and the WCA are clearly more into advocacy territory for their members. Also, a more general association approach like the GCCA and the WCA may clash with regional bodies like the PCA and Cembureau. Regional bodies seem better suited to the way governance works globally with regional groups such as the European Union (EU) or government departments in continental sized countries such as the US, China and India. However, a truly global cement body could respond better to coordinated environmental lobbying and fill in the gaps around the world in places with looser regional representation.

Sustainability is the immediate link between the CSI, the GCCA and the WCA. Indeed the WCA recently held a ‘Global Climate Change’ forum in Paris to discuss its own climate action plan. Yet, with the GCCA taking over the work the CSI does and the WCA saying it wants to cooperate with the CSI, the obvious outcome is that the GCCA will become the world’s apex cement association. It will represent the companies with the most cement production capacity, have a presence in every inhabited continent and take the lead on WBCSD issues. Beyond this though it will be interesting to see what, if anything else, the GCCA chooses to do.


Canada: Hervé Mallet, the president and chief executive officer (CEO) of McInnis Cement, is leaving the company. He has been in post since November 2016. He will be replaced, with immediate effect, by Jean Moreau, chief financial officer, who will assume the role of president and CEO on an interim basis

Moreau joined McInnis Cement in the spring of 2017. He holds experience in company, finance and operations management, and has held leadership positions within private and public entities in the finance and operations management sectors. McInnis Cement said that, “Moreau is familiar with McInnis and will ensure business continuity.”


Germany: Möllers Group has promoted Area Sales Manager Tobias Steffens to responsibility of the Asia Pacific Region. As a channel partner, he will intensify cooperation with the local sales partners and oversee the implementation of new products in the target markets.

Steffens, aged 39 years, studied mechanical engineering at the University of Applied Sciences in Wiesbaden. He worked in a position of responsibility at Swisslog and Kardex for the regions of Asia, Europe, the Middle East and Australia and was more recently a Design & Engineering Manager for intralogistic systems and special applications.


Germany: Holcim Germany’s Beckum cement plant has gained a silver sustainability certificate from the Concrete Sustainability Council (CSC). The company said that certificate is the highest that a cement plant can obtain. It certifies that the plant promotes transparency about the production process and supply chain as well as considering its impact upon the environment.

The company said that the unit is the first LafargeHolcim cement plant in the world to have CSC certification. It also plans to certify cement grinding plants and ready mix plants in Germany in the near future.


Pakisan: Fauji Cement has approved plans to set up a 12.5MW captive solar plant. The company operates a 3.4Mt/yr cement plant near to Attock in Punjab Province.


Zambia: ZCCM-Investment Holding, an investment company owned by the Zambian government, says that it will be the junior partner in a cement plant that it is planning to build in a joint venture with China Machinery Construction Group Limited (SinoConst). ZCCM will hold 35% of the joint venture, Central African Cement, and SinoConst will hold the remaining 65%. The US$680m project was announced in early 2018.

ZCCM also announced that its subsidiary, the Ndola Lime Company, was continuing to be in ‘distress.’ It said that its board was considering its options. The lime producer has reportedly suffered from liquidity problems and low production due to old equipment.


Indonesia: A barge delivering coal to Lafarge Indonesia’s cement plant at Lhoknga, Aceh has spilled around 7000t coal on a beach in Northern Sumatra. The barge was delivering coal to the plant at the end of July 2018 when it ran aground, acccording to the Antara News Agency. Lawyers representing local environmental groups have demanded that the subsidiary of LafargeHolcim be legally responsible for the cleanup operation.


Denmark: Equipment manufcaturer FLSmidth says that the cement market has remained ‘unchanged’ so far in 2018. It described the market for new cement capacity as ‘subdued’ but that opportunities for small and medium projects were available. In addition, the second quarter of 2018 showed a number of single equipment and upgrade project orders which the company has marked as a strategy area.

