Global Cement Newsletter

Issue: GCW463 / 08 July 2020

Headlines


Hydrogen and its use in cement production has been adding a dash of colour to the industry news in recent weeks. Last week, Lafarge Zementwerke, OMV, Verbund and Borealis signed a memorandum of understanding (MOU) to plan and build a full-scale unit at a cement plant in Austria to capture CO2 and process it with hydrogen into synthetic fuels, plastics or other chemicals. This week, Air Products and ThyssenKrupp Uhde Chlorine Engineers (TUCE) signed a strategic agreement to work together in ‘key regions’ to develop projects supplying green hydrogen. Both of these developments follow the awarding of UK government funding in February 2020 to support a pilot project into studying a mix of hydrogen and biomass fuels at Hanson Cement’s Ribblesdale integrated plant.

As the title of this column suggests there is an environmental colour code to describe how hydrogen is made for industrial use. This is a bit more codified than when grey cement gets called ‘green’ but it pays to remember what the energy source is. So-called ‘green’ hydrogen is produced by the electrolysis of water using renewable energy sources such as hydroelectric or solar, ‘Grey’ hydrogen is made from steam reforming using fossil fuels and ‘Blue’ hydrogen is similar to grey but has the CO2 emissions from the fuels captured and stored/utilised. Price is seen as the main obstacle to wider uptake of hydrogen usage as a fuel in industry although this is changing as CO2 pricing mounts in some jurisdictions and the connected supply chain is developed. A study by BloombergNEF from March 2020 forecasted that green hydrogen prices could become cheaper than natural gas by 2050 in Brazil, China, India, Germany and Scandinavia but it conceded that many barriers would have to be overcome to get there. For example, hydrogen has to be manufactured making it more expensive than fossil fuels without government policy support and its, “lower energy density also makes it more expensive to handle.”

The three recent examples with respect to the cement industry are interesting because they are all exploring different directions. The Lafarge partnership in Austria wants to use hydrogen to aid the utilisation side of its carbon capture at a cement plant. The industrial suppliers, meanwhile, are positioning themselves in the equipment space for the technology required to use hydrogen on industrial plants. Secondly, ThyssenKrupp has alkaline water electrolysis technology that it says it has used at over 600 projects and electrochemical plants worldwide. Air Products works with industrial gas production, storage and handling.

Finally, the Hanson project in the UK will actually look at using hydrogen as a partial replacement for natural gas in the kiln combustion system. A Cembureau position paper in mid-2019 identified that the challenges to explore in using hydrogen in cement production included seeing how its use might affect the physical aspects of the kiln system, the fuel mass flows, temperature profile, heat transfer and the safety considerations for the plant. Later that year a feasibility study by the Mineral Products Association (MPA), Verein Deutscher Zementwerke (VDZ) and Cinar for the UK government department that is funding the Hanson project concluded that a hydrogen flame’s high heat in a burner alone might not make it suitable for clinker formation. However, the study did think that it could be used with biomass to address some of that alternative fuel’s “calorific limitations” at high levels. Hence the demonstration of a mixture of both hydrogen and biomass.

That’s all on hydrogen but, finally, if you didn’t log into yesterday’s Virtual Global CemProducer 2 Conference you missed a treat. One highlight was consultant John Kline’s presentation on using drones to inspect refractory in some hard to reach places. Flying a camera straight into a (cool) pyro-processing line was reminiscent of a science fiction film! Global Cement has encountered the deployment of unmanned aerial vehicles in quarry and stockpile surveys previously but this was a step beyond.

The proceedings pack - including video, presenter slides and delegate list - for the Virtual Global CemProducer 2 Conference 2020 is available to buy now


India: Sunny Gaur has resigned as the managing director of Jaiprakash Associates due to personal reasons. The conglomerate operates its cement plants in a cluster around Satna in Madhya Pradesh. In 2017 it sold six integrated cement plants and five grinding plants to UltraTech Cement for US$2.5bn in order to reduce its debts.


