Global Cement Newsletter

Issue: GCW425 / 02 October 2019

Headlines


No overarching theme this week but rather four changes of note in different markets. The first is Lehigh Hanson’s agreement to buy the integrated Bath plant in Pennsylvania, US, from Giant Cement, a subsidiary of Mexico’s Elementia. Lehigh Hanson, a subsidiary of Germany’s HeidelbergCement, plans to pay US$151m for the 1.1Mt/yr unit giving it a cost of US$137/t of cement capacity. That’s a similar price that Elementia paid when it acquired Giant Cement in 2016. The Mexican conglomerate paid US$220m for a 55% stake in 2016 for three cement plants with a combined production capacity of 2.8Mt/yr or US$143/t.

The purchase by HeidelbergCement draws a line following problems selling its business activities in Ukraine. The group blamed a drop in profit in the first half of 2019 on this. Since then though it has been linked to a takeover of UltraTech’s stake in Emirates Cement, the owner of the 0.5Mt/yr Emirates grinding plant in Dhaka, Bangladesh. Buying a cement plant in North America, its second most lucrative region after Western and Southern Europe, looks set to be a wise investment.

The timing here is interesting given that Elementia, the building materials company partly-owned by ‘Mexico’s richest man,’ Carlos Slim, has been steadily expanding in recent years. As stated above it only acquired Giant Cement in 2016. However, its net sales and earnings fell in the second quarter of 2019 caused by a market contraction in Mexico affecting all of its businesses. Sales from its cement businesses in the US and Central America grew but they fell by 6% at home in Mexico. Elementia said that proceeds from the sale of the Bath plant will be used for debt repayment and ‘general’ corporate purposes. Notably, Ricardo Naya Barba, the president of Cemex Mexico, has also described the local market as ‘difficult’ this week, in comments reported upon by local media.

Meanwhile in Africa, China’s Huaxin Cement purchased Maweni Limestone from Athi River Mining (ARM) Cement in Tanzania as part of the latter’s on-going administration process. Local press reported the transaction as costing US$116m and subject to regulatory approval. This one’s interesting because it shows a major Chinese cement producer buying related assets outside of China. This is likely part of the country’s Belt and Road Initiative to develop industry and infrastructure around the world and to give its overproducing industries new markets. Perhaps the surprise here is that Huaxin Cement hasn’t gone after the rest of Kenya’s ARM Cement… yet.

The other African news story of note this week was the confirmation that Singapore’s International Cement Group (ICG)’s intended purchase of Schwenk Namibia had failed. This deal was announced in March 2019 but it later ran into trouble when the Singapore Exchange blocked the proposed acquisition in June 2019 on the grounds that ICG didn’t appear to have the money to pay for it.

Lastly, Yamama Cement announced that it wants to sell its Production Lines 1-5, which have a daily clinker production capacity of 5600t/day. The producer previously temporarily shut down the lines in 2017 and it has been planning to build a new cement plant. Since then though it has faced shrinking sales and profits in the tough Saudi Arabian market.

The takeaway from all of this is that, despite the doom and gloom of a world producing too much clinker, some cement companies are targeting growth in specific territories. Sometimes these schemes succeed, as in the case of HeidelbergCement and Huaxin Cement, and sometimes they don’t, as ICG has found out. Heavy building materials like cement are costly to move around so a plant or assets in the right place at the right time can make a fortune.


Pakistan: Thatta Cement has appointed Naheed Memon as the chairperson of its board of directors. She succeeds Khawaja Muhammad Salman Younis, who left the role on 23 September 2019.


Germany: ThyssenKrupp has appointed Martina Merz as its chief executive officer (CEO). The current chairwoman of the supervisory board will be delegated to the group executive board for a maximum period of 12 months after which she will return to the supervisory board. Guido Kerkhoff, the current CEO, has agreed to leave the post by mutual agreement.

In addition, the supervisory board has appointed Klaus Keysberg to the executive board of ThyssenKrupp where he will be responsible for the materials businesses on the group executive board. He has held various positions at ThyssenKrupp since 1996 and has been CEO of the Business Area Materials Services since the beginning of 2019. He will continue to hold this position until a successor is appointed.