Order intake for its cement division fell by 42% year-on-year to Euro215m from Euro368m. However, revenue rose by 2% to Euro272m. Overall, the group’s order intake fell slightly to Euro1.35bn but revenue rose by 18% to Euro1.2bn.

"We saw the highest order intake in the Minerals division for several years, which shows that miners are starting to put action behind their investment plans. Most activity is related to single equipment and brownfield expansion. We benefit from our business model of full life-cycle offerings which enables us to support customers in their pursuit of productivity enhancements", said group chief executive officer (CEO) Thomas Schulz.


France: Vicat’s earnings rose in the first half of 2018 due to good performance in the US, Turkey, France and Kazakhstan. Its earnings before interest and taxation (EBIT) increased by 21.3% year-on-year to Euro104m from Euro86m. Its sales revenue rose by 2.7% to Euro1.28bn from Euro1.25bn. The company’s cement production increased by 5.3% to 11.4Mt from 10.8Mt.

“Excluding currency movements, which have a particularly large negative impact this year, the croup achieved notable progress in Turkey, the US, France and Kazakhstan,” said the group’s chairman and chief executive officer (CEO) Guy Sidos. He added that the group also benefitted from the start of work on new infrastructure projects in India.

However, the group reported a 21.9% fall in earnings before interest, taxation, depreciation and amortisation (EBITDA) to Euro22.7m in India due to falling prices and mounting energy costs. In West Africa EBITDA declined by 14.5% to Euro22.2m due to falling prices and rising production costs. In Europe EBITDA fell by 16.9% to Euro35m due to contacting sales in Switzerland as well as issues Italy. Finally, EBITDA fell to a loss of Euro3.9m in Egypt due to falling sales in the wake of military intervention in the Sinai region.


Russia: The head of Job Safety, Industrial Safety & the Environment Department at Eurocement’s Nevyanskiy Tsementnik cement plant has been fined Euro42,000. The fine was issued by the local authorities for emissions of non-organic dust with high silicon content, according to URBC Daily News. The plant does not have an emissions permit.


India: FCI Aravali Gypsum and Minerals India Limited (FAGMIL) is preparing to build a 1000t/day white cement plant in Himachal Pradesh. The state-run company, under the control of the Department of Fertilizers, Ministry of Chemicals & Fertilizers, has received a letter of intent from the state government of Himachal Pradesh granting it a mining lease to support building a white cement plant. This will be followed by the signing of a memorandum of understanding between FAGMIL and the state government.

The lease area is 108 hectares and it is located near Nohra Dhar Village, Tehsil Sangrah in the Sirmour District. Limestone from the site will be used to support a white cement plant. A pre-feasibility study has been completed by the National Council for Cement and Building Materials, Ballabgarh in Haryana and further planning activities are in progress.


India: Coal India plans to supply 4.65Mt/yr of coal to the cement industry via online auctions until 2023. Of this amount 1.14Mt/yr will be despatched by railway and the rest by road, according to a Coal India executive quoted by the Economics Times newspaper. Most of the coal will be supplied by Coal India’s subsidiary South Eastern Coalfields with the rest sourced from Western Coalfields, Mahanadi Coalfields and Eastern Coalfields. Bharat Coking Coal and North Eastern Coalfields are not part of the auction, as they do not offer any coal to the cement sector.


Nigeria: A group of investors from the US have visited Ibeto Cement’s Nigercem plant in Nkalagu. The visit was part of an assessment to prepare Ibeto Cement for a listing on a stock exchange in the US, according to the This Day newspaper. Cletus Madubugwu Ibeto, the chief executive officer (CEO) of Ibeto Group said that Chinese contractors were due to work on upgrading the plant to a production capacity of 6000t/day with a 45MW waste heat recovery unit. In May 2018 Beta Cement signed an investment deal with US-based private equity firm Milost Global for US$850m.


