Global Cement Newsletter

Issue: GCW439 / 22 January 2020

Headlines


The visible lobbying work by Cembureau, the European cement association, has been building in recent months as it has started to tackle the European Green Deal. Last week’s move was its aim to align with the objectives of the new legislation. To this end it plans to review the targets from its 2050 Low Carbon Roadmap (2013/2018) to fit with what the European Commission’s (EC) policy initiatives are aiming to do. It intends to publish the new roadmap in the spring of 2020.

The immediate problem for the European cement industry is that the EC wants to pick up the pace. Before the Paris agreement in 2016 it was aiming for a 40% reduction in greenhouse gas emissions by 2030 compared to 1990 levels. The overall target, remember, was an 80% reduction in emissions by 2050. However, the wording from the EC to the European Parliament about the Green Deal in December 2019 is now targeting carbon neutrality and the 2030 target has increased to ‘at least 50%’ and toward 55% in a ‘responsible way.’

To give readers an idea of the uphill battle facing the cement industry. Cembureau said it was on target in 2015 with a 14% reduction in emissions per tonne of cement produced from direct, indirect and transport sources. For comparison, gross CO2 emissions Cement Sustainability Initiative (CSI) data from the Global Cement & Concrete Association (GCCA) shows a 29% drop from 1990 to 2017 from Cembureau members. The EC now wants to make it even harder to meet the 2030 target.

The cement industry’s problem is that it is energy intensive and that making clinker releases CO2 (process emissions) as limestone is calcined. Cembureau’s roadmap offered multiple paths to its end goal including resource efficiency, energy efficiency, carbon sequestration and reuse, product efficiency. However, most of these things - like lower clinker factors, production efficiency use of alternative fuels, better transport efficiency and so on - only reach a reduction of a little below 35%. We should note here that great work has been achieved in all of these with Europe leading the way for many. The other 45% was intended to come from breakthrough technologies such as carbon capture and usage (CCU) and/or storage (CCS). Again, Europe has been leading the way worldwide with its various research and pilot projects. Yet, given that there are no commercial-level carbon capture installations at any cement plants in Europe in 2020, the EC is potentially cutting off the industry’s escape route to meet the 2030 deadline.

The EC gives the impression that it knows that energy intensive industries need help meeting the targets with the publication of its masterplan for energy-intensive Industries in November 2019. CCS, CCU, biomass, alternative binders to make cement, more efficient use of cement in concrete and the use of alternative fuels were all listed as being of in use of high potential to the sector. These are similar to Cembureau’s five paths on its roadmap. Incidentally, more recently Cembureau has been promoting its so-called 5C approach: clinker, cement, concrete, construction & built environment, and (re)carbonation. This is intended to initiate a wider debate across the construction industry supply chain along similar lines to the objectives in the roadmap. It also follows the general industry pivot towards concrete.

However, just one badly-considered measure from the legislators could scupper this. The new tax on refuse-derived fuel (RDF) imports in the Netherlands is one example of this. It potentially complicates alternative fuels markets in Europe. Another, more subtle risk that Cembureau warned of in December 2019, was of the EC’s intent to propose a carbon border adjustment mechanism to reduce the risk of carbon leakage. Its argument was that a new untested scheme could create uncertainty in an industry already at risk being replaced by production capacity outside of the EU.

So now we wait to see how many more reductions Cembureau can squeeze out of its revised roadmap in the spring. It may be able to gain more from its existing measures or offset emissions more widely along the construction chain. Whether it does or does not though the bulk of emissions reduction needs to come from the continued research, testing and implementation of novel technologies like CCU/S. CCS also needs help setting up the infrastructure to move CO2 to the storage sites. To this end the EU heavy industry expert group says that developing large-scale pilot projects on ‘clean’ technologies should be supported with EU funds and by easier access to private financing. The ongoing question is how and when can this funding be unlocked? The answer is far from clear.


Austria: RHI Magnesita, the leading global supplier of refractory products and solutions, is adding a new member to its Executive Management Team. Ticiana Kobel, 49, will join RHI Magnesita as Executive Vice President and General Counsel.

“We are really happy to have Ticiana Kobel on board,” said Stefan Borgas, CEO of RHI Magnesita. “With her more than 20 years of experience in different positions providing legal insight on a global scale, leading legal departments and making strategic decisions in legal and governance matters at multinational companies, she perfectly fits the needs of our global company and will be an asset in the future development of our success.”

Kobel, who completed a law degree with an emphasis in corporate law and an LLM in international economic law and European law in Lausanne and Geneva, Switzerland, has gained valuable management skills in a wide range of global business branches, leading legal departments in the manufacturing industry, the aviation industry, the technology industry, the service sector and the engineering industry. She has been in charge of crucial projects pertaining to all legal matters, such as spin-offs, entity sales, potential acquisition targets and corporate governance issues, and assisted with the design and implementation of compliance functions, mergers and acquisitions and partnerships.