Siegfried Russwurm will succeed Martina Merz as the head of the supervisory board. The former Siemens executive board member has been a member of the supervisory board since April 2019.


US: Solidia Technologies has appointed Jules Kortenhorst to its board of directors. Kortenhorst is currently the chief executive officer (CEO) of the Rocky Mountain Institute (RMI). Prior to this he was the founding CEO of the European Climate Foundation (ECF) and he also served as a member of the Dutch parliament for the Christian Democratic Party.

Kortenhorst was the CEO for International Operations of ClientLogic Corporation and he worked for almost 10 years for Royal Dutch Shell, including managing director at Shell Bulgaria. He began his career as an analyst at McKinsey & Co.

He currently serves on the Energy Transition Commission and is the co-chair of the WEF Global Future Council on Energy. He also is a non-executive board member of the Energy Web Foundation and an advisory board member of Land Life Company. He holds an MBA from Harvard and a Master’s in Economics from Erasmus University, Netherlands.


India: UltraTech Cement has declared the scheme of arrangement between itself and Century Textiles and Industries as part of its merger process. It will issue one equity share worth US$0.14 each for every eight equity shares of the same value held by the shareholders of Century Textiles and Industries. UltraTech Cement received approval from the Competition Commission of India (CCI) for the acquisition of the cement business of Century Textiles and Industries in late August 2018 but it faced legal challenges subsequently.

The acquisition further strengthens UltraTech Cement’s lead in the Indian market. It says it is now the only company outside of China to have a production capacity of more than 100Mt/yr in a single country. It also claims that it is the third largest cement company in the world excluding those based in China.


Nigeria: Aliko Dangote, the chairman of Dangote Cement, plans to increase his company’s cement production capacity in Africa by 29% to 62Mt/yr. It aims to add 6Mt/yr in Nigeria in 2020 to support exports to grinding plants in Cameroon and West Africa, according to Bloomberg. The cement producer previously said it had a production capacity of 45.6Mt/yr in 2018 from operations in 10 countries.


Namibia: Ohorongo Cement has marked nine years in a partnership with Transnamib, Namibia’s state railway company. The partnership covers coal transportation from the Port of Walvisbay to Ohorongo’s integrated cement plant at Otavi and despatches of palletised cement. Transnamib also arranged additional train services between Tsumeb and Ondangwa to support shipments to the north of the country.

“We highly value our relationship with Ohorongo Cement as their increased utilisation of rail transport allowed for the implementation of our road-to-rail strategy which have resulted in a reduction of approximately 150 trucks on the road between Tsumeb and Ondangwa,” said Zebby Mukungu, Marketing and Sales Manager at Transnamib.


Saudi Arabia: Yamama Cement plans to sell its production lines 1 – 5 as part of a move to a new site. The old lines have a combined clinker production capacity of 5600t/day. The lines were ‘temporarily’ shut down in early 2017 due to poor market conditions.


Saudi Arabia: Al Jouf Cement has signed a six-month technical contract with China’s Riga Company to convert its second production line to produce white cement. The contract was signed to coincide with the arrival of the project team that will handle the conversion. No value for the upgrade has been disclosed.


France: Hoffman Green Cement Technologies has launched an initial public offering (IPO) to raise Euro50m on the Euronext Growth market. The company wants to use the funds to build two new plants with a capacity of 0.25Mt/yr in Vendée and in the Paris region, according to the Le Figaro newspaper. Hoffmann Green Cement Technologies inaugurated its pilot plant at Bournezeau, Vendée in 2018. The unit is developing cement products using flash-calcined metakaolin and blast-furnace slag.


Russia: Eurocement has received nine new Volvo FM 8x4 heavy-duty dump trucks for its Kavkazcement and Maltsovsky Portland Cement plants. The vehicles have a capacity of 32t and include Volvo’s CareTrack telematics system. The cement producer hopes to increase the volumes of limestone it transports from each plant’s quarries by 15%. It has spent Euro1.3m on the new trucks.


Vietnam: SCG Cement – Building Materials Vietnam and Ho Chi Minh City University of Technology have signed a memorandum of understanding for a three-year collaboration on innovation including research, development and human development. The agreement follows work between the two organisations over the last year, according to The Vietnam Investment Review newspaper. They will now form a collaborative expert group to carry out research projects in line with the needs of SCG, to improve product quality, increase labour productivity and accelerate the application of new technologies in production and construction.


