Global Cement Newsletter

Issue: GCW453 / 29 April 2020

Headlines


The headline from the cement section of FLSmidth’s first quarter results summed up what may be the current situation for many companies supplying the sector: “service relatively stable – cautious on capex.” The general picture across both its mining and cement businesses was ‘significantly’ increased demand for local resources, remote support and digital products. On the mining side FLSmidth pointed out that it was impossible to assess the impact of coronavirus on its business because of the difference between government policies. Some places continue lockdowns or impose additional restrictions but others are starting to ease them. This point has ramifications for multinational cement producers and other suppliers too. It seems likely to continue during the coming months as lockdowns ease at different rates in different countries.

On cement specifically, FLSmidth provided a good global view of what the pandemic and government responses are actually doing to the industry. It reports that around 80% of the world's cement plants (excluding China) are currently in operation with some operating at reduced capacity. It described the market for services as ‘relatively stable’ in the first quarter but that cement consumption was being reduced by lower construction activity, plant shutdowns and restricted access to sites leading to reduced demand for technical services and commissioning. By region it identified the biggest impact to its business from coronavirus in India and the Middle East. Generally, it says that cement producers are suspending capital investments until the impact of coronavirus on economies is clearer. There has been some good news though, with the supplier noting that several of its customers have been looking for services that can reduce their operational costs.

The European Commission tackled this pervading sense of uncertainty in its roadmap towards lifting coronavirus containment measures that was published on 15 April 2020. The Committee for European Construction Equipment (CECE) was keen to share this with its members this week, pointing out how the European Union (EU) plans to lift border controls and re-start economic activity.

The plan is to ease travel restrictions between border regions for cross-border and seasonal workers, and then between European areas with low coronavirus infection rates. External borders can later be reopened with access by non-EU residents to the EU scheduled for a second stage. To re-start economic activity the EU recommends, again, a phased approach focusing on sectors that are ‘essential’ to facilitate economic activity such as transport. The commission says it will also create a rapid alert function to identify supply and value chain disruptions, relying on existing networks such as Enterprise Europe Network (EEN), clusters, chambers of commerce and trade associations, small and medium enterprise (SME) envoys and more. Whether the EU can actually coordinate a return to normality following its poor response in aiding Italy at the start of the European outbreak of coronavirus remains to be seen. Yet, its historical roots as an economic community dating back to the Treaty of Rome in 1957 suggests it may be more successful when coordinating technical aspects of trade.

Detailed above are the views and plans of just one supplier and one continental organisation, although they are both prominent. The takeaway from this is that uncertainty is a major problem so far for the cement industry in the wake of the coronavirus outbreak. Companies have faced a cash crunch in the short term as economies slowed down and they are reluctant to release cash until the future becomes clearer. Large parts of the cement industry and its suppliers are very international, which exposes it to even more uncertainty. Different countries enforcing different restrictions and different easing strategies at different times create a major headache for everyone and a block to investment. Making cement is undeniably an essential industry and this realisation by legislators can be seen in some countries that at first shut down their plants before understanding that they needed them open after all! Suppliers should benefit from this too, although at reduced activity levels. We don’t know what kind of recovery will come – hopefully one releasing plenty of pent up demand. Yet one thing is certain. The work of the regional cement associations and those representing suppliers is going to be crucial in the coming months.


Egypt: Suez Cement has appointed Yasser Elnaggar as its chairman. He succeeds Hayrullah Hakan Gurdal in the role.

Elnaggar is the chief executive officer (CEO) of EN Investment, a management advisory and investment house. Previously he worked as CEO of the Chemical Industries Holding Company (CIHC), a conglomerate made up of 23 Egyptian companies. Alongside this he holds over 25 years experience as a diplomat for the Egyptian government with a notable posting in from 2010 to 2014 as the Deputy Chief of Mission of the Embassy of the Arab Republic of Egypt in Washington, DC. Domestic government roles he has held include working as the Principal Deputy Minister of Planning, Monitoring and Administrative Reform. In this position he helped oversee the implementation of Egypt's 2030 Vision strategy. He also held the post of Principal Deputy Minister of Investment until April 2016.


Thailand: Germany-based KHD Humboldt Wedag has reported the successful commissioning of a new Comflex grinding line at Siam City Cement’s Plant 1 in Saraburi. The line replaces two ball mill circuits, maintaining a production capacity of 350t/hr with a 40% lower energy consumption. The Comflex comprises a roller press, RPM18–200/180 static coarse material separator, VS620 static fine material separator, LS8600 system fan, HKSK 236/346 and four product separation cyclones. KHD says that Siam City Cement awarded it the engineering, procurement and construction (EPC) contract because of the system’s low specific power consumption of 13.36kWh/t, compared to over 21kWh/t in the previous system.


