Global Cement Newsletter

Issue: GCW484 / 02 December 2020

Headlines


Cement scalpers in Tanzania have been threatened with jail time for hoarding cement! The country faced a shortage of cement and other building materials in October 2020 and Prime Minister Kassim Majawali ordered an investigation into the issue following the conclusion of the presidential election earlier that month. Both regional commissioners and the National Prosecution Service have been dragged into the initiative. Director of Public Prosecutions Biswalo Mganga promised to local press that wrongdoers could face up to 30 years in prison for daring to hoard products or distort the market.

Rhetoric aside, the situation is curious given that HeidelbergCement’s local subsidiary, Tanzania Portland Cement, seemed to think in its 2019 annual report, that the country faced a 5Mt/yr overcapacity from integrated and grinding plants compared to a total production base of 10.6Mt/yr. However, the East African newspaper reported that despatches fell to 150,000t in October 2020 from 450,000t in September and August 2020, with a 30% surge in the price in some parts of the country.

In the wake of this, Dangote Cement apologised publicly for failing to communicate a planned stoppage at its Mtwara plant to the wider public. Tanga Cement then denied that its production was down. It said instead that production was at the highest level and that large chunks of its output was servicing government-backed infrastructure projects like the Standard Gauge Railway (SGR) and the Kigongo-Busisi Bridge, which will span the southern end of Lake Victoria. It also blamed a lack of trains on the Tanga-Moshi, which was reopened in mid-2019. It seems reasonable that cement prices might vary quite markedly, even before the profiteers got involved, due to the reasons above. Other issues locally include poor transport links, long distances in a country like Tanzania, the recent election and lingering hiccups from the blockage of imports from Kenya in 2018 that may not have helped either. The investigation continues.

A wider issue here is how much cement production capacity the country and the region can support given a propensity for spikes in prices. As Global Cement has covered previously (GCW456 and prior issues) Chinese producers have been heading into Sub-Saharan Africa over the last decade. Huaxin Cement bought ARM Cement’s assets in Tanzania in May 2020. It renamed the company African Tanzanian Maweni Limestone and then started trial production of clinker at the newly upgraded 0.75Mt/yr Maweni Limestone clinker plant in July 2020. Depending on how long ARM Cement’s former subsidiary was out of action, this one seems unlikely to rock the market too much. Tanga Cement also took the opportunity in November 2020 to say that talks with the government about a new 0.5 – 0.75Mt/yr grinding plant in Arusha were progressing

The proposed 7Mt/yr CNBM/Sinoma ‘mega’ plant is another matter entirely. Most of its output is intended for export but any disruption to local transport links, current or future, could swamp the local market. The export of Chinese infrastructure development around the world through its loan system could offer (occasionally literal) bridging solutions here as cement from a Chinese-backed factory is used to build the transport networks backed by Chinese loans that allow exports to proliferate. Tanzanian President John Magufuli’s comments that the poor terms for a US$10bn Chinese loan supporting a port project could “…only be accepted by a drunken man,” may not have helped international diplomacy. Still, Chinese money is actively getting things built here and elsewhere around the world at a rate previously unheard of.

Returning to the present, it makes a change to highlight a market where cement is truly demanded. A coronavirus-related lockdown may have slowed sales in the first half of 2020 but Dangote Cement estimated that the total market for cement in Tanzania was about 4.2Mt in the first nine months of 2020 and it reported its highest ever orders and dispatches in September 2020. That the country’s prime minister decided to discuss cement prices is a reminder of how important the commodity remains in parts of the world.


Sweden: HeidelbergCement’s subsidiary Cementa has appointed Jörgen Staflund as the plant manager of its integrated Skövde cement plant with effect from the start of 2021. He succeeds Matilda Hoffstedt, who has been in the post since 2010. She has been appointed to the role of Technical Support Manager within HeidelbergCement Group.

Staflund started his career working for Volvo in Skövde before becoming the maintenance manager for Cementa at the Skövde plant. He later worked as the Senior Technical Advisor Cement Operations Northern Europe before becoming the plant manager of Cementa’s Degerhamn plant in 2018 and 2019. He was recently been working on setting up a new concrete plant in Norway.


