Global Cement Newsletter

Issue: GCW432 / 20 November 2019

Headlines


Microsoft co-founder Bill Gates entered the world of cement this week with a public relations blitz for Heliogen. He’s one of the backers of a new Californian technology startup looking to use concentrated solar power (CSP) to power heavy industrial processes like clinker or steel production. The company says it has concentrated solar energy commercially to levels above 1000°C.

Its process, called HelioMax, uses a closed-loop control system to improve the accuracy of a heliostat system. It says it achieves this by using computer vision software to better align an array of mirrors to reflect sunlight towards a single target. Temperatures of up to 1500°C is one of its targets so that it can apply itself to a variety of processes in the cement, steel, mining, petrochemical and waste treatment industries. It says it can do this for US$4.5/MCF. Another target once it hits 1500°C is to start manufacturing hydrogen or synthetic gas fuels.

Heliogen’s press release was picked up by the international press, including Global Cement, but it didn’t mention the similar work that SOLPART (Solar-Heated Reactors for Industrials Production of Reactive Particulates) project is doing in France. This project, backed by European Union Horizon 2020 funding, is developing a pilot scale high temperature (950°C) 24hr/day solar process for energy intensive non-metallic minerals’ industries like cement and lime. It’s using a 50kW solar reactor to test a fluidised bed system at the PROMES (PROcédés, Materials and Solar Energy) testing site in Odeillo, France.

Heliogen’s claim that it can beat 1000°C is significant here but it doesn’t go far enough. Clinker production requires temperatures of up to around 1450°C in the sintering phase to form the clumps of clinker. SOLPART has been only testing the calcination stage of clinker production that suits the temperature range it can achieve. Unless Heliogen can use its method to beat 1450°C then it looks likely that it will, similarly, only be able to cut fossil fuel usage in the calcination stage. If either Heliogen or SOLPART manage to do even this at the industrial scale and it is cost effective then the gains would be considerable. As well as cutting CO2 emissions from fossil fuel usage in cement production this would reduce NOx and SOx emissions. It would also cut the fuel bill.

As usual this comes with some caveats. Firstly, it doesn’t touch process emissions from cement production. Decomposing limestone to make calcium oxide releases CO2 all by itself with no fuel. About one third of cement production CO2 emissions arise from fossil fuel usage but the remaining two thirds comes from the process emissions. However, one gain from cutting the amount of fossil fuels used is a more concentrated stream of CO2 in the flue gas. This can potentially reduce the cost of CO2 capture and utilisation. Secondly, concentrated solar power systems are at the mercy of the weather, particularly cloud cover. To cope with this SOLPART has been testing a storage system for hot materials to allow the process to work in a 24-hour industrial production setting.

Looking more broadly, plenty of cement producers have been building and using solar power to supply electricity. Mostly, these are photovoltaic (PV) plants but HeidelbergCement built a CSP plant in Morocco. Notably, PPC Zimbabwe said this week that it was building a solar plant to supply energy to two of its cement plants. It is doing this in order to provide a more reliable source of electricity than the local grid. India’s Birla Corporation has also said that it is buying a solar energy company today. The next step here is to try and run a cement plant kiln using electricity. This is exactly what Cementa, HeidelbergCement’s subsidiary in Sweden, and Vattenfall have been exploring as part of their CemZero project. The pilot study demonstrated that it was technically possible but only competitive compared with ‘other alternatives in order to achieve radical reductions in emissions.’

None of the above presents short or medium-term reasons for the cement industry to switch to solar power in bulk but it clearly deserves more research and, critically, funding. One particular strand to pull out here about using non-fossil fuel powered clinker production systems is that it produces purer process CO2 emissions. Mounting carbon taxes could gradually force cement plants to capture their CO2 but once the various technologies above become sufficiently mature they could bring this about sooner and potentially at a lower cost. In the meantime the more billionaires who take an interest in cement production the better.


South Africa: PPC’s sales have fallen due to poor sales volumes in South Africa and Zimbabwe. Its results were also negatively affected by ‘significant’ currency exchange effects between the South African Rand and the Zimbabwean Dollar. Its revenue decreased by 12% year-on-year to US$334m in the six months to 30 September 2019 from US$378m in the same period in 2018. Sales volumes fell by 17% to 2.6Mt. Earnings before interest, taxation, depreciation and amortisation (EBITDA) dropped by 20% to US$58.6m from US$70.2m.