Peru: Total cement volumes in March 2020 were 0.42Mt, down by 51% year-on-year from 0.86Mt in March 2019 and down by 51% month-on-month from 0.85Mt in February 2020. Clinker volumes fell by 51% to 0.35Mt from 0.71Mt in March 2019 – down by 55% month-on-month from 0.78Mt in 2020.

Peru’s March cement exports were 6200t, down by 46% year-on-year from 11,400Mt in March 2019 and 55% month-on-month from 13,700Mt in February 2020. Imports in March 2020 were 102,000t, down by 3.6% year-on-year from 106,000t and up by 2150% month-on-month from 5000Mt.

Domestic demand fell by 47% year-on-year and 48% month-on-month to 0.49Mt, from 0.92Mt and 0.94Mt respectively.


Norway: Private accreditation body DNVGL has certified Aker Solutions’ 400,000t/yr carbon capture and storage (CCS) system installation at Germany-based HeidelbergCement subsidiary Norcem’s 1.2Mt/yr integrated Brevik plant in Telemark as safe. HeidelbergCement Northern Europe director of sustainability and alternative fuels Per Brevik said, “The promising results from pilot testing in Brevik give us confidence that realisation of the full-scale capture plant will be successful. We trust that the project risk related to novel technology elements is low.”

Following an 18-month test of the partial installation, the certification ensures that the full-scale project will receive government funding.


Australia: Germany-based Siemens subsidiary Flender has published plans for a drives production plant in the Tonkin Highway Industrial Estate, West Australia. The plant will serve the gear needs of the energy, minerals and cement industries. The unit is equipped with a 1.5MW test bench capable of testing drive systems of up to 6.6kV. Flender Australia chief executive officer (CEO) and managing director Kareem Emara said, “Western Australia has been an excellent market for us in the recent years. It’s only natural for us to reinvest in this key market and be where our customers are to offer them the combined brains trust of over 50 facilities worldwide through this new state-of-the-art centre.”


Germany: Lubricants specialist Fuchs has announced its collaboration with chemicals company BASF in performing a cradle-to-grave analysis of different mineral oil hydraulic fluids that takes into account all environmental and economic aspects of their lifecycle. The study concluded that high performance multigrade hydraulic oil (HVLP) has a lower environmental impact and lower overall cost than monograde hydraulic oil (HLP). Fuchs said, “This advantage is mainly based on an improved diesel fuel economy throughout the use phase - primarily due to improved volumetric fluid efficiency, lower friction and lower fluid mass circulation ratio.”

Fuchs and BASF both supply lubricants and chemical products to the cement industry.


China: Anhui Conch’s profit in the first quarter of 2020 was US$690m, down by 19% year-on-year from US$860m in the corresponding period of 2019. Sales fell by 24%, to US$3.28bn from US$4.31bn. The coronavirus outbreak in China impacted the results, notably through decreased sales volumes and a 190% increase in financial expenses due to devaluation of the local currency.


India: Ambuja Cements’ profit in the first three months of 2020 was US$52.4m, down by 6.5% year-on-year from US$56.2m in the corresponding period of 2019. Sales were US$3.72bn, down by 3.4% from US$3,86bn. The company said the shutdown of all plants in March 2020 due to the coronavirus pandemic ‘impacted operations.’ It added, “Taking into account directives from the government, operations at a few plants have commenced in a phased manner since 20 April 2020.’

Ambuja has said that together with ACC it has donated US$434,000 to non-governmental organisations (NGOs) to provide food and ration kits to vulnerable people affected by the coronavirus outbreak. LafargeHolcim CEO India and Ambuja Cements managing director and CEO Neeraj Akhouray said, “Collaborative models are more effective in both containment of the disease as well as support for those whose livelihood and even survival is at risk. We believe that our contributions to these NGOs that are delivering grass-roots relief measures, coupled with our own companies’ efforts on ground working with local communities, will greatly accelerate the scale and impact we will have.”