Ethiopia: Ethiopia has failed to meet its cement export target for the 2017 – 2018 financial year that ended on 7 July 2018. It planned to raise US$42m in revenue from cement exports, according to Cement and Related Industry Research Development Technology Director Simegn Degu, who was quoted by the Ethiopian Herald newspaper. However, its exports only rose by 47% year-on-year to US$25m from US$17m. Degu blamed the shortfall on shortages of input materials and a lack of foreign currency.


China/US: China’s Ministry of Commerce has proposed placing retaliatory tariffs on products from the US, including cement. The list covers 5207 items and proposes adding import taxes of up to 25% on them. It includes clinker, white cement, limestone, quicklime, slaked lime, gypsum, refractory products and cement packaging machinery. The ministry said that the new tariffs will take effect at a date to be announced later on.


India: The board of Birla Corporation has confirmed plans to build a new 3.9Mt/yr cement plant at Mukutban in Maharashtra. The unit will also include a 40MW captive power plant and a 10.6MW waste heat recovery system. The project has an investment of US$356m and it is intended to be completed by early 2022.

The cement producer says it has acquired land, mineral concessions and environmental clearance for the plant. It added that the proposed site has good railway and road links. The project is also eligible for an ‘attractive fiscal incentive’ from the state government of Maharashtra.

Birla Corporation operates a grinding plant at Butibori in Maharashtra through its Reliance Cement subsidiary.


India: Penna Cements is close to starting operations at its new terminal at Cochin Port in Kochi, Kerala. The 0.8Mt/yr unit at Ernakulam wharf includes a bagging plant and it has an investment of just under US$9m, according to the Hindu newspaper. Once it opens it will join Zuari Cement, Ambuja Cement and UltraTech Cement, which also operate from the port.


Tajikistan: The government has supported a new cement plant project to be built in the Surxondaryo Region. The unit will be financed by private investors, according to Uzbekistan Newsline. Several new cement plants are planned locally including a 2.4Mt/yr integrated project from Russia’s Eurocement Group with an investment of US$220m and two Chinese-backed projects. Xin Lei is planning to build a 1Mt/yr plant for US$108m in the Akhangaran region. Akhangaranshifer also wants to build a 1Mt/yr plant for US$100m.


Central America: Denmark’s FLSmidth has been awarded two contracts for cement plants worth over Euro250m. One deal is for a new plant and the other is for an expansion to an existing site. The expected start-up for each project is by mid-2021 and once operational, the cement plants will have a capacity of 2000t/day and 3500t/day respectively.

Both contracts include design and engineering, equipment supply, automation systems, training as well as advisory services for installation and commissioning. Each project is also dependent on FLSmidth receiving an agreed down payment before work can commence.


Paraguay: Industria Nacional del Cemento’s (INC) has officially inaugurated a second cement mill at its Villeta plant. The state-owned cement producer spent US$12m on the upgrade, according to the Agencia de Información Paraguaya. The new mill was built by China’s Sinoma. It has a cement production capacity of 80t/hr or be able to produce around 800,000 bags/month of cement. INC also plans to start operating a pozzolan drying unit at Villeta in September 2018.


US: The Federal Trade Commission (FTC) has approved a final order settling changes for Ireland’s CRH acquisition of Ash Grove Cement following a period for public comment. The FTC issued its consent for the transaction in June 2018 on the condition that CRH sell the Three Forks cement plant in Montana to Mexico’s Grupo Cementos de Chihuahua (GCC).

Also under the settlement, because the CRH cement plant in Montana currently sells a significant amount of cement into Canada through two CRH terminals in Alberta, GCC will have the option to use those terminals for three years. CRH also has agreed to purchase, at GCC’s option, cement produced at the plant for distribution in Canada for up to three years. The FTC also forced CRH to sell other assets in Montana, Nebraska and Kansas.


Canada: The government has made a proposed new carbon tax easier for large-scale industrial emitters such as cement and steel producers. Originally the new legislation proposed imposing a levy on around 30% of a company’s CO2 emissions from the start of 2018, according to the Globe and Mail newspaper. However, the revision has reduced the tax on so-called vulnerable industries with the cement and steel sectors only having to pay 10%. The levy will start at US$15/t in January 2018, rising to around US$40/t in 2022.