“The positive operational results in Rwanda and the Democratic Republic of the Congo have partially offset difficult and competitive market conditions in South Africa and Zimbabwe,” said chief executive officer (CEO) Roland Van Wijnen. “PPC has continued its efforts to implement necessary price increases to lay the basis for a sustainable domestic cement industry in South Africa.” In South Africa PPC blamed imports and blender activity for exacerbating a poor local market. It also noted that its fuel costs grew by 30% in the reporting period.


India: Birla Corporation and its subsidiary RCCPL have acquired a 26% stake in AMPSolar Clean Power. The cement producer plans to buy solar power for its Raebareli cement grinding plants and its Kundanganj cement grinding plant.


Algeria: Trade Minister Said Djellab has revealed that the country’s cement exports are expected to reach a value of US$400m by 2021. Export earnings were around US$20m in 2018 and then tripled to US$60m in 2019, according to the El Mujahid newspaper. The minister made the comments at a ceremony marking an export of cement from a Ciment Lafarge Souakri (CILAS) plant. He added that the local market has a cement production capacity of 40Mt/yr and that only 22Mt/yr is required domestically. Producers are targeting countries in west Africa, including Guinea Bissau, Senegal, Gabon and Mali.


UK: Breedon Group’s revenue grew by 8% year-on-year to Euro933m in the ten months to the end of October 2019. Its cement sales volumes increased by 6% but its ready-mixed concrete sales fell by 5%. Aggregate and asphalt sales volumes also rose. The group said that its results were achieved against the backdrop of a flat construction market in the UK where lower industry sales volumes were recorded for all major heavyside construction materials in the nine months to 30 September 2019.


Paraguay: The Ministry of Industry and Commerce (MIC) has lifted restrictions on cement imports following problems with local production. The local market needs around 100,000 bags/day of cement and state-owned Industria Nacional del Cemento (INC) normally provides around half of this, according to the ABC Color newspaper. However, production problems at INC’s plants have seen significant drops in supply.


China: Cemex’s corporate venture capital subsidiary Cemex Ventures is preparing to enter the Chinese market offering innovations for the construction industry. It wants to build relationships with startups in order to do this and it has signed deals with local companies Glodon, a digital platform service provider in construction industry based in Beijing, and Interdream Ventures, a venture capital firm that focuses on the digitalisation of construction and decoration industry.

"This type of alliance between two segments that fit together, is key to finding new successful business models, and operate in the Chinese market. Glodon and Interdream Ventures also have a complete vision of the entire value chain and are good partners to drive the construction revolution,” said Juan Nieto, a representative of Cemex Ventures Asia.

Cemex Ventures is the corporate venture capital wing of Cemex that was launched in 2017. It invests in startups with potential in the construction industry and works with entrepreneurs, universities and other stakeholders.


US: Global Cement is exhibiting at the 36th International Cement Seminar & Exhibition taking place in Atlanta, Georgia. The long running cement equipment and technology event has returned after a lengthy break. Portland Cement Association (PCA) chief economist Ed Sullivan gave the keynote address at the conference with an industry forecast for 2020.


Brazil: Markets in Brazil and North America have supported Votorantim Cimentos’ sales so far in 2019, despite setbacks in Turkey and Latin America. Its sales revenue rose by 2% year-on-year to US$907m in the first nine months of 2019 from US$891m in the same period in 2018. Overall sales volumes of cement fell slightly to 8.4Mt. The cement producer’s adjusted earnings before interest, taxation, depreciation and amortisation (EBITDA) decreased by 5% to US$188m from US$199m, with declines reported in all operation regions except North America.


Taiwan: Taiwan Cement’s profit has risen so far in 2019 due to stable cement prices and falling coal prices. Its net profit increased by 11.1% year-on-year to US$214m in the first nine months of 2019, according to the Taipei Times newspaper. However, its sales revenue fell by 3.5% to US$2.87bn. The cement producer says it has a production capacity of 102Mt/yr following the formation of a joint venture in Turkey and an acquisition in Portugal in 2018.

The company reported higher labour, transportation and raw material costs in China in the third quarter of 2019. Its expenses were also inflated by environmental upgrades. Company president John Li said, that despite falling prices in Guizhou province, demand in regional markets, including Guangdong, Guangxi and Jiangsu provinces was expected to remain beneficial.