China: Dongwu Cement has appointed Liu Dong as chairman and Wu Junxian as chief executive officer (CEO) following the resignations of Xie Yingxia and Jin Chungen for personal and retirement reasons respectively.

Liu, aged 51 years, has been an executive director of Dongwu Cement since mid-2019. Since leaving university he worked as a diplomat for the Chinese government and the United Nations. From 2005 he has held a number of senior positions at companies including Orient Holdings Group, Huilitong Industry, Sunshine Oilsands, Orient International Resources Group, Global Mining and Sino-Sindh Resources. He holds over ten years’ experience in capital market and investor relationship sectors in Hong Kong and has a Master of Philosophy from the University of Cambridge.

Wu, aged 39 years, is an executive director of Dongwu Cement and the general manager of Suzhou Dongwu Cement. He joined the group in 2009, and has held various positions in Suzhou Dongwu such as assistant to general manager and deputy general manager. He became general manager of Suzhou Dongwu in 2013. Previously, Wu worked for Orient Holdings and Shanghai Keli Communications Technology. He holds a bachelor degree in management administration from Nanjing Audit University.


China/India: UltraTech Cement has agreed to sell its majority stake in Shandong Binani Rongan Cement for around US$120m. As part of the deal its subsidiaries Krishna Holdings and Nathdwara Cement will both divest their shareholdings in the company. UltraTech Cement picked up the 3Mt/yr plant in 2018 as part of its acquisition of Binani Cement in 2018. The buyer has not been named.


Uzbekistan: Akhangarantsement says that it has installed a ThyssenKrupp raw materials grinding unit at the site of an upcoming 5Mt/yr integrated cement plant in Tashkent Region. The equipment consists of a jaw crusher for primary crushing and a hammer mill for secondary crushing. The company said that the upcoming plant will “provide the market with a line of high-quality products for the construction of housing, industrial and infrastructure facilities.”


Philippines: Germany-based Gebr. Pfeiffer says a ready2grind system it supplied to Petra Cement started in early December 2019. The clinker grinding mill is operational at a grinding plant on the Zamboanga Peninsula in Mindanao. No value for the order has been disclosed. Petra Cement’s sister company , Big Boss Cement, has also ordered a modular mill system from Gebr. Pfeiffer.


France: LafargeHolcim France says that it has “responded to the demand for low-carbon concretes” with the launch of a CEM-II Portland limestone cement product with 25% lower carbon dioxide (CO2) emissions than Ordinary Portland Cements (OPC) in its Galaxim Planet range. The new addition to the range, of which LafargeHolcim plans to produce 100,000t by 31 December 2020, contains 35% limestone, up by 23% from 12% in ordinary Portland limestone cement.

LafargeHolcim France south region cement sales director Olivier Mespouilles said, “Our goal is to offer all builders a cement offering properties equivalent to a conventional cement with the advantage of a reduced carbon footprint. This tour de force was successful thanks to the involvement of all our teams, and we are the first player in France to offer this type of limestone cement in such a volume." The cement is due to enter the market in the Languedoc-Roussillon region. From 2021 the company hopes to supply 80% of customers there with the low-carbon cement.


Russia: Eurocement subsidiary Kavkazcement has announced the launch of a new CEM-II Portland limestone cement product. The company says that the cement has a wide range of applications, from “general purpose structures to objects operating under aggressive environmental conditions: concrete and reinforced concrete structures, monolithic structures, massive foundations and indoor structures, as well as in screeds, plaster mortars and dry building mixes.” Kavkazcement general director Nikolai Muradov said, “The use of cements with mineral additives provides a high-quality concrete surface; in finished products, the risk of efflorescence, cracking and other defects is reduced.” Customers can purchase the product in 50kg or 1t bags.


US: Mexico-based Cemex has announced its investment in Arqlite, a producer of aggregates from waste plastic. Arqlite won the Cemex Ventures Global Construction Startup Competition in 2019. Other investors in the company, which began its research and development process in Argentina in 2016, include Kamay Ventures and Chris Graff.

