Global Cement Newsletter

Issue: GCW485 / 09 December 2020

Headlines


Manoj Kumar Rustagi was on hand yesterday to discuss JSW Cement’s operations in the UAE at the Virtual Middle Eastern Cement Conference. At the event, jointly organised by Global Cement Magazine and the Arab Union for Cement and Building Materials (AUCBM), Rustagi mainly stuck to the development of the producer’s new integrated plant in the Fujairah Free Zone but he also gave an overview of JSW Cement’s presence in India. For example, as part of an industrial conglomerate, JSW Group, the cement producer benefits from links to steel production by JSW Steel that enables it to use blast furnace slag. Notably, JSW Cement’s Shiva Cement subsidiary announced plans at the end of November 2020 to spend around US$200m on a new 1.4Mt/yr integrated cement plant in Sundergarh district, Odisha with the clinker production line supplied by ThyssenKrupp Industries India.

JSW Cement is not alone in ordering new production capacity. This week, UltraTech Cement approved a planned increase of 12.87Mt/yr for around US$740m. This is in addition to new capacity projects of 6.7Mt/yr that are currently underway. All of these new projects are scheduled to be commissioned in a phased manner by the end of the 2023 Indian financial year (by March 2023). It is unclear at present how exactly these projects are distributed but they are centred in the Northern, Central and Western Zones of the country, and the new tranche includes the previously announced Pali plant in Rajasthan. At this price the inference is that the much of the new capacity will be in the form of grinding plants and/or upgrades to existing clinker lines. Around the same time as this, LafargeHolcim said it wants to spend US$112m on waste heat recovery (WHR) plants for six of its cement plants in India by the end of 2022.

Graph 1: Change in Indian cement production year-on-year (%). Source: Office of the Economic Adviser.

Graph 1: Change in Indian cement production year-on-year (%). Source: Office of the Economic Adviser.

These three projects by major producers suggest that the Indian cement sector is recovering from the effects of the coronavirus lockdown in late March 2020. Graph 1 above shows the sector finally recovering in October 2020, with growth of 3% year-on-year to 26.9Mt. Kumar Mangalam Birla, the chairman of Aditya Birla Group, credited the economic situation with the Indian government’s Atmanirbhar Bharat stimulus program for his decision to commit to UltraTech Cement’s spending spree. This outlook gels with that of Fitch Ratings. The credit ratings agency has forecast in a recent report that ‘strong’ margins during the first half of the 2021 financial year (April – September 2020) are going to limit the financial risks to the larger Indian cement companies despite the lower cement sales volumes due to coronavirus. Pent-up demand helped the industry recover after the lockdown and this was further aided by lower energy/fuel costs and general cost cutting.

Needless to say all of the above is good news for the Indian cement industry after the year it has had. One thought to consider from all of this is who might UltraTech Cement order its mills and clinker lines from? Atmanirbhar, the name of the Indian stimulus plan, has been described as ‘self-reliance’ or ‘self-sufficiency’ in the local press. Unfortunately, relations have been poor between India and China in 2020 due to armed skirmishes along the Line of Actual Control on the border, amongst other issues. Ordering a new clinker production line from, say China-based Sinoma, may not look especially ‘self-sufficient’ in the current climate.

The proceedings pack and video from the Virtual Middle Eastern Cement Conference 2020 is availabe to buy now


Austria: Scheuch Group has announced a number of changes to its management, starting with the appointment of Thomas Eberl as the third managing director of Scheuch Management Holding in August 2020. He remains in his role as chief financial officer (CRO) for Scheuch Group and joins Stefan Scheuch and Jörg Jeliniewski as a managing director.

Eberl has experience from his group and investment controlling role at Vivatis and from the automotive industry, where he worked in international locations at the ZKW Group for 20 years, the final nine of which were spent as CFO.

The group has also appointed Thomas Rainer and Michael Brandl as the managing directors of Scheuch and Scheuch Components respectively. This follows the stepping down of Stefan Scheuch and Jörg Jeliniewski from their interim Business Unit management roles at the start of November 2020.

