Global Cement Newsletter

Issue: GCW386 / 09 January 2019

Headlines


Peru’s been the place over the last week with news reports of new production capacity and its targeting as a key export market by Vietnam.

Local press reported this week that three new cement grinding plants are planned to start production in 2019. Cemento Inka plans to build a 0.6Mt/yr grinding plant at Ica near Pisco. It also plans to upgrade the kilns at its plant at Cajamarquilla near Lima. Then Mixercon, a ready-mix concrete firm, wants to spend US$20m towards building two new plants in northern Lima, also in 2019. It also has plans to open distribution centres around the capital too.

For a local industry generally dominated by local often family-controlled producers this is quite a change. The larger companies – Pacasmayo, UNACEM and Yura – normally dominate the headlines and the market here. Unsurprisingly then that Pacasmayo and Yura also have upgrades planned for their plants in 2019 too.

Changes to capacity started in late May 2018 when Salaverry-based importer Invecem was said to be buying equipment for a 0.25Mt/yr grinding plant. Then things really started moving when Unacem bought Cementos Portland (Cempor), a joint venture between Chile's Cementos Bío Bío and Brazil’s Votorantim Cimentos. The foreign companies were planning to build a plant near Lima but the project was delayed by a legal battle over environmental issues intitiated by Unacem. This was followed by Cal & Cemento Sur (Calcesur), a subsidiary of Grupo Gloria, announcing that it was going to add a new production line to its cement and lime plant in Puno.

With this level of interest in grinding plants going on it’s unsurprising that Vietnam, a major exporter of cement, has taken an interest. Imports of cement to Peru rose by 65% year-on-year to 0.94Mt in the 12 months from December 2017 to November 2018 from 0.57Mt in the same period previously. Imports of clinker rose by 37% to 0.78Mt from 0.57Mt. This compares to a rise of 21% to 0.61Mt in cement imports in 2017 and a fall of 1.2% to 0.51Mt in 2016. In the 12 months to the end of November 2018 most of that imported cement (81%) came from Vietnam followed by 14% from China and 3% from Mexico. Clinker imports have been more varied with 39% from South Korea, 31% from Vietnam, 19% from Ecuador and 11% from Japan. The general situation for the clinker producers has been a slight increase in cement production to 10Mt for the 12 months to the end of November 2018 and slightly higher increases in despatches.

So, it looks like an apparent cement demand is up in Peru and the importers are rushing to meeting demand. The question, then, is why haven’t the clinker producers announced projects to squeeze out the grinders? As mentioned above Pacasmayo and Yura have upgrades planned but nothing really large seems to be coming yet. Also, given the tough time Cempor was given by the local companies what kind of opposition are the new projects by Cemento Inka, Mixercon and Invecem likely to face? The country’s gross domestic product (GDP) growth rate is below the glory days of the 2000s when it topped 6% but it is still one of the strongest in South America with 3.8% forecast for 2019 by the World Bank. This is the country in the region to watch in 2019.


Nepal: Surendra Prasad Paudel has resigned as the general manager of Udayapur Cement following his appointment as the head of the Nepal Oil Corporation. Paudel became the head of the cement producer in February 2018, according to the Kathmandu Post newspaper. The chartered accountant improved the financial situation at the company, reporting a profit in the last financial year and clearing debts.


Saudi Arabia: Tabuk Cement has appointed Ali bin Mohammed Al-Saif Al-Qahtani as its new general manager. It follows the resignation of Ali Bin Mohameha Al-Asmari. Al-Qahtani holds a bachelor's degree in Chemical Engineering from King Saud University and worked for a variety of companies including Saudi Aramco.


Tunisia: United Cement Investor will start building a new 1.5Mt/yr cement plant at Bir Thlathin in southern Tataouine in March 2019. The project has a cost of around US$320m, according to the Agency Tunis Afrique Press. Local investment will total around US$95m. The project is expected to create 419 direct jobs and 600 indirect jobs.

ThyssenKrupp Industrial Solutions (France) has been involved with the project. Investment is coming from local, UAE-based and German financiers.


Bangladesh: Chhatak Cement plans to spend US$106m on building a new dry production line at its plant near Dhaka. The project is scheduled to be completed by 2021, according to the Financial Express newspaper. The subsidiary of the Bangladesh Chemical Industries Corporation (BCIC) plans to finance the upgrade with a US$63m loan from the government. The plant is currently using equipment that is up to 80 years old. At present it has a production capacity of 70,000t/yr despite upgrades in the 1980s and 2000.