The Cemex Ventures Global Construction Startup Competition 2020 remains open to applicants until 26 July 2020.


UK: Germany-based Loesche has joined a network of expert companies that “share relevant information and results regarding the reduction of environmental impact and the use of coal and enhanced energy security globally” in becoming an IEA Clean Coal Centre knowledge partner. The company said, “We are excited to be part of this renowned group of companies that aim to improve the environmental impact by use of green technologies, renewable resources, and alternative use of energy sources for more sustainable engineering projects.”


Germany: Following a comprehensive review of its assets HeidelbergCement has announced a Euro3.4bn impairment to its company value compared to the figure from a precious valuation prior to the second quarter of 2020. The company gave the reasons for the impairment as: the demand impacts of the coronavirus pandemic; economic effects on operations in individual countries; notably in the UK post-Brexit; and an increase in the market risk premium used by the Institut für Wirtschaftsprüfer (German public auditing body) for valuation to 7% from 6%. The largest regional impairment was Euro2.7bn, in Western and Southern Europe. Euro2.3bn of the total impairment, “relates to the Hanson acquisition” by HeidelbergCement in 2007.


Tanzania: Huaxin Cement subsidiary African Tanzanian Maweni Limestone has ignited the kiln and begun trial production of clinker at its newly upgraded 0.75Mt/yr Maweni Limestone clinker plant. Huaxin Cement acquired the subsidiary in May 2020 and begun upgrading the kiln line on 1 June 2020, in spite of the fact that only 14 Huaxin Cement management team colleagues remained in the country due to the company withdrawing staff to China prior to the coronavirus lockdown.

Huaxin Cement says that it will not upgrade the plant’s grinding unit “for various reasons.” The company said, “subject to the epidemic prevention and control situation, the company will send an excellent management team to implement advanced cement process technology and management. We are committed to turning Maweni Limestone into a benchmark industrial enterprise in Tanzania and promoting the local cement industry to achieve quality.”


US: Air Products has shared details of a partnership with ThyssenKrupp Industrial Solutions subsidiary ThyssenKrupp Uhde Chlorine Engineers (TUCE). Under the partnership, Air Products will build and operate water electrolysis plants for hydrogen production using TUCE’s equipment, engineering and technical services. TUCE chief executive officer (CEO) Denis Krude said, “We are set to supply one 1GW of water electrolysis plants per year, and we are prepared to ramp up the capacity in this rapidly evolving market.” The engineering company has to date realised a total rating of 10GW across 600 electrochemical plants for customers globally.


Belarus: Belarusian Cement Company (BCC) sold 1.85Mt of cement over the first five months of 2020, up by 12% year-on-year from 1.65Mt in the corresponding period of 2019. The Belarusian Architecture and Construction Ministry has reported that, of BCC’s three subsidiaries, Krichevtsementnoshifer recorded the largest sales growth in the period, of 9.6% to 465,000t. Belarusian Cement Mill sold 657,000t, up by 3.6%, including 249,000t to Russia, and Krasnoselskstroymaterialy sold 568,000t, up by 0.2%.


Nigeria: BUA Group subsidiary BUA Cement has shared plans to establish a 3Mt/yr-capacity integrated cement plant in Guyuk, Adamawa State. The Sun newspaper has reported that the company also plans to establish a 50MW power plant in nearby Lamurde, also in Adamawa State. BUA Group chairman Abdul Samad Rabiu said, “We will use new technologies to supply power to the proposed cement plant and communities of Guyuk and Lamurde.” The state’s limestone deposits with provide the raw material for clinker production.


Zimbabwe: PPC Zimbabwe has announced that it has entered into a preliminary agreement with a Zimbabwe-based energy investor “with technical partners in South Africa” that will build and operate the company’s planned 32MW solar power plant in Matabeleland South. 16MW will power PPC Zimbabwe’s cement production and the rest will be fed in the national electricity grid, according to the Herald newspaper. The unit will be located adjacent to PPC Zimbabwe’s 0.5Mt/yr integrated Colleen Bawn plant.


