Global Cement Newsletter

Issue: GCW372 / 26 September 2018

Headlines


More positive news emerged from the UK cement industry this week with the news that Cemex is planning to restart the second kiln at its South Ferriby plant later in 2018. This marks the full recovery of the plant after a disastrous flood in late 2013 and it is an all round good news story. Around the same time the local government in Scotland approved the planning application for an upgrade to Tarmac’s Dunbar cement plant. That project involves installing a new cement grinding mill, a new cement storage silo and a rail loading facility.

 Graph 1: Domestic cement, imported cement and other cementitious sales in the UK, 2001 - 2017. Source: Mineral Products Association.

Graph 1: Domestic cement, imported cement and other cementitious sales in the UK, 2001 - 2017. Source: Mineral Products Association.

The timing is interesting given the general uncertainty in the UK economy ahead of the UK exit from the European Union (EU). However, data from the Mineral Products Association (MPA) shows that total cementitious material sales (cement plus products made from fly ash and ground granulated blast furnace slag (GGBS)) reached 15.3Mt in 2017 from a low of 10.3Mt in 2009 following the financial crash. This isn’t as high as the 15.8Mt figures recorded in 2007 but it does mark a recovery. This masks to an extent the change in the market since 2007. Cement sales in 2017 at 10.2Mt were still below a high of 11.9Mt in 2008. The recovery has been driven by higher imports, 1.9Mt in 2017, and higher use of fly ash and GGBS products, which reached 3.2Mt in 2017.

Cemex and Tarmac are not alone in announcing projects. HeidelbergCement’s local subsidiary Hanson is upgrading its Padeswood plant with a new Euro22m mill. Irish slag cement grinding company Ecocem opened its import terminal at Sheerness in mid-2017 and French grinding firm, Cem'In'Eu, has also expressed interest in building a plant, in this case in London.

As discussed earlier in the year, new upgrade projects in the UK appear to carry an element of risk given the unknown status of its departure from the EU. Supply chains may be affected, companies are delaying investment and the value of Pound Sterling is falling. The collapse of construction services company Carillion also had a knock-on effect in the industry and, with major work on the Crossrail infrastructure project finishing, the industry has no major infrastructure projects in support. A quarterly graph of UK construction industry output volume by Arcadis shows almost uniform growth since mid-2012 although this started to flatten in 2017. A badly-handled Brexit (UK exit from the EU) could undo this growth.

All of this presents a picture of risk-adverse capital projects in the UK. The MPA figures help to explain the focus on grinding at Padeswood and Dunbar. The market has changed since 2007, with a growing focus on imports and secondary cementitious materials. Hence spending money on equipment to process these inputs makes sense. The decision to increase production at South Ferriby meanwhile depends on reviving existing equipment. Regional cement sales figures to 2016 from the MPA appear to indicate static demand in counties close to the plant (Yorkshire and Humberside) but sales have increased in the East Midlands and the East of England.

Just compare the current UK approach to the situation in Egypt. This week the head of the cement division of the Chamber of Building Materials described the decision to build the Beni Suef cement plant to local media as “not based on precise information” and that it had harmed local production. In case you had forgotten, that plant is one of the biggest in the world with six lines. The commentator may well have been representing smaller local producers but opening a 12Mt/yr plant in Egypt in these turbulent economic times marks a different approach to risk than the modest plant upgrades in the UK. Let’s wait and see who has the best approach.


Ghana: Nigeria’s Dangote Cement has appointed Brice Houeto as its new country director for Ghana. He replaces Tor Nygard who has retired after two and half years of managing the business, according to the Daily Graphic newspaper. Houeto holds over a decade of management experience in the cement industry across Africa. Previously, he was the country managing director of Lafarge Cement, Guinea.