Finally, the group has made changes to its personnel in its North America subsidiaries, with the appointments of Jim Weber as Vice President of Sales at Schust and Dan Bruyn as chief operating officer (COO) at Camcorp.
Weber succeeded John Rothermel, who was recently promoted to president of Scheuch USA, Schust's parent company, in mid-November 2020. He holds nearly 25 years of sales and leadership experience. He previously served in the US Army and graduated from West Point with a Bachelor of Science in Mechanical Engineering.

Bruyn started the newly created role for Camcorp from mid-November 2020. He holds 25 years of operations management experience in manufacturing environments. He was most recently Director of Operations at Garsite, where he led the business through a divestiture and financial turnaround. Earlier in his career he helped implement ‘lean’ management initiatives at Gardner-Denver, Harley-Davidson and Pentair. He is a graduate of the University of Missouri in Columbia where he earned Master of Engineering and Industrial & Manufacturing Systems qualifications, and a Bachelor of Science in Industrial Engineering.


UK: Northern Ireland-based Terex Materials Processing has appointed Matt Dickson as Business Line Director for Terex Finlay and General Manager of its Omagh site, and Barry O’Hare as Business Line Director for EvoQuip. Paul O’Donnell, the previous Business Line Director for Terex Finlay, will become the Director of Strategic Sourcing at Terex Materials Processing.

Dickson has led the EvoQuip business for the last four years and holds a commercial and engineering background. He previously worked for Terex Finlay in Omagh for over 10 years, eventually becoming its Engineering Director.

O’Hare holds experience in the crushing and screening industry, having worked in several positions for Powerscreen and Terex MPS over the past 12 years. Most recently, he worked on strategic and operational sales for EvoQuip and led the development and management of territory sales.


Kenya: A court in Nairobi has reinstated Jacob Omondi Guma as a production manager for the East African Portland Cement Company (EAPCC). It follows the company’s decision to appoint Japheth Ombogo to the position, according to the Business Daily newspaper. The judge annulled the company’s decision on the grounds that it was marked by irregularities and may have been ‘malicious.’ The court ruled that Guma may stay in post until his three-year contract ends in September 2022 unless otherwise lawfully terminated. He was removed from the role in November 2019 after serving for just two months. The cement producer denies the allegations and says it removed him from the post due a lack of qualifications.


Pakistan: The government of Punjab Province has approved five cement plant plans worth a total of US$1.25bn. The Frontier Post newspaper has reported that Chief Minister Usman Buzdar chaired a cabinet meeting in which No Objection Certificates (NOCs) were issued to five planned cement plant projects.


Philippines: The Department of Trade and Industry (DTI) has raised the import duty per 40kg bag of cement to US$0.20 from US$0.19. The Manila Bulletin newspaper has reported that the department issued the administrative order following a petition from the Cement Manufacturers Association of the Philippines (CeMAP). The petition suggested a US$0.25/bag levy as an effective means to maintain domestic cement production. The association has blamed growing imports on a surplus in countries such as Vietnam.

The DTI previously imposed tariffs on imported cement for three year from October 2019 with a staggered reduction in the duty. However, the DTI said it would review the safeguard measure in order to modify the rate as it deemed necessary.


Indonesia/Japan: Taiheiyo Cement and Semen Indonesia have finalised a collaboration agreement with the aim of building a comprehensive partnership, including consultations on promotion and sale of cement and clinker. Taiheiyo Cement said, “The business alliance is for business collaboration and research and development of cement, resources, environment, building materials and more.”

In accordance with the agreement Taiheiyo Cement will buy shares in Semen Indonesia’s subsidiary Solusi Bangun Indonesia, formerly Holcim Indonesia. The deal is expected to be completed in early 2021. In April 2020 Taiheiyo Cement agreed to buy a 15% stake in Solusi Bangun Indonesia for between US$186m and US$232m.


Mexico: Cemex subsidiary Cemex Ventures has invested in excavation materials marketplace Soil Connect. The online platform says that it connects the supply and demand algorithmically based on the users' proximity and needs. It is mainly used for aggregates. In digitising the marketplace it reduces landfill while lowering transportation distances, according to the investor. It says that this results in tremendous cost savings for construction professionals. This also promotes circular economy within the sector.