US: Cemex is looking to sell its majority stake in the Kosmos Cement plant at Louisville in Kentucky. Sources quoted by the El Financiero newspaper said that the integrated plant could be valued as high as US$750m. Cemex is working with Bank of America and Citigroup on the potential sale. Buzzi Unicem, through its subsidiary Dyckerhoff, owns the remaining stake in the plant. Cemex’s decision to try and sell the plant follows falling sales and profits for the Mexican building materials producer so far in 2019.


Philippines: The Philippine Competition Commission (PCC) is considering voluntary commitments submitted by First Stronghold Cement and related parties in connection to its proposed acquisition of Holcim Philippines. First Stronghold Cement, an indirect subsidiary of San Miguel Corporation, has agreed to buy an 85.7% stake in Holcim Philippines, according to the Philippine Star newspaper. Companies undertaking acquisitions can make behavioural or structural voluntary commitments during the process to alleviate competition concerns with the PCC. Behavioural commitments include market constraints imposed by the PCC whilst structural commitments cover divesting assets.

Initial findings by the PCC on the proposed purchase found it could affect the market concentration of relevant products in parts of Luzon, and Northern and Southern Mindanao. This would normally prompt a stage two review of the proposed acquisition. However, if the PCC accepts the suggested voluntary commitments it would bypass this step.


India: HeidelbergCement India is targeting expansion options to increase its production capacity to 20Mt/yr from 12.5Mt/yr. Managing director Jamshed Cooper said that the company is looking at companies in the range of 5 – 10Mt/yr in order to avoid the National Company Law Tribunal (NCLT) process, according to the Indo-Asian News Service. The cement producer is also planning to build a 22MW waste heat recovery unit at its Zuari plant in Yerraguntla, Andhra Pradesh at a cost of US$28m. Debottlenecking initiatives are also being conducted at a cost of US$7m to increase overall production capacity by 0.5Mt/yr when completed in 2021.

The group operates two subsidiaries locally: HeidelbergCement India and Zuari Cement. HeidelbergCement India serves the central markets and Zuari Cement, a former Italcementi subsidiary, focuses on the south of the country.


Egypt: Arabian Cement’s sales revenue fell by 5% year-on-year to US$139m in the first nine months of 2019 from US$147m in the same period in 2018. Local sales dropped whilst export sales and services rose. Its profit for the period after tax decreased to US$2m from US$13.3m.


Nigeria: UK-based Entec International has secured a contract to optimise maintenance, repair and operations (MRO) supply chains for Lafarge Africa. The project will involve the consolidation of 125 separate suppliers into a single supply chain, which will be managed by Entec, operating in a single currency with standardised terms. No value for the deal has been disclosed.

“This is a great step for Entec, this contract opens up a new market with huge potential for us. We are delighted to be working with LafargeHolcim, whose commitment to innovation and environmental sustainability reflects our ethos at Entec,” said Entec sales director Charlie Patterson.

Patterson expects Entec to achieve a 12% reduction in freight, clearance and handling costs for Lafarge Africa in year one of the three to five-year contract. Supply chain consolidation is predicted to cut the number of shipments by more than half and will deliver a reduction in the volume of purchase orders and invoices currencies into a single currency, replacing multiple payment terms from different suppliers into a single payment term and converting multiple air freight shipments from Europe and China into consolidated ocean freight.

Entec specialises in saving costs and reducing complexity for client companies by managing their MRO supply chains. It has managed complex supply chains for manufacturers in over 70 different shipping destinations. Entec’s client base includes customers in the food and beverage packaging industries, oil, gas production, textile processing and mining and minerals sectors.


US: Heliogen, a new technology venture, says it has concentrated solar energy to exceed temperatures greater than 1000°C at its commercial plant in Lancaster, California. The company hopes to use the process to replace fossil fuels used in industrial cement, steel and petrochemical production processes. It is using computer vision software to align a large array of mirrors to reflect sunlight to a single target.

The company is based in Pasadena, California and is lead by Bill Gross, the founder of Idealab, a US technology startup incubator. Heliogen is supported by Parsons Corporation, a company that operates in defence, intelligence and critical infrastructure markets. Other backers include Bill Gates, the co-founder of Microsoft.


Pakistan: DG Khan Cement has asked the government of Punjab province if it can expand the production capacity at one of its cement plants by 12,000t/day. Bloomberg said that it had seen a letter sent to the local government and that Javed Iqbal Malik, a senior economic adviser at Punjab province's industries department, had confirmed receiving it. The approval process could take up to 12 months. If accepted the upgrade could see DG Khan Cement surpass Bestway Cement to become the country’s largest cement producer with a production capacity of 10.7Mt/yr.