Philippines: Big Boss Cement and the related company Petra Cement are spending US$193m on cement grinding plant projects in Pampanga and Zamboanga. Big Boss Cement is building four cement lines at its Pampanga plant, according to the Business Mirror newspaper. Petra Cement is building two lines at Zamboanga del Norte. Both companies have the same shareholders, led by prominent businessman Henry Sy Jr.

Company President Gilbert S Cruz said that the companies will spend US$135m at Pampanga plant and US$58m at the Zamboanga plant. Each line will have a cement production capacity of around 0.5Mt/yr. Two production lines have been completed at the Pampanga plant and the remaining two are scheduled for completion in the first quarter of 2020. The first new line at Zamboanga will be completed in November 2019 with preliminary work on the second to follow afterwards. Big Boss Cement and its related companies also plan to build new plants at General Santos, Negros and Iloilo. It aims to reach a production capacity of over 5Mt/yr by the mid-2020s.

The company says it is using a grinded activated sand by heating (G-ASH) process to produce a binding material for concrete that does not use imported clinker. It has claimed that it is the first cement company in the world to do so.


Pakistan: Thatta Cement has blamed a fall in profit on rising input costs and negative currency effects. Its profit dropped by 40% year-on-year to US$1.36m in the financial year to 30 June 2019 from US$2.27m in the same period in 2018. Sales and distribution costs more than tripled to US$1.4m. Its net sales grew by 22% to US$22m from US$18m. Total cement and clinker despatches increased by 34% to 0.56Mt from 0.42Mt.


Mexico: Ricardo Naya Barba, the president of Cemex Mexico, has admitted that 2019 has been a ‘difficult’ year for the subsidiary of the building materials company. He said that sales volumes of cement , concrete and aggregates had fallen by 12 – 15% in the first seven months of the year, according to the Mural newspaper. He blamed the decline partly on falling national infrastructure invesment. In 2018 the country accounted for 46% of Cemex’s overall earnings before interest, taxation, depreciation and amortisation (EBITDA) around the world.


Kyrgyzstan: Kant Cement has upgraded its packing equipment at its integrated plant. Russia’s Vselug supplied a Turbo K8 filling machine and Germany’s Berg provided compressors, according to Cement and its Applications magazine. The company plans to sell at 60% of its products in 25kg and 50kg following the upgrade.

The plant has also been installing general upgrades at the site, including a new combination burner from Austria’s Unitherm Cemcon in 2018. It is also planning to upgrade an electrical distribution substation by the end of 2019 to reduce interuptions to production.


US: The US Department of Energy (DOE) has recognised Better Plants partner CalPortland for achieving an energy intensity reduction goal of 28% since 2010. As part of DOE’s Better Buildings Initiative, the Better Plants Program works with leading manufacturers and water and wastewater treatment agencies to boost their competitiveness through improvements in energy efficiency. The cement producer was presented with an award for its efforts at the Better Plants conference in late September 2019.

CalPortland used DOE programs and software tools to help identify energy savings and accelerate investment in energy efficiency technologies and practices. Additionally, the company performed DOE in-plant training sessions driving innovation, cost savings, and the sharing of solutions company-wide to reach its target.


US: A team of researchers at the Massachusetts Institute of Technology (MIT) have demonstrated an electrochemical process to make clinker in a laboratory. A paper on the work by Yet-Ming Chiang, the Kyocera Professor of Materials Science and Engineering at MIT, with postdoctoral researcher Leah Ellis, graduate student Andres Badel and others has been published in the Proceedings of the National Academy of Sciences of the United States of America (PNAS).

In the new process, pulverised limestone is dissolved in acid at one electrode in an electrolyser and carbon dioxide (CO2) is released in a pure, concentrated stream. Lime is precipitated out as a solid at the other electrode. The lime can then be processed in another step to produce clinker.

Benefits of the new process include potentially substituting fossil fuels with electricity supplied from renewable sources and the production of a pure source of CO2 that could be captured with less or no scrubbing compared to conventional clinker production.