US: Bulk Handling Systems (NHS) has appointed Matthias Erdmannsdoerfer as managing director of Max-AI. Prior to this new role, Erdmannsdoerfer worked for more than six years as the president of National Recovery Technologies (NRT), a developer of optical sorting technology and subsidiary of BHS. In his new role Erdmannsdoerfer will be responsible for the Max-AI product line including sales, business development and product and application development.

Launched by BHS in 2017, Max-AI technology powers robotic sorters, optical sorters and reporting systems, and will continue to be integrated into new and existing equipment throughout material recovery facilities (MRFs). Since its inception, more than 50 Max-AI AQC (Autonomous Quality Control) robotic sorters have been sold in quality control (QC) applications of both fibre and containers.


Greece/UK: Titan Group has joined the Global Cement and Concrete Association (GCCA), a global organisation dedicated to strengthening and promoting the sector’s contribution to sustainable construction. The cement producer said that its participation would build on its commitment to, “actively engage in collaborative initiatives aiming to address global sustainability challenges.”

Launched in January 2018, the GCCA intends to become a respected industry voice and trusted source of information on sustainable construction. It complements and supports the work done by cement associations at national and regional level. As of January 2019 GCCA will incorporate the activities of the Cement Sustainability Initiative (CSI) following a strategic partnership with the World Business Council for Sustainable Development (WBCSD).


Ghana: Brice Houeto, the new country head of Dangote Cement in Ghana, says that the company expects to open its new grinding plant in Takoradi by end of 2019. The incoming manager made the comments to the Daily Graphic newspaper. The new unit will have a production capacity of 1.5Mt/yr. It is expected to create 1000 new jobs in the Western Region.


India: JSW Cement has started building a 1.2Mt/yr cement grinding plant at Kalinganagar Industrial Complex in the Jajpur district of Odisha. The unit will be used to produce Ordinary Portland Cement and ground granulated blast furnace slag (GGBS), according to Projects Today. The project had been on hold since 2016 due to issues with the land. The unit is expected to be operational by September 2020.


Philippines: Cemex Holdings Philippines (CHP) is running an assessment to see how a local government order to stop mining operations in Naga will affect its business. APO Land & Quarry has been requested to stop quarrying operations in Naga City, Cebu following landslides, according to the Philippine Star newspaper. APO Land & Quarry supplies raw materials to CHP’s subsidiary Apo Cement, and it is indirectly 40% owned by Mexico’s Cemex.


Australia: Adelaide Brighton is seeking damages from a former credit manager over US$9m in missing funds. The cement producer has accused former employee Glenda Ivy Burgess of the embezzlement following an internal audit, according to the Advertiser newspaper. Burgess worked for Adelaide Brighton for 18 years but was dismissed in February 2018.

The allegations include misallocating customer payments, falsifying accounts, increasing customer credit limits without authority and providing false information.

The construction company launched a civil lawsuit against Burgess at the same time that a police investigation was ongoing. This has subsequently led to a clash between civil and criminal proceedings as the accused successfully petitioned the Supreme Court to delay the civil case whilst the criminal investigation continues.


Pakistan: The Flying Cement Company has ordered a vertical roller mill from Germany’s Loesche for a new 7000t/day production line in Lahore. The raw material mill will be used at Flying Cement’s plant at Mangowal, where it will grind 600t/hr. The plant is mainly used to produce Ordinary Portland Cement (OPC).

Along with the mill, the scope of supply also includes a Hurriclon system from A TEC, a member of the Loesche Group, for separating finished material from the gas flow leaving the mill.

Commissioning is expected to take place at the end of 2018.


Rwanda: Kenya’s ARM Cement is set to auction off its Kigali Cement plant in Nyarugenge District for a second time, following a first attempt. The company forced a legal postponement to the first auction when offers for the unit failed to reach a level it deemed acceptable, according to the New Times newspaper. The only bid it received was for US$113,000 a figure significantly short of the estimate US$1.4m market value of the plant. Kigali Cement operates a 0.1Mt/yr plant.