Uzbekistan: The State Committee of Uzbekistan for Ecology and Environmental Protection plans to create a system of monitoring stations for automatic measurement of air pollution, including particulate matter (PM), throughout the country. Part of this will include the installation of automatic emissions sampling and analysis stations at a number of industrial plants, as well as static monitoring stations within and near plant sites, including in the cement sector. Installation will be at the cost of the industrial facility.

In late 2019 the State Committee for Ecology, together with the Ministry of Health and Uzhydromet, took samples of air from 13 cement plants, finding that five greatly exceeded international norms for dust emissions. Based on the results of the audit, the committee has developed a draft government decree on strengthening environmental control over cement plants. If the document is approved, then all existing cement manufacturers will be obliged to install automatic sampling stations for analysis of air pollution by 1 January 2022, as well as stationary posts in the adjacent territory at their own expense.


Australia: National press in Australia has reported that the Irish building materials giant CRH has approached Boral regarding a possible takeover. CRH snapped up US$6.5bn of assets from Lafarge and Holcim in 2015 following their merger to become LafargeHolcim, and it consequently became the third-largest building materials supplier by market value internationally.

The speculation comes amid market expectations that Boral could be broken up if a takeover does not unfold soon. Suitors have looked at Boral before but a deal has never eventuated. The company’s market value is US$3.9bn, so it could be within the grasp of a cash-rich strategic player or private equity firm from overseas. Three years ago Boral was worth more than US$4.8bn.

Meanwhile, Australia's devastating recent bushfires have affected Boral’s Berrima plant in New South Wales, likely leading to lower production and margins. This was due to extended leave for staff and road closures.


Vietnam: Maintaining exports will be critical for the Vietnamese cement industry amid rising production output and anticipated sluggish domestic sales in 2020, according to Nguyễn Quang Cung, President of the Vietnam Cement Association (VCA).

Cung also reported that two new cement plants will go into operation during 2020: a 2.5Mt/yr plant in Tân Thắng Commune in the central province of Nghệ, and a 4.6Mt/yr plant in Bỉm Sơn Commune, Thanh Hóa. These new facilities will give the domestic cement industry a total production capacity of more than 100Mt/yr, with local demand estimated to be closer to 70Mt/yr. “Maintaining exports will be critical for the cement industry this year,” said Cung, but domestic projects are likely to remain ‘sluggish’ due to stagnant infrastructure projects.

Over the medium term, Cung said that cement exports would fall to 25Mt in 2021 form 34Mt in 2020, based on an expectation that domestic sales will increase.


India: A 20 year old man has been arrested in Nalanda, Bihar for allegedly creating a fake UltraTech Cement website. The individual reportedly took payment for cement and then ceased contact, leaving genuine UltraTech Cement representatives in the state with angry enquiries. UltraTech then reported the site to police.

Police have stated that the arrested man, Rohit Kumar Balram Prasad, has been charged under sections 482 (using false property mark), 483 (counterfeiting a property mark used by another), 419 (cheating by personation) among others of the IPC and the Information Technology Act. They added that further arrests are expected.


Germany: The 4th Global CemBoards Conference & Exhibition has begun at the Marriott Hotel in Freising, near Munich, Germany. The event, which covers global market trends in cement-based boards and panel systems, the latest advances in production technology and how producers can add value to their products worldwide, will hear nine presentations over the course 21 and 22 January 2020.

The event is also host to a related exhibition of suppliers to the global cement board sector. Extensive opportunities for networking will be available, with the Global Boards Social Evening held at the Bayerische Staatsbrauerei Weihenstephan on the evening of the first day.

A full report from the event will be published in due course.


Sweden: The Land and Environmental Court has ruled in favour of Cementa for the renewal of its extraction licence for its quarry near the 2.5Mt/yr integrated Slite plant in Gotland. The company says that the decision ensures the continued operation of the cement plant. “We see this as confirmation that it is possible to continue limestone extraction without jeopardising water security or harming protected areas or species,” said Cementas CEO Magnus Ohlsson. “This gives us peace of mind and the chance to focus on future work in order to further develop sustainable cement production in Slite.”


Denmark: FLSmidth has announced details of the business improvement initiative it gave forewarning of in late 2019. The cement technology supplier is sacking 500 staff. Its most recent Annual Report stated that it had 11,368 staff at the end of 2018, meaning that around 4.4% of employees will lose their jobs. 80 of these redundancies will effect employees at its Copenhagen headquarters, with the remainder impacting personnel at operations across the globe. “Despite a healthy pipeline, this is an unfortunate yet necessary action given the weakening market for large capital investments in 2019 and our ongoing efforts to improve internal efficiency,” said FLSmidth CEO Thomas Schulz.