The decision to soften the carbon tax follows lobbying by the affected industries. The tax applies to provinces that do not have existing carbon emission controls, such as cap-and-trade schemes, that meets the central government’s standards. The provincial government of Ontario, which contains six of the country’s 17 integrated cement plants, recently decided to leave its own carbon pricing system. It will be subject to the new rules. Saskatchewan will also be affected.


Benin: HeidelbergCement’s subsidiary Cimbenin has removed two polychlorinated biphenyl (PCB) transformers from its grinding plant in Cotonou. The toxic components will be disposed of by a French company, according to the La Nation newspaper. The Société Nationale de Ciment (SONACI) installed the transformers in 1977. Subsequently Cimbenin bought the unit in 1991 and put the affected equipment into storage in 2012. The decision to remove the transformers was part of the company’s ISO 14001-2004 certification, which it obtained in 2012.


Italy: Buzzi Unicem’s sales revenue and earnings have suffered from negative currency effects in the first half of 2018. Its net sales fell by 1.2% year-on-year to Euro1.34bn from Euro1.35bn and its earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 5.7% to Euro227m from Euro241m. However, its cement sales volumes grew by 3.8% to 12.9Mt from 12.5Mt. By region the cement producer reported that its net sales rose in Italy, Germany, the Czech Republic, Slovakia, Poland and the US. Net sales fell in Luxembourg, Netherlands, Ukraine and Mexico.


US: Summit Materials’ mid-year results have been negatively affected by poor cement sales and lower aggregate sales from its Houston operations. Revenue rose by 15% year-on-year to US$717m in the first half of 2018 from US$623m in the same period in 2017. However, its sales volumes of cement fell by 10% to 0.97Mt from 1.08Mt. The company’s net loss rose to US$19m from US$3m.

“Organic sales volumes in our cement segment were impacted by a combination of high precipitation levels during April and May, together with competitive pressures in the markets we serve,” said chief executive officer (CEO) Tom Hill.

The building materials producer operates an integrated cement plant under the Continental Cement subsidiary at Hannibal in Missouri.


UK: The Global Cement and Concrete Association (GCCA) has formed a strategic partnership with the World Business Council for Sustainable Development (WBCSD) to facilitate sustainable development of the cement and concrete sectors. As part of the new agreement, the work carried out by the Cement Sustainability Initiative (CSI) will transfer from WBCSD to the GCCA on 1 January 2019 with activities managed out of the GCCA’s London offices. The new partnership will also create synergies between work programmes to benefit both the GCCA and WBCSD and their respective member companies.

“Transferring the activities of the CSI to the GCCA is a logical step and further underlines the cement and concrete sector’s commitment to advance sustainable development across the construction cycle. As the authoritative worldwide voice of the cement and concrete sector, the GCCA is ideally placed to take this work to the next level, building on the strong foundations established by WBCSD,” said Albert Manifold, chief executive officer (CEO) of CRH and GCCA President.

The CSI, which was established in 1999 and currently operates under the auspices of WBCSD, is a global effort by 24 major cement producers to advance sustainable development. Over its 19-year history, the CSI has focused on understanding, measuring, managing and minimising the impacts of cement production and use by addressing a range of issues including: climate change, fuel use, employee health and safety, airborne emissions, concrete recycling and quarry management.


Algeria: LafargeHolcim Algeria has exported 40,000t of clinker from the port of Oran. This is the company’s first export of clinker, following exports of cement carried out earlier in the year, according to the Algeria Press Service. The subsidiary of LafargeHolcim operates two cement plants in the country and it holds stakes in two others.


Belarus/Russia: The Belarusian Architecture and Construction Ministry says that the trade turnover of the Belarusian-Russian cement market reached up to US$400m between 2014 and 2018. Following the signing of a bilateral agreement in 2014 Belarusian cement was allowed to be sold in Russia via Eurocement Group, according to the Belarusian Telegraph Agency (BelTA). Belarusian Architecture and Construction Minister Anatoly Cherny and Eurocement Group President Mikhail Skorokhod met in early August 2018 to discuss performance in the first half of 2018.