India: The Chief Minister of West Bengal Mamata Banerjee says that workers have cleared land in Jalpaiguri District on which for Star Cement to establish a 2.0Mt/yr grinding plant. The Times of India newspaper has reported that the planned US$61m grinding plant will receive its clinker from the company’s Lumshnong cement plant in Meghalaya.

Chief executive officer (CEO) Sanjay Kumar Gupta said that plant, which will bring the company’s total installed cement production capacity to 6.0Mt, will serve a state with a domestic cement demand of up to 25Mt/yr.


India: The Indian Department of Mines and Geology has fined Trishul Cements around US$13.6m for the alleged unlawful extraction of 14,000t of limestone from the Konuppalapadu limestone mine in Andhra Pradesh. The Times of India has reported that the state government terminated its lease of the land in relation to Trishul Cements in February 2020. Investigations unearthed continued mining activity at the site in Anantapur District, along with two other companies’ sites in the Muchakota forest area of the district.


Germany: CRH subsidiary Opterra’s Karsdorf cement plant has been awarded a Concrete Sustainability Council (CSC) Gold certificate for ecologically, socially and economically responsible cement production, including in its supply chains. The company says that it achieved top marks across 96% of audited areas.

Chief executive officer (CEO) Danilo Buscaglia said, “The CSC certification leads to a continuous increase in the sustainable management of the cement and concrete industry. With this in mind, the Karsdorf plant has provided evidence of responsible behaviour in an extensive auditing process. We are proud that we have achieved gold certification status. At the same time, the good results are an incentive for us to continue working on improvements in the manufacturing process and in product development.”


Bangladesh: LafargeHolcim Group subsidiary LafargeHolcim Bangladesh has launched Holcim Water Protect, a water-resistant cement “developed through the company’s in-house product innovation and manufacturing capabilities in collaboration with the Innovation Centre of LafargeHolcim Group.” The product is “scientifically formulated and customised for the Bangladesh market by leveraging LafargeHolcim Group’s Smart Blend Technology (SBT). Holcim Water Protect ensures reduced capillary action, resisting the permeation of water thus making it damp and seepage resistant.” The company says that use of the product will result in “stronger and more durable homes” compared to Ordinary Portland Cement (OPC).

Chief executive officer (CEO) Rajesh Surana said, “We are delighted to introduce our most innovative and premium product Holcim Water Protect for our customers in Bangladesh. This product has been developed through continuous consumer engagement, research and thorough understanding of the damaging impact of water on houses. Given the heavy rainfall in Bangladesh, we believe that Holcim Water Protect shall help our customers build their dream homes, free from dampness and seepages.”


Japan: Sumitomo Osaka Cement has formulated a set of medium-term goals and long-term policies in order to enable it to achieve carbon neutrality, in line with the Japanese government’s target, by 2050. These consist of a 30% reduction in energy-derived carbon dioxide (CO2) emissions intensity between 2005 and 2030 and efforts toward carbon neutrality in energy and process-derived emissions by 2050. These efforts include: “reduction to the limit of fossil energy, development and introduction of process-derived CO2 emission reduction technology, carbon-free electric power, technology development and supply expansion related to low-carbon cement and concrete products, development and supply of innovative bonding materials and development and introduction of innovative technology related to carbon capture, utilization and storage (CCUS).”


UK: The Mineral Products Association (MPA) has launched an updated version of its biodiversity strategy, first published in 2013. The new strategy “commits the MPA and its members to continuing to take a positive approach to nature conservation and recovery, leaving behind more and better quality habitats than before mineral extraction and a net gain in biodiversity wherever possible, through site selection, management, restoration and aftercare,” according to the association. It sets out the commitment under eight actions, which include “monitoring to identify what works best and inform future work, sharing and celebrating good practice and successes throughout the industry, influencing policy and using our assets to engage and educate.”

Chief executive officer (CEO) Nigel Jackson said, “The minerals industry is uniquely placed to contribute to conservation and enhancement of biodiversity and has an unrivalled legacy compared to other industrial sectors. I am immensely proud of what our members have achieved and excited about what they can and will do in the future. It is high time that our significant contributions are properly recognised by policy and decision makers, to help provide our members with the support to continue doing what they do best. I believe we may be the only business sector that has been actively contributing to nature recovery at scale for so long that our strategy is unique. I will not rest until government, particularly the Department for Environment, Food and Rural Affairs (DEFRA), acknowledges that environmental expertise and action is not the sole preserve of non-governmental organisations (NGOs) and activists. Our members have built a significant legacy and have vast practical experience of working in and with the environment to enhance and protect nature. We don’t just talk a good game, we deliver it on the ground.”