Bangladesh: Mohammed Amirul Haque, the managing director, of Premier Cement, says that the company has built two more units at Narayanganj and Chattogram for around US$150m. He said that upgrade has increased the company’s production capacity to 5.2Mt/yr from 2.4Mt/yr, according to the Daily Star newspaper. The new units are currently at the trial stage. Vertical roller mills (VRM) supplied by Denmark’s FLSmidth will be used to attain production rates of 460t/hr and 270t/hr at the new plants in Narayanganj and Chattogram respectively.

The expansion plans were initiated in 2017. At present the country has a cement production utilisation rate of 57%. Bangladesh’s per capita cement consumption is around 181kg. It is expected to increase to 220kg by 2020.


India: Dalmia Cement (Bharat) and Dalmia Refractories plan to merge their refractory businesses. The subsidiaries of Dalmia Bharat have approved schemes of arrangement to consolidate under a single company known as Dalmia OCL. Dalmia OCL in turn will be held by a holding company known as Dalmia Bharat Refractories. The intention of the merger process is to create a single refractory company of ‘significant’ size, to simplify the corporate structure and to achieve economies of scale.


Sweden: A failure on a conveyor belt between the kiln and a mill at the end of October 2019 has caused a ‘significant’ loss of production at Cementa’s Slite plant. The subsidiary of Germany’s HeidelbergCement says that a temporary solution is in place but that the unit’s capacity has been reduced. Repair work is expected to continue until the end of November 2019. The cement producer said that deliveries of its Basement product would be reduced while it looks for an external supplier to bolster supply.


Kenya: Mombasa Cement has started building a 36MW wind farm at its integrated Vipingo plant. The project is intended to support a new grinding unit being constructed at the site, according to the Business Daily newspaper. It is intended to reduce the cost of electricity and minimise disruptions caused by power cuts. The wind farm will consist of 12 turbines with a capacity of 3MW each. The cement plant is also installing a high-power voltage line from the Kaloleni substation to improve its connection to the local electricity grid.


US: CalPortland has been awarded a US$175,000 grant from the Mojave Desert Air Quality Management District (MDAQMD) to replace a 1999 Terex Bore/Drill rig with a 2019 Caterpillar MD2650 drill. The new drill expects to see a 76% reduction on average in nitrogen oxides (NOx), reactive organic gases (ROG) and particulate matter (PM) combined. The grant comes from the Carl Moyer Program, which provides monetary grants to private companies and public agencies to clean up their heavy-duty engines beyond legal requirements through retrofitting, repowering or replacing their engines with newer and cleaner ones.


US: Union workers at the Keystone Cement plant in Bath, Pennsylvania have started legal action against the company over its sale to HeidelbergCement. The American Federation of Labor and Congress of Industrial Organizations (AFL–CIO) union says that the company must honour its contracts, according to the Morning Call newspaper. It is representing around 132 workers at Keystone’s cement and aggregate operations.

According to the lawsuit, HeidelbergCement’s subsidiary Lehigh Hanson announced in October 2019 that it would not accept or assume the terms of any existing contracts. The union claims that this contravenes a requirement that any new owners or operators of the plant assume the contracts in place at the time of sale. The agreement to sell the plant to Germany’s HeidelbergCement for US$151m was announced in late September 2019. It is subject to regulatory approval.


Paraguay: Paraguay’s main cement producer, state-owned Industria Nacional del Cemento (INC), has ‘significantly’ slowed production at its 1.0Mt/yr integrated Puerto Vallemi plant to a rate of 12,000 bags/day, creating a supply gap that imports and Intercement’s 0.4Mt/yr integrated Asunción plant have been unable to fill. Esmerk Latin American News has reported that the shortage has precipitated a 33% price rise in the cost of a bag of cement in the country to US$10.20 from US$7.00 when the shortage began in October 2019.


Uganda: The Uganda government’s Committee on Natural Resources suspended pozzolano extraction at quarries in eastern Uganda on 14 November 2019. The Daily Monitor reported the cause of the suspension as pollution of water sources. Speaking at Tororo Cement’s Chemangal quarry, committee chair Kefa Kivanuka said that “The regulatory authorities were negligent,” and that activity at quarries was suspended until the completion of a damage assessment involving committee meetings with cement producers for the review of their pozzolano extraction licences. Besides Tororo Cement, Hima Cement, Kampala Cement and Kenya-based National Cement subsidiary Simba Cement all supply plants with pozzolano extracted in the region.