Poland: Lafarge Poland officially opened the Siekierki ash separation plant in July 2018. The unit was developed with local power generation company PGNiG Termika. The plant uses technology from the US’ Separation Technologies, using its proprietry electrostatic process.

The unit converts fly ash into two products: ProAsh containing less than 5% flammable parts and HiCarbon fuel containing about 30 - 50% flammable parts. ProAsh ash is used as a construction product used in cement production, ready-mix concrete and prefabricated construction. HiCarbon is used as a fuel because it contains significant amounts of unburnt carbon and so it can be reused in furnaces.

The National Fund for Environmental Protection and Water Management (NFEP&WM) awarded the project a loan of around Euro9m. PGNiG Termika operates a 2078MW coal-power plant at Siekierki.


Italy: Cemitaly has been allowed to use slag and ash in cement production at its Taranto plant following an investigation, according to the Il Fatto Quotidiano newspaper. The former Cementir unit was investigated in 2017 as part of an illegal waste probe that examined whether the Taranto plant purchased ‘illegal’ by-products from Enel and the ILVA steel plant to produce cement.


UAE: Lafarge Emirates has ordered a Jetflex Plus burner for its Fujairah cement plant from FLSmidth. Thierry Terriere, the plant manager, and Simon Jensen, head of FLSmidth Middle-East, signed the contract.

“As the business has shifted towards using low-cost fuels with high-quality clinker, we have made an ambitious decision and chosen the best option on the market – this next generation burner from FLSmidth," Sohail Qaiser, Process Manager at Lafarge Emirates Cement. He added that the company expects a ‘significant’ change in its fuel mix cost as well as a more sustainable kiln operation.

FLSmidth says that the Jetflex Plus burner is the first to be installed in the LafargeHolcim Group and that the company was selected for procurement and supervision of the installation of it. The burner product has rotatable jet air nozzles allowing for optimal adjustment of the flame as well as the low NOx emissions for various fuel types and operating conditions.

The relationship between the companies dates back to 2007 when FLSmidth built the 7500t/day Fujairah plant for Orascom.


Spain: Cemex España has submitted a proposal to the local government to extract a total of 15Mt of limestone from its Can Negret quarry near to its Lloseta cement plant in Majorca. The proposal will run until 2032, according to the Ultima Hora newspaper. The company was previously granted a concession at the quarry in 1982.


Myanmar: Three local activists have been arrested for protesting against a new cement plant being built at Patheingyi Township in Mandalay Region. In late July 2018 local residents marched on environmental grounds from Mandalay to Nay Pyi Taw in protest against the construction of a 5000t/yr coal-fired cement plant in Dahattaw Village-tract, Patheingyi Township, according to the Asia News Network. However, police intervened and started legal action against some of the protestors.


Germany: ThyssenKrupp has decreased its earnings forecast for its 2017 – 2018 financial year due to the poor performance of its Industrial Solutions division. The division is expected to report a negative adjusted earnings before interest and taxation (EBIT) of Euro200m in the third quarter of the year due to higher expected total costs, particularly for a cement plant in Saudi Arabia and two other industrial projects. The group said that the number of major projects in the cement and fertiliser sector had decreased ‘considerably,’ partly due to the production overcapacity in the cement market.

"It is important to me to call it what it is. The results of our analysis at Industrial Solutions are anything but satisfying. The structure of plant construction must be adjusted to the changed market conditions in order to achieve a turnaround and finally become competitive again. We must act swiftly here," said Guido Kerkhoff, chairman of the executive board of ThyssenKupp. The group has proposed focusing its Industrial Solutions division on small and medium-sized projects and targeting plant construction on the higher-margin service business.

In mid-2017 the group announced plans to reorganised its Industrial Solutions division, including the decision to cut 1500 jobs in operational areas.