Pakistan: Shariq Siddiqui, chief executive officer (CEO) of Pakistan International Bulk Terminal (PIBT), forecasts that coal imports for cement producers will rise to 10Mt/yr in 2020 from 8Mt/yr at present. This growth will be driven by new cement production capacity that is being commissioned, according to the News International newspaper. Overall, total coal imports are expected to grow to 30Mt/yr in 2020 driven by new coal-fired power stations.


Iran: Jafar Sarqeini, the Deputy Minister of Industry, Mine and Trade for Mining Affairs, says that US-backed trade sanctions have not slowed cement exports. He added that the embargo has only placed some obstacles in the way of financial transactions and return of money to the country, according to the Islamic Republic News Agency. The official said that the local industry can export up to 20Mt/yr of cement. Local production capacity is forecast to reach 120Mt/yr by 2025. However, a recession in the mining sector has kept production behind capacity.


Sri Lanka: Insee Group has signed a memorandum of understanding with the International Union for Conservation of Nature (IUCN) to protect limestone hills in the company’s quarrying sites in Sri Lanka, Cambodia, Thailand and Vietnam.
The ultimate goal of the partnership is to turn the limestone quarrying sites into forests through rehabilitation programmes.

In Sri Lanka, the agreement is intended to strengthen Insee Cement’s capacity to rescue and release threatened wildlife, prepare mine restoration guidelines and carry out annual ecological monitoring of restored mines in Insee Cement’s quarry sites in Aruwakkalu and Puttalam.

“In Sri Lanka we have worked with IUCN since 2007 to ensure conservation in quarry sites, as the partnership is focused on delivering practical solutions which protect Sri Lankan ecosystem. We take pride in meeting the expectations of our local stakeholders and join hands with our group and OpCo’s on the dedicated commitment to enhance forestry and quarry management in Asia,” said Nandana Ekanayak, the chief executive officer (CEO) of Insee Cement.


India: UltraTech Cement and local truck companies have ended a dispute over the size of payloads in Himachal Pradesh after mediation from the state government. The disagreement over increasing the size of truckloads to 12t started in late December 2018, according to the United News of India agency.


US: Charah Solutions has installed its MP618 thermal beneficiation technology at its terminal in Sulphur, Louisiana. The upgrade is intended to improve the quality of fly ash and to increase its supply of marketable fly ash to concrete producers. The proprietary process reduces loss on ignition, ammonia, activated carbon and moisture in fly ash.

The company hopes to provides concrete product producers and builders with a source of Class F fly ash to support a growing number of construction projects in the greater Lake Charles and Sulphur region. The Sulphur terminal is Charah Solutions’ second barge-supplied location in southern Louisiana. Its LaPlace, Louisiana terminal currently serves customers in Louisiana, Mississippi and Alabama.


US: Continental Cement’s Hannibal plant has been awarded Energy Star certification by the Environmental Protection Agency (EPA). To qualify for the certification the cement producer was required to perform in the top 25% of cement plants nationwide for total energy efficiency (thermal and electrical) and meet environmental performance levels set by the EPA.

“Continental Cement Company is pleased to accept EPA’s Energy Star certification in recognition of our energy efficiency efforts,” said Matt Helms, plant manager at the unit.

To earn the Energy Star certification Continental Cement established an energy management policy, it identified operating characteristics and energy usage, it promoted energy efficiency and it followed the Energy Star guidelines for energy management.


Paraguay: Denmark’s FLSmidth has been awarded a contract to deliver equipment for a new cement plant. The contract has a value of over US$54m. The expected plant start-up is within 24 months and the plant is expected to be fully operational in 2021. The plant will have a capacity of 2500t/day and will mainly supply cement to its local market.

FLSmidth will design and engineer the production line and will deliver equipment for the entire production line, from crushing to packing, while the customer will be in charge of the civil design and construction of the plant.

"The customer needed a state-of-the-art solution to meet the steady demand for cement in this developing region. This contract reinforces our position as the leading supplier of the most productive and energy-efficient equipment and technology for customers in the cement industry who focus on productivity, reliability and sustainability," says Jan Kjaersgaard, President, Cement, FLSmidth.


Chile: FCT Combustion has been awarded a kiln conversion project by an unnamed cement company. The project is a conversion of an existing direct-fired rotary kiln into a state of the art indirect-fired kiln using pulverised coal. Delivery for material is scheduled by April 2019 and for it to be commissioned by October 2019.

FCT is responsible for the complete engineering and procurement supply, including the following main equipment: coal bag filter; process ID fan; fire and explosion detection and suppression; coal dosing; multi fuel burner for coal, natural gas and fuel oil; motorised burner trolley; coal pneumatic conveying; primary air fan; emergency cooling; automatic ignition; flame monitoring; and fuel oil pumps and valve train. The project targets are low NOx emissions, better kiln operation and stability and improved fuel consumption.