Colombia: Austria-based Mondi Group plans to open its first South American paper bags plant in Cartagena in January 2021. The unit will start with one production line with a capacity of approximately 50m bags/yr. The bags will be targeted at the cement, chemical and food industries. The group said that the plant is located in a free-trade zone with good access to ports in Panama, the east coast of the US, the Gulf of Mexico and other Caribbean ports.

"Our global network already includes 39 plants across 22 countries. We are excited to be expanding our footprint to Colombia, helping us to provide innovative, sustainable and customer-focused paper packaging solutions to customers in South America who share our commitment to quality," said Claudio Fedalto, Chief Operating Officer Paper Bags, Mondi.


UK: The Competition and Markets Authority (CMA) has accepted Breedon Group’s proposed divestments as part of its acquisition of certain assets from Cemex subsidiary Cemex Investments. The agreement will see the divestment of 14 sites - including a cement terminal, two quarries and 10 ready-mix plants - to Tillicoultry Quarries.

The building materials producer said that it “notes the announcement today by the CMA that it has accepted Breedon's undertakings in lieu of a reference to a Phase 2 investigation in respect of its acquisition of certain assets from Cemex Investments Limited.”


Egypt: Metallurgical Industries Holding has sold its 18% stake in Egyptian Tourah Portland Cement for just under US$3m. Mubasher has reported that Arab African International Securities (AAIS) acted as broker for the transaction.

In October 2019, the Financial Regulatory Authority (FRA) approved HeidelbergCement subsidiary Suez Cement’s mandatory tender offer (MTO) for 100% acquisition of Egyptian Tourah Portland Cement for around US$33m.


Vietnam: The General Statistics Office (GSO) has estimated total domestic cement production in the first eleven months of 2020 of 90.0Mt, up by 3.4% year-on-year from 87.0Mt in the corresponding period of 2019. The Viet Nam News newspaper has reported that November 2020 production reached 9.1Mt, up by 4.6% year-on-year from 8.7Mt in November 2019.

In 2019 Vietnam’s full-year cement production rose by 7.9% to 96.5Mt.


India: Police have fired warning shots after protesters outside LafargeHolcim subsidiary ACC’s Sindri cement plant in Jharkhand threw stones at them, according to the Pioneer newspaper. Sub-divisional manager Satyendar Kumar’s officers made three arrests. Residents of Dhanbad district are reportedly protesting a lack of local jobs. ACC had been in talks with local people when the disturbance broke out.


China: The Bauma China 2020 trade fair took place from 24 - 27 November 2020, attracting 2867 exhibitors and a total of 80,000 trade visitors from China. The oragnisers said that in spite of the Covid-19 pandemic, the exhibition was able to take place across a 300,000m2 area, thanks to a “sophisticated safety and hygiene concept.” It said, “In these difficult times, Bauma China 2020 gave the entire industry a reason to enter the coming fiscal year with confidence and hope.”


Ethiopia: Denmark-based FLSmidth says that its contract with Abay Industrial Development Share Company for engineering, procurement and supervision on the upcoming Dejen cement plant is now effective. The 5000t/day plant will cost US$120m and create new 300 jobs, according to the supplier. It said that the plant will “play an important role for the development of local infrastructure.”

The supplier is responsible for design and engineering, full equipment supply, automation systems, installation and commissioning, as well as training and extended supervision. Key deliveries are due to begin in late 2021.

FLSmidth president Carsten Riisberg Lund said, “We are happy to see the contract now in effect. Following months of challenging working conditions on sites around the world, we are eager to get started on the project. This contract once again underlines our position as the preferred supplier of sustainable and productivity-enhancing solutions to the global cement industry."


Indonesia: Semen Indonesia has signed a memorandum of understanding with rail freight company Kereta Api Indonesia (KAI). Indonesia Government News has reported that the memorandum covers a planned increase in cooperation on rail-based transportation and medium and long-term land leases, the conduct of joint studies into railways and infrastructure and the development of other forms of potential cooperation.