UK: Global not-for-profit organisation CDP has included HeidelbergCement on its Climate Change A-List 2019 for environmental transparency and performance aimed at facilitating a zero-net carbon economy. Only a handful of industrial producers achieved inclusion on the list, including the German steel sector’s Thyssenkrupp and French gypsum wallboard producer Saint-Gobain.


UK: Quinn Building Products has fitted a waste heat recovery (WHR) plant into the aircrete block production process at its Quinn Lite Plant in Fermanagh. The installation will pump thermal energy from excess heated water back into the pre-curing chamber to sustain the chemical processes by which the blocks are aerated. Quinn Lite production manager Kieran McGorman said that the upgrade ‘forms part of a larger, company-wide drive to minimise the impact of our operations on the environment and to maximise efficiencies wherever possible.’


UK: Tarmac has marked the UK’s national squirrel day (21 January 2020) by renewing its commitment to conservation at one of England’s rare red squirrel habitats: its Harden quarry in Northumberland. Harden quarry manager Gareth Williams said, “The team has set up a feeding station and has been working to monitor the number of visitors.”

Two Tarmac employees are trained squirrel wardens and are responsible for keeping track of the resident red population.


Philippines: Phinma Corp.’s cement subsidiary Philcement has ramped up its return to production with the commissioning of a 2.0Mt/yr integrated cement plant with attached terminal facilities in the port of Bataan. The Philippine Star has reported that the company, whose six integrated plants had a majority market share in the country prior to the Asian Financial Crisis of 1997, has invested US$100m on its re-entry to production, including on the Bataan facility, since it announced the return of its Union cement brand to the market in 2018.

Phinma Corp. president and CEO Ramón del Rosario said, “We believe in this government’s ‘Build Build Build’ program and we want to help ensure the success of this program by augmenting supply and offering the highest quality cement to support critical projects.”

Phinma Corp. is among domestic producers awaiting the result of an appeal by the country’s importers against the legality of the government’s safeguard duty on imported cement.


Tajikistan: Tajikistan produced 4.20Mt of cement in 2019; up by 11% from 3.80Mt in 2018. Cement exports in the period rose by 11% year-on-year to 1.55Mt from 1.40Mt. 2018’s exports amounted to 0.89Mt (64%) to Uzbekistan, 0.58Mt (41%) to Afghanistan and 0.08Mt (5.8%) to Krygyzstan. Asia-Plus News has reported that tightened pollution legislation in China has driven Chinese-based producers, which accounted for over 90% of Tajik production in 2018, to relocate operations to their country’s western neighbour.


Nepal: The Nepalese government has implemented new cement regulations specifying the minimum compressive strength of 33MPa. The Republica newspaper has reported that this will follow the 1997 Cement Standard in restricting magnesia (MgO) content to 5% and insoluble residues to 2%. Two higher grades will designate cement with compressive strengths of 44MPa and 55MPa.

The government also introduced regulations governing the compression strength, insulation and density of autoclaved aerated concrete (AAC) blocks.


India: France-based Imerys has announced the acquisition of calcium silicate producer Hysil by its subsidiary Calderys Indian Refractories from CK Birla Group for Euro10.1m. SeeNews has reported that the expansion to Imerys’ Indian operations is aimed at securing lower prices for raw materials for use in high temperature insulation in various industries, especially the cement sector.


Bangladesh: Switzerland-based LafargeHolcim’s subsidiary LafargeHolcim Bangladesh announced its intended expansion from cement production into building materials solutions provision at an event marking one year since the completion of its merger with Holcim Cement (Bangladesh). LafargeHolcim Bangladesh CEO Rajesh Surana said, “We will build on strengths of these two most premium and globally reputed companies and provide customers with multiple products and solutions under one umbrella rather than being a mere cement producer.” The Financial Express has reported that the company has a total capacity of 4.2Mt/yr of Supercrete and Holcim brand cement.


Pakistan: Pioneer has announced the completion of a new 3.7Mt/yr integrated cement plant with a 12MW waste heat recovery (WHR) power plant and 24MW coal-fired power plant. It said that production and dispatch would start ‘in due course.’ It commenced construction of the facility in 2017.


Oman: Raysut Cement’s revenue fell by 7.6% year-on-year to US$223m in 2019 from US$241m in 2018. However its profit for the year before tax rose five-fold to US$13.8m and its expenses fell by 12% to US$208m.