Argentina: China’s Sinoma International says that it has successfully lifted the first steel column of the pre-heater tower on a 5800t/day production line it is building at Loma Negra’s L'Amalí cement plant. The work in late December 2018 marked the start of the installation phase of the project. It is the subsidiary of China National Building Material’s (CNBM) first engineering, procurement and construction (EPC) project in South America. When the project was first announced in late 2017 it had a completion date of early 2020.


Paraguay: Industria Nacional del Cemento (INC) says that its despatches of cement grew by 2% year-on-year to 12.7 million bags in 2018 from 12.6 million bags in 2017. The company described how it overcame a ‘difficult moment’ in late 2018 by normalising the cement despatch process and supplying overdue orders. Local media reported a shortage of cement and technical issues at INCs Villeta plant in late 2018.


Algeria: Germany’s Aumund has received two clinker conveying equipment orders for cement plants at Zahana and Bechar. The two orders comprise 26 belt and chain bucket elevators, two bucket apron conveyors, ten pan conveyors and ten drag chain conveyors. No value for the deals has been disclosed.

The first order is for the 4500t/day Société des Ciments de Zahana (SCIZ) plant near Oran. Here three chain bucket elevators with centre distances ranging from 22.5 - 34.9m and capacities from 50 - 220t/hr will be used to convey cement and clinker. 11 belt bucket elevators (22.5 -116.1m) will convey raw meal, cement and clinker with capacities between 190 - 680t/hr. The Aumund bucket apron conveyor, with a centre distance of 61.1m and a capacity of 360t/hr, will join the five Aumund pan conveyors (18.3 - 106.8m, capacity 300 - 360t/hr) in conveying clinker. The ten Aumund drag chain conveyors with centre distances between 6.1 - 33.8m will be used in clinker dust extraction and are designed for conveying capacities from 15 - 80t/hr.

The second order is for the 3200t/day Bechar cement plant. This order was placed by China’s CBMI to Aumund Beijing with support from Aumund France. This plant will operate 15 Aumund belt and chain bucket elevators, five Aumund pan conveyors and an Aumund bucket apron conveyor for its bulk materials handling. The bucket elevators, with centre distances ranging from 11 - 102.9m, will convey raw meal, cement and clinker with capacities from 70 – 480t/hr. The five pan conveyors, with centre distances from 22.2 - 89.8m, will convey their loads at up to 480t/hr. The Aumund bucket apron conveyor in Bechar (centre distance 88.5m, capacity 200t/hr) will also convey clinker.


Ivory Coast: China’s Tianjin Cement Industry Design & Research Institute says that it received the provisional acceptance certificate (PAC) from an unnamed customer for a grinding plant project in late November 2018. Commissioning, first cement production and project sign-off was received for the two lines. Cimasso, a subsidiary of Cim Metal Group, reported first cement production at its new 2.6Mt/yr grinding plant Bobo Dioulasso in November 2018.


China: West China Cement says that it is expecting its net profit to record a ‘substantial’ increase year-on-year in 2018. It has attributed this to a rise in average cement prices. Subsequently, its sales revenue rose by 28% year-on-year for the first eleven months of 2018 compared to the same period in 2017.


India: Birla Corporation has entered the construction chemicals and additives business by launching three new products. It is promoting Perfect Plus IWP, Perfect Plus SBR Latex and Perfect Plus Wall Putty, according to the Business Standard newspaper. The products will have been released in Uttar Pradesh and further rollout will follow. The initiative is intended to create a new revenue stream for the cement producer.


Central America: The value of Chinese imports of cement grew by 2% year-on-year to US$77.1m in the first half of 2018 from US$75.6m in the same period in 2017. Nicaragua imported around US$28m, Guatemala US$18m, El Salvador US$12m, Honduras US$7m, Panama US$6m and Costa Rica imported around US$5m, according to CentralAmericaData.


Indonesia: Semen Baturaja’s cement sales volumes rose by 24% year-on-year to 2.17Mt in 2018 from 1.76Mt in 2017. President Director Jobi Triananda Hasjim said that the growth was 5% greater than the industry’s average in 2018, according to the Antara news agency. Data from the Indonesian Cement Association shows that in November 2018 Semen Baturaja had a market share of 54% in South Sumatra, 26% in Lampung,14% in Jambi, 8% in Bengkulu and 5% in Bangka Belitung.