Denmark: FLSmidth’s revenue in the first three months of 2020 was Euro607m, up by 2.5% year-on-year from Euro592m in the corresponding period of 2019. FLSmidth’s cement division’s sales were Euro240m (40% of total revenue), down by 2.6% from Euro246m. The company said that the coronavirus outbreak impacted results, especially in March 2020, when ‘customer hesitation on large investments intensified, particularly in cement,’ and customers increasingly deferred large investments. It added, “Demand for spare and wear parts is relatively stable, whereas technical services are challenged by restricted access to sites.”

FLSmidth says that it aims to ‘carry out business as usual’ throughout the coronavirus outbreak, with an increased reliance on ‘remote monitoring, maintenance and support.’

FLSmidth’s 2020 financial guidance remains suspended.


Russia: TimluyCement has received a Hyundai Robex 210W-9S excavator at its 0.8Mt/yr Timluisky plant. The vehicle replaces the plant’s Twex EK-14. The new excavator is equipped with a bulldozer blade, outriggers and a hydraulic line for attachments and has a bucket capacity of 1.1m3. A Webasto pre-heater will warm up the engine before starting it in the cold season, increasing service life. TimluyCement managing director Vladimir Klichko said, “The modernization of the fleet of special equipment is an integral part of our production process. By acquiring high-performance, reliable vehicles, we increase work efficiency, minimise operating costs and also improve the working conditions of our employees.”

Hyundai previously provided the Timluisky plant with front-end loaders.


US: The Environmental Protection Agency (EPA) has declared Cemex USA an Energy Star Partner of the Year, the highest award for energy-efficient production in the US. Cemex USA President Jaime Muguiro said, “Sustainability is embedded in our day-to-day operations and is an integral part of our core business strategy. Energy conservation is part of our vision as we are building a better future and believe it’s our responsibility to vigorously practice energy management through on-going initiatives and the use of alternative fuels.”

Cemex USA has earned more than 50 Energy Stars since 2007.


China: China Resources Cement (CRC)’s profit in the first three months of 2020 was US$144m, down by 25% year-on-year from US$192m in the corresponding period of 2019. Sales were US$722m, down by 26% from US$969m. CRC sold 11.2Mt of cement over the period, down by 27% from 15.2Mt, although prices hadincreased. Cement sales constituted 82% of total revenue at US$589m, down by 22% from US$752m.


Sweden: Refractories specialist Höganäs Borgestad opened its new headquarters at Gävle, Gävleborg county on 27 April 2020. The facility will house the Energy and Kiln Engineering, Installation and Management departments.

During the coronavirus lockdown one project of note for Höganäs Borgestad has been refractory maintenance at Germany-based HeidelbergCement subsidiary Norcem’s 1.2Mt/yr Brevik cement plant in Telemark, Norway, for which it supplied 600t of refractories and 45 workers over a three week period.


Mexico: Cemex has implemented more than 50 new safety protocols to minimise the risk of coronavirus spread in its cement, ready-mix concrete and aggregates operations. Cemex said that it recognised ‘the importance of the construction industry in supporting the maintenance and service of essential infrastructure required to face the pandemic and contribute to the economy,’ and would resume or continue all possible operations in line with the regulations of the countries in which it operates.

“The health and safety of its employees is the company’s number one priority,” said Cemex. “Among the protocols implemented are the company’s Personal Hygiene Protocol, Physical Distancing Protocol, Screening at Workplace Protocol, Cemex Truck Drivers Protocol, Workplace Cleaning Protocol, and Commuting To and From Work Protocol,” all developed in line with advice from national and international bodies such as the World Health Organization (WHO).
Cemex has leveraged its Cemex Go digital platform to limit physical contact and ‘protect employees, customers and suppliers.’


Sweden: Norway-based Geminor received a batch of refuse-derived fuel (RDF) produced at its Braunsbedra plant in Saxony-Anhalt, Germany for use at Scandinavian cement plants on 23 April 2020. The shipment was Europe’s first international shipment of RDF by rail, without the use of trucks. Geminor plans for the 110t delivery to be the first of many on the 50,000t-capacity line. Geminor CEO Kjetil Vikingstad said, “Since transport by ship is only effective within a radius of 200km from a port, central Germany becomes a natural starting point for
transport by train. This is the beginning of extensive waste transport by train in
Europe.”


UK: A team of Hanson employees has produced a sign from recycled materials from around the company’s 1.0Mt/yr Purfleet slag cement grinding plant. The 6m-long luminous sign, which reads ‘NHS Thank You,’ has been installed at the plant on the mill three tower overlooking the QE2 Dartford Crossing. Hanson Purfleet plant manager Warren Scott said, “The team wanted to show their appreciation for the NHS and key workers and came up with and executed this idea in their own time.”