UK: Fuchs Lubricants is building a new Euro5.5m raw materials warehouse at its headquarters in Staffordshire. Work on the project started in August 2019 and it is due for completion in the second quarter of 2020. Once completed it will ‘significantly’ increased the amount of raw materials the business can store on-site.

The warehouse will have a capacity of approximately 4000 pallet spaces, with ability for automatic or manual storage place allocation. Two wire-guided driverless Very Narrow Aisle trucks will operate in the unit. Warehouse Control and Warehouse Management Systems will streamline the process, with benefits including goods receipt entry and booking, a paperless put away process, inventory support and batch traceability.


Namibia: Singapore’s International Cement Group (ICG)’s intended purchase of Schwenk Namibia for US$104m has fallen through. The company stated that it will not buy the subsidiary of Germany’s Schwenk Zement, whose 1.0Mt/yr total integrated capacity consists of Ohorongo Cement’s Walvis Bay plant, over four months ahead of the deal’s long stop date of 31 January 2020. The deal’s deadline had previously been extended from 30 June 2019 following the Singapore Exchange forestalled the deal due to ICG’s inability to pay for the unprofitable company.


India: A boiler at Birla Cement’s 2.5Mt/yr Chanderia plant in Rajasthan exploded on 29 September 2019, injuring an estimated 15 people. The Hindustan Times has reported that 11 people are in a critical condition. It is believed that the furnace overheated, which caused coal to scatter over workers below. Local government says that a report will come from its administrative-level investigation within 10 days, with criminal action to follow where appropriate.


Belarus: Belarus Cement Company (BCC) has begun selling its cement in 15kg bags in addition to its usual 25kg. BCC general director Alexsandr Dovgalo has said the company intends the move to increase the ability of its product to meet consumer demand.


Tanzania/China: China’s 100Mt/yr-capacity Huaxin Cement has bought Maweni Limestone from the Kenyan-based Athi River Mining (ARM) Cement. Huaxin has stated that this first incursion into East Africa is ‘integral to its broader strategy’ of expansion in emerging markets. It adds the Tanzanian producer of Rhino cement to its burgeoning portfolio of overseas assets including cement plants in Tajikistan, Uzbekistan, Cambodia and Nepal.


Germany/US: HeidelbergCement has purchased Giant Resource Recovery’s 1.2Mt/yr integrated Keystone cement plant in Bath, Pennsylvania for US$151m. HeidelbergCement CEO Bernd Scheifele has called the cement plant, which has 90 years’ experience as a supplier to the Pennsylvania, New York and New Jersey markets, ‘an excellent strategic addition’ to the company’s North American market presence.


Egypt: Siemens has submitted an integrated survey of the digitalisation potential of various industries in four zones to the Ministry of Industry (MoI) with a view to improving the competitiveness of the country’s products. Daily News Egypt has reported that the Germany-based technology company has already signed contracts for the supply of digital efficiency solutions with El Ameria Cement and Lafarge Egypt. It is also negotiating with Misr Beni Suef for the installation of thermal emission measuring units at its 3.5Mt/yr integrated cement plant in Beni Suef, Maadi.


Germany: Klaus Eichas of KE Consulting has taken over the role of consultant to KIMA Process Control’s Eastern Europe, Russia and Central Asia region sales and engineering team. KIMA provides real-time measurement solutions for various applications in the cement industry, including fill level in ball mills.


Kenya: Chattan Vyas, general manager of a Rai Group-owned grinding plant in Kenya’s Rift Valley province, has been found dead in bed on the morning of 22 September 2019 under mysterious circumstances. The Standard has reported that the attending pathologist confirmed the cause of death as strangulation, noting also that Vyas had been bound.


Germany: Six apprentices from Holcim South Germany’s 1.1Mt/yr integrated Dotternhausern cement plant have completed an assignment of real-world application to their plant, at a training workshop in Albstadt. The Schwarzwälder Zeitung has reported that Holcim South Germany required a means of stirring cement used for event demonstrations. The apprentices’ ‘eyecatching’ solution incorporates a filler neck at the top and an outlet at the bottom, is 100% leak-proof and was built entirely from parts constructed at the Albstadt workshop.