US: Vicat subsidiary National Cement has received a fine of US$148,000 from the Alabama Department of Environmental Management (ADEM) for exceeding mercury emissions regulations over a 123-day period between May 2019 and February 2020 at its integrated Ragland plant in Alabama. The Daily Home newspaper has reported that unexpectedly high mercury levels in coal and other raw materials burned as fuel during that time caused the breach, which the company immediately reported to ADEM.

National Cement president Spencer Weitman said, “The issue took several months to fix.” Multiple upgrades and operational changes solved the issue, including installation of a US$400,000 mercury absorption carbon injection system. ADEM said, “National Cement did not economically benefit from the emissions violations.”

In January 2020 National Cement began work on construction of a new US$250m kiln line, due for completion in 2022.


Australia: US-based bauxite, alumina and aluminium producer Alcoa has said that it will not renew its US$48.5m/yr lime supply contract with Adelaide Brighton subsidiary Cockburn Cement following its expiry at the end of June 2020. Business News Western Australia has reported that the end of the 50-year contract puts between 40 and 50 jobs at risk at Cockburn Cement.

Adelaide Brighton chief executive officer (CEO) Nick Miller said, “We are disappointed with Alcoa's decision to displace a locally-manufactured product with imports from multiple sources. We will work quickly to mitigate the impact on local jobs supporting our lime business and we remain committed to supplying our Western Australia resources sector customers.”


India: JSW Group says that it will cease US$400m/yr worth of imports of Chinese equipment and materials due to Chinese military activities on the Sino-Indian border in Kashmir. Managing director Parth Jindal said, “The unprovoked attack by the Chinese on Indian soil, on our brave jawaans has been a huge wakeup call and a clarion call for action.”


India: JK Super Cement has signalled its support for the work of builders with the hash tag “#YehPuccaHai,” meaning, “This is strength.” The hash tag has now gone viral, garnering 25.5m social media shares, while the accompanying video has had 1.5m internet views.


Israel: The Environmental Protection Ministry (EPM) has granted Nesher-Israel Cement Enterprises a licence to substitute more refuse-derived fuels (RDF) for petcoke than was previously permitted at its 5Mt/yr integrated Ramle, Central District cement plant. The Times of Israel newspaper has reported that the licence also allows for greater metal emissions. The company said, “As is customary in the global cement industry, the Nesher plant in Ramle uses raw materials and alternative fuels, thus achieving a number of environmental goals, including reducing landfill, minimising the use of natural resources and reducing greenhouse gas emissions.”


Zimbabwe: LafargeHolcim subsidiary Lafarge Cement Zimbabwe has reported a profit of US$178m in 2019, up by 4.8% year-on-year from US$170m in 2018. Inflation-adjusted sales rose doubled to US$919m from US$449m. Cement volumes remained level at 323,000t. The company said that it, “recorded its best financial performance in over five years. The construction of a US$2m dry mortar mixing plant was completed and installation of the equipment on site is set to be completed in the second half of 2020.”


Egypt: Suez Cement has recorded a loss of US$18.0m in the first three months of 2020, compared to a profit of US$11.0m in the first three months of 2019. Sales fell by 27% year-on-year to US$80.6m from US$110m in 2019. Domestic demand in relation to Egypt’s production overcapacity fell in March 2020 due to the coronavirus outbreak. Daily News Egypt has reported that the second quarter 2020 results will carry greater losses for Suez Cement due to coronavirus lockdown measures and seasonal factors such as Ramadan, with cement volumes down by 27% year-on-year in May 2020.


Saudi Arabia: Najran Cement has announced that it has completed the repayment of a US$12m loan from Banque Saudi Fransi. Mubasher news has reported that the loan had been due for repayment in instalments in the first half of 2020. The cement producer retains US$94.6m in outstanding loans.


Iran: A new cement company has registered with the Tehran stock exchange. Called Tamin Cement Holding, it says that it will invest in cement, other related products and construction, according to the filing.