Pakistan: Local cement sales fell by 1.41% year-on-year to 19.6Mt in the first half of the reporting year to December 2018. The decline, the first in nine years, has been blamed in a cut in development spending, according to the News International newspaper. The All Pakistan Cement Manufacturers Association (APCMA) said that the decline in domestic cement consumption was more pronounced in the northern region where most of the country’s production capacity is based. Cement sales fell by 5.95% to 15.5Mt in the north but they increased by 20.7% to 4.1Mt in the south. Despite this, exports rose by 48% to 3.6Mt, supported by plants in the south.


UK: Cemex says that it will use 100% renewable electricity at supplied sites in a partnership with energy, services and regeneration group Engie. Engie has been providing electricity to over 150 Cemex UK sites for over 10 years, also supplying gas to 33 of these sites. The current contract is to be extended for a further 12 months. All of the electricity supplied to the sites will be from 100% renewable energy sources including wind energy.

“Cement manufacture is inherently energy-intensive and we work hard to minimise energy consumption within the process constraints. The switch to electricity from renewable sources is playing a key role in our carbon reduction strategy,” said Martin Hills, Head of Energy and Carbon at Cemex in the UK.

Cemex is also using Engie’s demand side services, such as load management to avoid peak tariffs and rapid frequency response, which generates extra revenue for Cemex UK. Engie manages all contractual requirements with National Grid on Cemex UK’s behalf.


India: The Central Pollution Control Board (CPCB) has ordered Malabar Cements plant at Walayar, Palakkad in Kerala to comply with emissions standards or face closure. The cement producer has been given seven days to comply from the 31 December 2018, according to the Times of India newspaper. Malabar Cements was originally granted extra time, to 10 May 2018, to meet the new standards. The CPCB later declared that no cement producer would be able to flout the rules past 31 August 2018. It also intends to fine the company around US$570/day from the end of August 2018 for breaking the standards.


India: Rajputana Properties, a subsidiary of Dalmia Bharat, has requested that the Supreme Court consider a review of its decision to dismiss a plea challenging the National Company Law Appellate Tribunal's (NCLAT) order allowing UltraTech Cement to acquire Binani Cement. The Supreme Court is scheduled to consider the review request in early January 2019, according to the Financial Express newspaper. UltraTech Cement declared that Binani Cement was its subsidiary in November 2018 following a protracted legal battle with Dalmia Bharat. It changed its name to UltraTech Nathdwara Cement in December 2018.


Oman: Raysut Cement has launched the use of SAP S4/HANA and SAP Success Factors as part of a change to its human resource (HR) digital business processes. SAP S4/HANA is a resource-planning package and SAP Success Factors is used to manage HR functions. The project has been supported by Fujitsui International. The implementation phase is intended to run until mid-2019.


Iraq: China’s Sinoma International Engineering has signed a contract to build a 6000t/day clinker production line for Iraqi Cement near Samawah in the Al Muthanna Governorate. The deal has a value of US$246m. The contract includes the entire production process from quarry to finished packaging of cement products. Once the contract is finalised and the customer’s credit secured then the project is expected to take 37 months to be completed.


China: Anhui Conch has continued a cement sale and purchase agreement with Jiangsu Conch Building Materials by entering into a new contract worth US$364m. Subsidiaries of Anhui Conch based in east China will sell a total of 7.5Mt of cement products to Jiangsu Conch, a non-wholly owned subsidiary of Anhui Conch, in 2019. Additionally, three of Anhui Conch’s subsidiaries in Shanghai region will procure 0.13Mt of fly ash and 70,000t of flue gas desulphurisation gypsum from Jiangsu Conch Building Materials in 2019 for a value of around US$3m. The deals follow a similar arrangement for Anhui Conch to sell cement to Jiangsu Conch in 2018.


Vietnam: Xie Guozhen, the head of the Vietnam office of Nanjing C-HOPE Cement Engineering Group, says that the company is planning to build a new production line at the Lien Khe plant in Haiphong. The Chinese engineering firm has previously built five cement production lines in the country, according to the Viet Nam News newspaper.


Niger: Industry Minister Malam Zaneidou Amirou says that the Malbaza Cement Company produced the first tonne of cement at its Malbaza plant in late December 2018. The plant has a production capacity of 0.65Mt/yr, according to the Pan African News Agency. It is expected to cover around 80% of domestic demand for cement and reduce imports. The site was a workforce of 347 employees, including 276 Nigeriens.


Peru: Three new cement grinding plants are planned to start production in Peru in 2019. Cemento Inka plans to invest US$25m towards opening a 0.6Mt/yr cement grinding plant at Ica near Pisco in late 2019, according to the Gestión newspaper. It also plans to update the kilns at its unit in Cajamarquilla. Mixercon plans to invest US$20m towards building two new cement plants in northern Lima. These new plants should open during the second half of 2019. Mixercon also intends to open at least one more distribution centre in Lima. Cementos Pacasmayo and Cemento Yura also have upgrades planned to their plants in 2019.