India: The leading global supplier of cement kiln refractories, has produced its first test batch of magnesia carbon bricks (MCBs) for use in cement kilns at its 18,000Mt/yr Tangi plant near Cuttack in the state of Odisha. The company acquired the fully-equipped plant in August 2019 for Euro5.5m and has said production will be supported by a ‘new state-of-the-art world-class research and development centre currently under construction in Bhiwadi’ in serving the needs of the regional cement industry.


France: LafargeHolcim has fulfilled its contract with the Port of Brest for the delivery of 10,000t of cement and almost 0.17Mt of draining sand by sea to the port in the Département of Brittany. A Euro220m project has been underway since 2016 for expansion and diversification of the port’s handling capacity, with completion scheduled for 2020. LafargeHolcim says that it proposed specific construction solutions for use of its materials in improving the accessibility of Brest’s existing wharves and building a new ‘heavy’ wharf.


Russia: Eurocement has announced an expansion in its cooperation agreement with consumer goods retailer Castorama. Eurocement’s regional subsidiary Mikhailovcement, which operates a 2.0Mt/yr integrated cement plant in Ryazan, dispatched the first batch of cement to Castorama in October 2019. Mikhailovcement and other Eurocement subsidiaries will now supply bagged cement to all of Castorama’s 19 branches across Russia.


India: JK Cement has revealed its rebranded JK Wall Putty, which will be known as WallMaxX. JK Cement operates 10.9Mt/yr of cement capacity across India. It launched its JK Wall Putty, the main constituent of which is its white cement, in 2002 to give a highly water-resistant finish to plaster that prevents seepage and flaking.


Cambodia: Thai Boon Rong’s 0.9Mt/yr integrated cement plant in Kampot province was commissioned on 14 November 2019, marking the end of a US$110m construction project on its 678 hectare site in Dangtong District.

Speaking at the inauguration ceremony, Cambodian Prime Minister Samdech Techo Hun Sen said that the plant, Cambodia’s fifth, would help meet rapidly growing domestic demand.


Colombia: Cementos Argos’ revenue in the three months to 30 September rose by 44% year-on-year to US$1.52bn for US$1.06bn. Lower sales across its cement and concrete sections caused the company’s three-month profit to drop by 65% year-on-year to US$10.3m over the period from US$29.6m. Higher costs also offset the income from the sale of the group’s Barranquilla natural gas power station to Glenfarne Group for US$420m in the quarter.


Philippines: Irish-based CRH has engaged JP Morgan, the bankers, for the sale of its entire Philippine unit. The company operates 3.1Mt/yr of integrated and 0.8Mt/yr clinker grinding capacity via its stake in Republic Cement’s three integrated plants and one grinding plant, inherited in 2015 from Lafarge and Holcim as a part of the pair’s merger.

The Irish Times has reported the estimated value of the divestment at between Euro1.82bn and Euro 2.73bn. The announcement caused CRH’s share price to rise to its highest level since May 2017.


Egypt: Misr Cement Qena’s profit in the three months to 30 September took a 67% year-on-year dive to US$1.85m from US$5.56m. Sales continued on an upward trend, ending the period up by 6.3% at US$146m from US$138m in the corresponding period of 2018.


Egypt: Misr Beni Suef’s sales over the three months to 30 September 2019 were US$29.6m, up by 24% from US$23.9m in the corresponding period of 2018. This growth failed to offset the challenges of profitability in a saturated market, with profit falling by 2.7% year-on-year to US$1.34m from US$1.37m.


UAE: Gulf Cement’s losses in the nine-month period to 30 September 2019 were US$1.06m, compared to a US$0.44m profit in the corresponding period of 2019. This was caused by a fall in nine-month revenue of 8.3% year-on-year to US$92.8m from US$101m.


US: LafargeHolcim subsidiary Lafarge North America’s Presque Isle quarry, which supplies raw limestone to its 2.6Mt/yr Alpena integrated cement plant – both in Michigan – has won the National Stone, Sand and Gravel Association (NSSGA)’s Gold Award in the Community Relations Excellence category. Business Wire has reported that it previously won Gold for Environmental Excellence in 2018. In recognition of its consecutive Golds, the NSSGA honoured the quarry with its prestigious Two Stars of Excellence award. LafargeHolcim’s operations in the country extend over 350 sites across 43 states. Its aim is to ‘help build better communities with innovative solutions that deliver structural integrity and eco-efficiency.’