Kigali Cement plant is being sold in order to pay its creditor, Rwanda Enterprise Investment Company (REIC) in a long running dispute between the companies. ARM Cement owns Kigali Cement but REIC has held shares in it since 2008. ARM Cement acquired a stake in Kigali Cement in 2010 and later took over the management of the company in 2014. Meanwhile, ARM Cement entered administration at home in Kenya in late August 2018.


India: Shailendra Chouksey, president of the Cement Manufacturers Association, has complained about imports of cement from Pakistan damaging the local industry. He told the Indo-Asian News Service that cement from Pakistan was up to 15% cheaper than Indian cement. There has been no customs duty on cement imports from Pakistan since 2007, making it competitive in comparison to local production, especially in states that neighbour Pakistan. By comparison, imports of cement to Pakistan face a duty of 11%.

Data from the Directorate General of Foreign Trade shows that 1.68Mt of cement was imported into India during the 2017 – 2018 financial year that ended in March 2018. 1.27Mt or 76% of this total was imported from Pakistan.

Indian producers have also complained about the high rate of the local Goods and Services Tax (GST) in the country. They are hoping to reduce the rate to 18% from 28% at present.


Egypt: Medhat Istvanos, head of the cement division of the Chamber of Building Materials, affiliated to the Federation of Egyptian Industries, says that exports from the country are being made uncompetitive due to the government’s decision to raise energy prices in June 2018. He said that the local exchange rate had aided exports but that “the government’s bureaucracy has eliminated export hopes,” according to the Daily News Egypt newspaper. The local industry exported cement worth US$57m during the first half of 2018.

Istvanos said that the industry has a production capacity utilization rate of 60% with a production capacity of 84Mt/yr but consumption of only 54Mt/yr. He added that the decision to build the new 12Mt/yr Beni Suef cement plant was “not based on precise information” and that it had harmed local production.


Morocco: Cement sales volumes at Ciment du Maroc have fallen by 2.6% year-on-year in the first half of 2018. This compares to a decline of 2.9% in national consumption, according to local media. Its operating turnover fell by 4.2% to Euro449m. The subsidiary of Germany’s HeidelbergCement also noted that it was happy with the progress of its Nador grinding plant project.


Philippines: Trade Secretary Ramon M Lopez has started an investigation studying whether the government should protect the local cement industry, following a rise in imports. A review by the Department of Trade and Industry (DTI) found that imports grew by 70% year-on-year in 2014, 4391% in 2015; 549% in 2016 and 72% in 2017, according to the Business Mirror newspaper. However, the market share of imports grew from 0.02% in 2013 to 15% in 2017, leading to claims that increasing imports are damaging local production.

The review contends that the domestic industry's sales revenue increased from 2013 to 2016 but that it declined by 12% in 2017. Industry earnings fell in 2017 following growth. The DTI paper also claims that the cost of cement imports is around 14% lower than local product and that this has led to local producers dropping their prices by 10% to compete.


Brazil: France’s Vicat has confirmed that it is in talks with Ciplan. Local newspaper Valor Econômico revealed that Vicat was in the ‘final stages’ of buying the cement producer. Ciplan was founded in 1968 and it operates an integrated plant at Sobradinho in Bahia near to Brasilia.


Eritrea/Ethiopia: High volumes of cement imports have been reported across the Ethiopian-Eritrean border following a normalisation of relations between the neighbouring countries. Since mid-September 2018 an estimated 50t/day of cement have been transported from Adigrat in Ethiopia to three border towns in Eritrea, according to business owners in Adigrat quoted by the Addis Fortune newspaper. “A minimum of 20 trucks carrying cement is leaving from Adigrat to Eritrea daily,” said Angesom Berhane, owner of a cement store in Adigrat.


South Africa: A ship carrying clinker and gypsum has arrived at the Port of Ngqura. The raw material is intended for Osho Cement, a company setting up a grinding plant at Coega special economic zone, according to the Herald newspaper. The imported clinker and gypsum was transported by truck to the new plant.