India: A probe by the Ministry of Corporate Affairs (MCA) has found ‘serious’ financial irregularities in the accounts of Burnpur Cement. The regional director of the MCA has recommended an investigation of the company, according to the Business Standard newspaper. The MCA has also recommended that the cement producer be barred from making interest payments without government permissions in the interest of its shareholders. The company was reported as a non-performing asset in 2016 and its repayment schedule to lenders has been monitored in the media. It made a loss of around US$15m in the financial year that ended in March 2018.


UK: Lafarge Cement, part of the Aggregate Industries business, has introduced Rapid Set Cement to its packed product range. It is an Ordinary Portland Cement containing calcium aluminate for rapid hardening. The product is designed for use in screeds and renders to prepare wall and floor surfaces prior to installing most tile types. It’s suitable for dry and wet installations, including swimming pools, and can be pumped for fast application. It is available in 25kg paper bags and is a quality-assured BS EN 197-1 CEM II, cement carrying CE marking.

“This new product follows significant investment over the last 18 months in expanding our portfolio of packed cement products. All of our products are designed to offer a solution to everyday problems faced by the trade. Rapid Set Cement ensures a strong, durable high quality finish in a fraction of the time compared with standard cement,” said Jamie Stratford, National Sales Manager at Lafarge Cement.


Turkey: Nihat Özdemir, the chair of Limak Holding and president of the Turkish Cement Manufacturers’ Association (TÇMB), has reassured the construction industry that the price of cement will not rise too sharply in 2019. He denied that the price would rise by up to 40%, according to the Hürriyet Daily News newspaper. However, he did confirm that prices would increase due to growing input costs and negative foreign currency exchange effects. Özdemir said that electricity costs had risen by 76%, coal by 182% and petroleum coke by 170%.

In late December 2018 the Construction Contractors Confederation (İMKON) complained about an expected 40% price rise in cement products and it called on the government to intervene. The Independent Industrialists’ and Businessmen’s Association (MÜSİAD) has also issued a similar warning.


Canada: Production has stopped at the McInnis Cement plant at Port-Daniel–Gascons in Quebec due to an unspecific mechanical issue. Maintenance is expected to take place until the end of January 2019, according to the Le Soleil newspaper. The cement producer refused to confirm whether that problem had been caused by the drive shaft overheating and damaging its metal shell. However, the company said that the repairs would only extend a planned maintenance period by a few weeks. No cost for the repairs have been disclosed.

Germany’s ThyssenKrupp Industrial Solutions (USA) was originally awarded the contract to build the plant in 2014. After a protracted building phase the plant produced its first cement in mid-2017 and was then inaugurated a few months later.


India: UltraTech Cement has created a joint venture with Amplus Energy to expand its solar power generation capacity. The cement producer has acquired a 26% stake in the Amplus Sunshine, according to VCCircle Network. Amplus Sunshine will set up a 15MW captive solar plant at one of UltraTech’s Cement’s plants for an investment of around US$10m. The cement producer has a capacity of 50MW from its solar power plants but it intends to increase this. Amplus Energy installs rooftop solar power plants for the industrial and commercial sector.


Philippines: Napoleon Co, the president of the Philippine Cement Importers Association (PCIA), says that the introduction of tariffs on cement imports may lead to higher prices. He said that if new tariffs were started some importers would cease operating, according to the Manila Standard newspaper. He then argued that local producers might raise their prices to match the higher cost of imported cement. Co made the comment in response to an on-going investigation into tariffs being run by the Department of Trade and Industry (DTI). Several importers allegedly stopped imported cement after the DTI launched the investigation in September 2018.


Vietnam: Data from the Vietnam Cement Association (VNCA) shows that the country’s export volumes of cement rose by 55% year-on-year to 31.7Mt in 2018. Producers generated an estimated US$1.2bn from exports, according to the Viet Nam News newspaper. The VNCA’s Chairman Nguyen Quang Cung attributed growing exports to decreased production in China, where production lines have been closed due to pollution.

The Ministry of Construction has attributed growing exports to better performance in the construction sector. Domestic cement consumption grew by 9% to 65.1Mt in 2018. It estimates that consumption will rise by up to 8% in 2019 to around 99Mt, comprising 69Mt for the local market and 30Mt for export. The main export markets in 2019 are expected to be the Philippines, Bangladesh, China, Taiwan and Peru.