Hanson has kept ‘a number of key sites’ open through the coronavirus outbreak in order ‘to supply key national infrastructure projects or to provide maintenance materials to critical sectors.’ Hanson has furloughed part of its staff under the government’s Coronavirus Job Retention Scheme.


US: A cloud of dust from Cemex’s 3.3Mt/yr Victorville, California plant caused the fire brigade to be called to the site at 17:00 on 24 April 2020. Victor Valley News has reported that what onlookers believed to be smoke was indeed escaped dust from silo refilling. Locals reported that dust frequently covers their cars.


Vietnam: US-based FCT Combustion has published details of a new contract with Vietnam National Coal and Minerals Industry Holding Group (Vinacomin) for the supply of an FCT Turbo-Jet burner to Vinacomin’s 0.6Mt/yr La Hiên plant in Thái Nguyên province. The upgrade aims to enable the use of lower calorific coal while maintaining clinker strength and specific fuel consumption, in order to reduce fuel costs.

FCT Combustion previously provided burners at Vinacomin’s 0.8Mt/yr Quan Trieu cement plant in 2019 and 1.5Mt/yr Quang Son cement plant in 2020, both in Thái Nguyên province.


India: Both Germany-based HeidelbergCement and Aditya Birla subsidiary UltraTech have responded to the government’s partial lifting of the coronavirus lockdown for rurally-located continuous industries by resuming ‘partial operations in some production facilities.’ Orient Cement subsidiary CK Birla said, “We are in the process of partially resuming our operations at our plants in Karnataka and Maharashtra.” Producers require the permission of the relevant state government to restart plants. In Telangana, where the government has not lifted the lockdown, CK Birla’s facilities remain shut.

The Economic Times newspaper has reported that ‘limited transportation facilities, higher than usual inventory and stricter rules regarding labour safety’ have added a note of caution to resumed operations. Shree Cement managing director Hari Mohan Bangur said, given the continuation of restrictions on construction in cities, “We expect just 10% of normal consumption, with hopes of a gradual increase.”


Malaysia: The Cement and Concrete Association of Malaysia (CCA) has praised the government’s decision to grant an exception to cement plants in order to allow production to resume in the third phase of the country’s lockdown, beginning on 28 April 2020. The Straits Times newspaper has reported that the current and previous stages of the lockdown have exacerbated the cement sector’s losses over the past two years.

The CCA said that the development ‘will have a multiplier effect on the economy.’ CCA chair Datuk Yeoh Soo Keng said that 100,000 jobs ‘depend either directly and indirectly on cement production,’ including many ‘in small and medium enterprises’ that will not survive the outbreak without it. “Cement is the fundamental building material of our country’s wealth,” he added. The CCA thanked the government for the ‘welcome reprieve’ and urged it to allow ‘related sectors to slowly and gradually resume operations, for the industry to effectively function.’


Slovenia: Salonit Anhovo suspended production from 20 April 2020 to 4 May 2020. SeeNews has reported the reason for the suspension as a lack of demand from its usual Italian and Slovenian markets amid the ongoing coronavirus crisis. Salonit Anhovo management board member Dejan Zwitter said, "We expect domestic sales to stabilise as the government is providing incentives for construction activities."

The company will continue to serve its customers with deliveries of it products.


Pakistan: Bestway Cement has donated US$3.75m to charity causes between 31 December 2019 and 24 April 2020, including a US$1.25m donation to the state coronavirus relief fund on 23 April 2020. Bestway Group CEO Zameer Choudrey said, “We are conscious of our responsibility as Pakistan’s largest overseas investor. More resources will be devoted as and when necessary.” Bestway Group is based in the UK.


Saudi Arabia: Denmark-based FLSmidth has announced that it has secured an engineering, procurement and construction (EPC) contract with Yanbu Cement for a ‘massive’ efficiency-increasing upgrade to reduce the heat and power consumption of the 5.9Mt/yr integrated Yanbu cement plant in Al Madinah Province.

FLSmidth previously supplied the Yanbu cement plant with an automation upgrade and burner system retrofit in 2018. It concluded a service agreement with Yanbu Cement in 2019.


Indonesia: Japan-based Taiheiyo Cement has announced its acquisition of a 15% stake in state-owned Semen Indonesia subsidiary Solusi Bangun Indonesia for between US$186m and US$232m, subject to the terms of a partnership agreement with Semen Indonesia.