UK: The Mineral Products Association (MPA) Cement’s five members – Breedon Cement, Cemex UK, Hanson Cement, Lafarge Cement and Tarmac – saw their direct CO2 emissions per tonne of cement rise by 0.6% year-on-year to 633kg in 2018 from 629kg in 2017. Refuse-derived fuel rates in 2018 were 43.2%, down by 0.5% from 43.8Mt in 2017. The industry achieved its seventh consecutive year in which producers sent zero process waste to landfill. Overall sales fell by 1.0% year-on-year.


China: Sinoma International’s income remained stable in 2019 at US$4.56bn. The number of new orders rose slightly to 142. By region, revenue from domestic markets grew by 57% year-on-year to US$2.02bn but overseas revenue fell by 21% to US$2.54bn. The equipment manufacturer and supplier said that a major project to build a 5000t/day clinker production line for Central African Cement in Zambia was still in the financing stage. The project has a value of US$480m.


Germany: Mechanical process engineering company Hosokawa Alpine AG has assumed 100% ownership of Solids Solutions Group and all its operations across three locations in Germany and Spain, which will be reorganised under the brand ‘Hosokawa Solids Solutions.’ Solids Solutions Group employs 100 people and develops and implements bulk solids handling solutions for customers in various industries including cement. Solids Solutions Group founder and departing CEO Hermann Linder said, “I am pleased to be able to hand over the Solids Solutions Group to a strong company in the field of mechanical process engineering and to know that the employees and customers are in good hands.”


UK: Cemex has agreed a new partnership with Turners, a privately owned transport company. This contract will see Turners operating 20 bulk cement tankers for Cemex across the country. No value for the deal has been disclosed.

“We are always looking for ways to improve our logistics operation, and this partnership with Turners will create new flexibility in our service, thanks to their large fleet of safe and efficient heavy goods vehicles (HGV),” said David Hart, Cemex’s Supply Chain Director for UK & France.


Switzerland: Fuchs Group, which serves Swiss cement producers through its local trading partners, has established three additional intensified trading partnerships with Aseol Suisse AG, Laveba and S. Affolter for distribution of its industrial lubricants and lubricants for special applications in various regions. Aseol Suisse AG and Laveba are lubricant producers and distributors, while S. Affolter is a physical and chemical heat transfer specialist.


Spain: Brazil-based Votorantim Cementos’ Spanish subsidiary Cementos Cosmos celebrated seven years, equating to 540,000 working hours, without injury at its 0.9Mt/yr integrated Córdoba cement plant in Andalusia on 15 January 2019. Cementos Cosmos Córdoba plant manager José de la Vega said, “This reflects the initiatives that the company has put in place to promote the safety of the workforce.”


Liberia: HeidelbergCement subsidiary Cemenco has commissioned a 0.3Mt/yr cement plant in Liberia following an investment of US$14m. The Daily Observer newspaper has reported that the plant is equipped with a 2000t silo, bulk truck unloading equipment and a bagging line, in addition to four Samson Eco Hoppers for dust-free delivery in the Port of Monrovia. Cemenco already operates a 0.8Mt/yr grinding plant on Bushroda Island in Monrovia.


India: Mangalam Cement has completed the installation of a 5.15MW WHR plant at its 1.0Mt/yr Morak cement plant in Adityanagar, Rajasthan. Accord Fintech newspaper has reported that a further 5.85MW expansion to the power plant will be commissioned in early 2020.


Germany: A Zollernalb, Baden-Württemberg resident who mounted legal action against Tübingen Council in June 2019 over LafargeHolcim subsidiary Holcim Süddeutschland’s use of waste glass in cement production at its 1.1Mt/yr integrated Dotternhausen plant has submitted ‘extensive reasoning’ for the challenge. The Schwarzwälder Bote has reported that Holcim Süddeutschland allegedly did not complete the proper tests before introducing glass to cement production at Dotternhausen in late 2017. The claimant ‘noticed a rise in heavy metal levels.’

At a subsequent council meeting, a Holcim Süddeutschland employee bore witness to the presence of a defective bag filter. By receiving glass ground to grains of a certain fineness, the claimant alleges that Holcim Süddeutschland was able to bypass federal waste regulations necessitating contaminant checks. They said the company was ‘taking citizens for idiots.’


India: Gebr. Pfeiffer has announced that it has received an order for one MVR 6000 C-6 roller mill for Chettinad Cement Corp. Pvt. Ltd.’s upcoming 2.0Mt/yr Vishakapatnam granulated blast-furnace slag (GBFS) and slag cement
Grinding plant in Andhra Pradesh. Gebr. Pfeiffer said the mill will grind slag and cement to a fineness of between 3000 and 3800 blaine at a rate of between 235t/hr and 340t/hr. It says the mill improves plant availability by the active redundancy of the grinding rollers, enabling mill operation with reduced rollers in the event of maintenance work or a malfunction.