President director Hendi Prio Santoso said, “This cooperation is a synergy to complement each other and provide the best results for both parties. Through the synergy that exists today, it is hoped that it can be more optimal in taking advantage of every opportunity, so that it can further contribute to the company, Badan Usaha Milik Negara (BUMN) and the Indonesian nation.” He added, “Today is the first step in a joint commitment. Hopefully, this cooperation can run smoothly and in accordance with our goals, expectations and planned target time.”


Kenya: East African Portland Cement Company (EAPCC) has threatened “recovery proceedings” in relation to the alleged unlawful extraction of building materials on the producer’s land in Mavoko County by China Road and Bridges Corporation (CRBC). EAPCC says that it has twice contacted the construction company, which is engaged in building the Nairobi Expressway toll road, to order it to desist, according to the Business Daily newspaper.

Acting managing director Stephen Nthei said, “The company cannot violate the country’s laws when constructing a commercial road. Any mining activities will devalue our land when we are eyeing prospective buyers. We might be forced to institute recovery proceedings against this company.”

The cement producer is seeking a buyer for the parcels of land, which are also home to illegal squatters.


Uzbekistan: The Ministry of Energy says that it has not shut off the electricity supply to various cement plants, as alleged within private messaging channels. It stated the example of the Okhangaran cement plant, which, during the alleged shutdown, was received a recorded 605,000kWh of power on 24 November 2020, up by 12% from its average supply of 540,000kWh/day.

The ministry said, “Anyone who disseminates any information to a specific audience needs to clearly understand their responsibility.”


Pakistan: Pioneer Cement has begun power generation at its upgraded 24MW coal-fired power plant. Link News has reported that the plant previously had a power generation capacity of 12MW.


India: Shiva Cement plans to invest around US$200m towards a new integrated cement plant in Sundergarh district, Odisha. The 1.36Mt clinker unit will also include a 1Mt/yr grinding unit, an 8MW waste heat recovery (WHR) unit, 4Mt/yr crushing plants at its dolomite and limestone quarries, a connecting 10km belt conveyor and a dedicated railway siding with a 12km track to the main network.

ThyssenKrupp Industries India will supply a 4000t/day clinker production line for the project. Larsen & Toubro has been awarded the contract for civil, mechanical and refractory erection work. The unit is expected to create around 500 jobs directly and indirectly. Commissioning is scheduled to take place by March 2022.

Parth Jindal, the managing director of JSW Cement said, "The new clinker unit at Shiva Cement in Odisha will provide a strategic advantage to service the needs of our customers in the region and further strengthen JSW Cement's leadership position in the Green Cement category in India.”

The subsidiary of JSW Cement intends to use the new plant as a strategic hub to access markets in the east of the country. It is part of the group’s aim to achieve a production capacity of 25Mt/yr by 2025.


Algeria: Groupe des Ciments d'Algérie (GICA) has completed the export of 41,000t of clinker to Haiti and the Dominican Republic. Algeria Press Service has reported that the company exported the clinker, produced at the Hadjar Soud (SCHS) cement plant, from the port of Annaba.

Chief executive officer (CEO) Youcef Merabet said, “Hadjar Soud cement plant, which operates two production lines totalling 0.9Mt/yr of cement production capacity, will promote its exports in 2021 especially as the demand for clinker will exceed 200,000t.”


Italy: Germany-based HeidelbergCement is reportedly considering a relocation of its subsidiary Italcementi’s research centre from Bergamo, Lombardy to Heidelberg in Baden Württemberg, Germany. The Italia Oggi newspaper has reported that Italcementi said, "The reorganisation of innovation and product research activities will be concentrated on a global level to better enhance the important skills acquired in Bergamo, making them available to all the countries that are part of the group. The process of relocation to Heidelberg of the research activities will be defined in detail during 2021 and at the same time all the possible solutions for the workers involved will be implemented through internal or external relocation offers."

The proposed move has attracted local resistance. Chamber of Deputies member for Lombardy Maurizio Martina said, “All the institutions, from the national government to the regional council, must promote an initiative to discuss with the owners the choice of moving the HeidelbergCement research centre to the German headquarters. The agreements signed in 2016 were different: we are talking about one of the most important research centres in the world, which brings quality employment and added value to Bergamo and Lombardy, and it is essential to do everything to ensure that it remains in our territory."