Under the ‘2020 Mid-Term Management Plan,’ Taiheiyo Cement says that it aims to ‘become a corporate group with a strong presence in the Pacific Rim.’ Its partnership with Semen Indonesia is part of Taiheiyo Cement’s response to a forecasted long-term decline in domestic cement demand in Japan.

In the first quarter of 2020 Semen Indonesia sold 9.36Mt of cement, up by 7.0% year-on-year from 8.74Mt in the corresponding period of 2019. InsiderStories News has reported that domestic demand in the period fell by 4.9% to 14.9Mt from 15.7Mt, while exports fell by 2.5% to 1.39Mt from 1.42Mt but rose by 6.2% on a month-by-month basis in March 2020 to 3.09Mt from 2.91Mt in February 2020. April 2020’s cement sales are expected to be lower due to the impacts of the coronavirus outbreak.


Russia: Eurocement subsidiary Belgorodsky Cement has dispatched the first batch of bagged cement from the new packing and palletising line at its 3.8Mt/yr integrated plant in Belgorod West, Belgorod Oblast. The 70t/hr-capacity line produces 50kg cement bags on pallets of 1.7t (34 bags).

Eurocement has also announced the first delivery of cement from its Belgorodsky Cement plant to Yaroslavl, Tolyatti and Nizhny Novgorod by river in 2020. Eurocement senior vice president Alexander Sapronov said, “The delivery of products by river transport is one of the most cost-effective methods of transportation. High-quality loading and reliable packaging guarantee consumers complete cargo safety.”

Eurocement has continued production throughout the coronavirus outbreak, but has restricted meetings, conferences and training sessions since 23 March 2020. The Group said, “Eurocement products are strategically important to the nation's economy. In order to ensure smooth operation of production facilities and of the group as a whole, measures have been taken to minimise the risk of spreading the coronavirus.” These include: ‘regular health check-ups and temperature measurements for employees and subcontractors, air disinfection, antiseptic treatment of operational surfaces, provision of skin antiseptics in toilets and informing employees about safety recommendations.’


EU: The European Council and European Commission have published their joint coronavirus exit strategy, entitled ‘European Roadmap Towards Lifting COVID-19 Containment Measures.’ It advises EU member states on a course of action aimed at restoring community life and the economy, while also preserving public health, after the coronavirus outbreak.

The roadmap consists of a progressive lifting of travel restrictions, initially between border regions, then between regions less affected by the outbreak and subsequently across internal and external borders of the EU. The strategy applies a similar approach to restarting the economy, beginning with ‘essential sectors’ such as construction. The Commission will maintain a rapid alert system for supply chain disruptions, with the help of existing networks such as the Enterprise Europe Network (EEN), Clusters, Chambers of Commerce and trade associations.


Hungary: Italy-based Entsorga has completed the installation of an automated alternative fuel (AF) line at a Hungarian cement plant.The upgrade consists of an Entsorga Spider crane and Pelican power system which will be able to maintain a continuous feed to the plant’s calcination system 24 hours a day.

Entsorga CEO Francesco Galanzino said, “Bringing a commission to a successful conclusion in the middle of the maximum intensity period of the coronavirus crisis has been a great satisfaction. The cement plant will make significant savings in CO2 emissions.”


Ireland: CRH has said that it had a ‘positive start to the year’ in the first three months of 2020. Total sales over the period rose by 3% year-on-year. In the Americas region, cement volumes rose by 4% and prices by 6%. European cement sales were ‘broadly in line with the same period of 2019’ due to general volume and price increases offset by a fall in volumes in Western Europe.

Government-implemented covid-19 restrictions on construction towards the end of the period impacted sales in Canada, the UK and France. The likely effects on 2020 profit ‘cannot be reasonably estimated at this time.’ CRH chief executive officer (CEO) Albert Manifold said, “With the financial strength of CRH and the experience of our leadership teams, we will endure through these unprecedented and uncertain times.”


Spain: Cement demand in the first quarter of 2020 was 3.14Mt, down by 13% year-on-year from 3.60Mt in the corresponding period of 2019. In March 2020 cement consumption in Spain was 924,000t, down by 28% year-on-year from 1.28Mt due to the effects of the coronavirus outbreak. Agencia EFE has reported that this is the lowest level of demand in any month since the immediate aftermath of the 2008 financial crash. Construction activity has been restricted by a government-imposed coronavirus lockdown since 14 March 2020.

On 23 April 2020 Spain’s confirmed coronavirus case count was 213,024, with 22,157 deaths.