The joint venture between South Africa’s Osho ventures and Germany’s Heidelberg Cement plans to market cement from its new unit to South Africa, Sub-Saharan Africa and islands in the Indian Ocean. The plant is scheduled to open the new plant in late 2018.


India: N Srinivasan, the vice-chairman and managing director of India Cements, predicts that cement demand is improving in the south of the country. At the company’s annual general meeting in Chennai he said that demand for cement is expected to improve the 70% capacity utilisation rate recorded in the 2017 – 2018 financial year, according to the Financial Express newspaper. The region had a cement production capacity of 160Mt/yr but demand was only up to 80Mt.

He added that India Cements reported a utilisation rate of 71% in the previous financial year and that this had improved to 80% in the first quarter of the current year. He also expected that the second quarter would be better despite floods in Kerala and a transporters' strike.


US: Cemex has celebrated the 50th anniversary of its Balcones Quarry in New Braunfels, Texas with an event attended by Cemex USA Regional President - Texas and New Mexico Region Joel Galassini, and which included a planned quarry blast.

Balcones Quarry began operations in 1968. Cemex purchased the quarry along with the neighbouring cement plant in 1994. The quarry currently processes more than 10Mt/yr of crushed limestone annually and supports infrastructure, residential and commercial projects across Texas. The United States Geological Survey (USGS) recently ranked the quarry as the top crushed stone producer in the country in terms of volume.

In 2016 the site opened a water recycling plant at the quarry to cut reliance on local water sources. Recently, Cemex opened its Wildlife Habitat Centre adjacent to the quarry to promote conservation and sustainability. The centre includes about 17 acres of restored prairie, pollinator gardens and meadows planted with native plants. An education centre and wheelchair-accessible produce garden are also on the site.


Oman: Oman Cement has launched a new brand identity and logo. The changes to its marketing are intended convey its strong brand value proposition that is synonymous with quality, strength and reliability, according to the Muscat Daily newspaper. The new brand identity is hoped to help the company’s sales and market share.


Russia: Lipetskcement, a subsidiary of Eurocement, has added Eurocem 500 Extra to its product portfolio over the current construction season. The CEM II / А-W 42.5Н strength cement uses mineral additives to offer lower production costs, higher strength and higher corrosion resistance and water resistance. The product is offered in bagged and bulk consignments.


Russia: Pervaya Stroitelnaya Kompaniya (PSK) plans to build a 1.2Mt/yr cement plant in the Petrovsky district of the Tambov region. The project has an investment of Euro126m, according to the Kommersant newspaper. The unit will use the Borisovsky deposit for its raw materials. PSK previously purchased the licence to develop the mine from Tambov-Cement company. The project is scheduled to be built from 2019 to 2025 in several stages.


Tajikistan: Average monthly volumes of cement exports have grown by 37% year-on-year to 115,000t in the first eight months of 2018 compared to 84,000t for the whole year in 2017. Data from the Ministry of Industry and New Technologies shows that 920,000t of cement was exported from January to August 2018, according to the Asia Plus agency. 520,000t was exported to neighbouring Uzbekistan, 340,000t to Afghanistan and 60,000t to Kyrgyzstan.


Pakistan: DG Khan’s sales rose by 3% year-on-year to US$271m in the year than ended on 30 June 2018 from US$263m in the same period in 2017. Its profit increased by 14% to US$72.4m from US$63.6m.


Oman: Raysut Cement has been added to a list of Sharia-compliant companies for the second quarter of 2018 compiled by the Muscat Securities Market. It joins Oman Cement, which was listed in the first quarter of 2018, according to the Oman Daily Observer newspaper. The list includes 31 publically listed companies that conform to the requirements of Islamic Sharia according to the rules approved by the Accounting and Auditing Organization for Islamic Financial Institutions, Companies on the list cover a cross-section of industrial sectors.