Zimbabwe: LafargeHolcim subsidiary Lafarge Cement Zimbabwe has said that cement demand has increased by 34% quarter-on-quarter in the third quarter of 2020 following the end of the national coronavirus lockdown. Business Weekly News has reported that the company said that cement demand in July 2020 was the highest in that month since July 2003 due to a 7% year-on-year sales rise.

Company chair Kumbirai Katsande said, “As business activity progressively continued to gain momentum into the third quarter of 2020, the demand for cement consequently outstripped supply, causing considerable supply backlog.” Katsande said that the shortage will ease as demand decreases “associated with rainfall” in the fourth quarter of 2020.


UK: The Competition and Markets Authority (CMA) has written to HeidelbergCement subsidiary Hanson UK to express concern and set out actions to prevent a recurrence of a breach of a market data order for “data disclosed which could have been a proxy for Individual Cement Market Data.” The CMA says that on 11 September 2020 Hanson made a payment in error to the Mineral Products Association (MPA) which involved three pieces of information: the payment; relating to MPA subscription fees, remittance advice relating to the payment; and an invoice following the MPA’s querying of the payment. In the view of the CMA each piece of information breached the Cement Market Data Order, because it contained ascertainable cement volume data information.

Hanson has explained that the breach arose due to administrative error.


Vietnam: The General Department of Vietnam Customs has reported total cement and clinker exports in the first ten months of 2020 of 31.6Mt, up by 19% year-on-year from 26.5Mt in the corresponding period of 2019. The Viet Nam News newspaper has reported that the value of exports rose by 7% to US$1.78bn. China bought 18Mt, worth US$611m, corresponding to 57% by volume and 34% by value of Vietnam’s cement and clinker exports.

In October 2020 Vietnam exported 3.58Mt of cement, down by 18% month-on-month from 4.37Mt in September 2020, at a total value of US$142m, down by 12% from US$160m.


Pakistan: Lucky Cement has placed an order for three 10MW 34DF dual-fuel engines for its Pezu cement plant in Khyber Pakhtunkhwa province from Finland-based Wärtsilä. The engines are capable of operating on various fuels but will be fuelled primarily by natural gas. They have been ordered to provide additional power for the unit’s captive power plant due to an increase in cement production capacity. The orders were placed in April, August, and November 2020. No value for the order has been disclosed.

“It is important for large cement producers to have operational flexibility to run the power plant on multiple fuels in case the gas supply is interrupted, or whenever otherwise required. Wärtsilä’s multi-fuel power generating technology provides the kind of flexibility that we need for an efficient and reliable power supply. The cement plant is relying purely on the power plant with Wärtsilä gensets supplying the power,” said Syed Noman Hasan, executive director at Lucky Cement.

In addition to the engines, Wärtsilä is also supplying waste heat recovery boilers needed to generate steam required for the steam turbines for electricity generation in combined cycle mode. The first Wärtsilä engine is being delivered in November 2020 and is expected to become fully operational in January 2021. The remaining two engines will be delivered by March 2021 and will become operational in May 2021.

The cement plant already uses ten Wärtsilä dual-fuel engines in its on-site power plant. The need for the new engines follows on from an increase in cement production capacity.


US: The Portland Cement Association (PCA) has announced the winners of the 2020 Safety Innovation Awards. The awards recognise ‘creative safety-enhancing projects in the cement industry’ across five categories.

Buzzi Unicem USA’s Joliet, Illinois cement terminal won the distribution award for its barge entry ladder, which reduced fall hazards associated with unloading cement from barges. Ash Grove Cement’s Durkee, Oregon cement plant won the general facility award for its burner pipes cart upgrade, which reduced safety hazards associated with moving cement kiln burner pipes. Further hazard reductions were made by Buzzi Unicem USA’s Chattanooga, Tennessee cement plant’s finish mill access platform and the Monarch Cement Company’s Humboldt, Kansas cement plant’s noise reduction upgrade, which jointly won the milling/grinding award. The pyroprocessing award went to GCC of America’s Pueblo, Colorado plant for its semi-automated clinker feeding system, while the quarry award went to Ash Grove Cement’s Louisville, Nebraska plant for its dump box hardened material extraction tool.

PCA president and chief executive officer (CEO) Michael Ireland said, “Our industry prioritises the safety of its employees above all else. We are proud of our members’ efforts to pursue excellence in safety innovation for their company and their colleagues.”