Cemex Ventures’ investment head Cristina Aparicio said, "For any relevant actor with a view to the future of our ecosystem, it is a priority to offer a solution to the millions of tonnes of materials that are generated annually in demolition projects, since much of the construction materials of tomorrow come from the projects to be demolished. We are very excited about this agreement with the Soil Connect team, which has created a business that adds value, both to those who generate the waste and to those who need construction material, prioritising this tool that provides agility."


Brazil: The National Cement Industry Association (SNIC) has predicted cement sales in 2020 to rise by 10% year-on-year to 60Mt. Valor International News has reported that president Paulo Camillo Penna said, “If in 2021 we maintain the 60Mt we expect to reach this year, or have some progress beyond this volume, it will be a very satisfactory result considering the high uncertainties ahead."


France: LafargeHolcim subsidiary Lafarge France has installed a new rotary kiln at its Martres-Tolosane cement plant. The installation is part of a Euro120m project to build a new production line at the site. The work will also increase the plant’s alternative fuels (AF) substitution rate to 80% from 30%.

The company said, “Once completed the work will increase the productivity of the cement plant, while reducing its environmental impact. The plant will be equipped with the latest environmental technologies, thus increasing the share of energy recovery from waste and its use in the production of clinker. The work will reduce energy consumption, reduce the carbon dioxide (CO2) footprint by 25% - 30% per tonne of cement and create local circular economy loops with partners in the greater South-West.” The on-going upgrade to the plant is on schedule for completion in November 2021.


South Africa: PCC recorded sales of US$332m in the first half of its 2021 financial year, up by 1% from US$328m in the first half of its 2020 financial year. Earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 15% to US$66m from US$58m. Cement volumes fell in South Africa by 5% and in Botswana by 10% due to 35% slump in total volumes in the first quarter. The company said that this was due to muted cement sales in April 2020 and May 2020 as a result of Covid-19-related trading restrictions in South Africa. Cement sales have since recovered with strong year-on-year growth since June 2020. The increase in volumes is primarily retail led. PPC also said that it is beginning to experience the positive impact of increased infrastructure spending.

Chief executive officer (CEO) Roland van Wijnen said, “I am pleased that we are once again able to serve our customers and play our part in keeping the economy going. My gratitude goes to my colleagues who have been working diligently to keep our operations running while observing stringent health and safety protocols. Our business has benefited from a strong recovery in cement sales in all our markets, post the easing of the lockdown restrictions, and this has resulted in improved financial performance for the group. Our efforts to improve cost competitiveness and reposition PPC on a sound financial footing are yielding encouraging results and we are making good progress on our capital restructuring project, which remains a key priority for the group.”


Mexico: Cemex has launched Vertua, a range of low and net-zero CO2 concrete products, in Mexico. Vertua uses a geopolymer binder solution created by Cemex’s Research and Development Center in Switzerland. It forms “one of the main components of the ambition to deliver net-zero CO2 concrete for all products and geographies by 2050,” according to the company.

Ricardo Naya, the president of Cemex Mexico, said, “With Vertua, we are taking a decisive step in addressing climate change in Mexico and the world, by offering a line of concretes with up to 70% lower carbon emissions. In Cemex, we embrace the circular economy concept and put it into action by offering our customers solutions like Vertua to keep them at the forefront of sustainability efforts."


Tanzania: Tanga Cement has won the award for the overall best-presented financial report for the 2020 financial year at the National Board of Accountants and Auditors (NBAA). The Daily News newspaper has reported that the award is the company’s fifth consecutive win in the category.

Chief accountant Isaac Lupokela said, “Everyone who prepares auditing knows that there is a competition behind that gives us a lot of motivation to do better. But professionally large accountants are the ones who make sure companies operate. Properly prepared calculations help those who use them to make better decisions.” The producer also won best-presented report in the manufacturers category.


India: Shree Cement plans to mark Vijay Diwas, the Indian commemoration day for the Indo-Pakistani War of 1971, with free donations of cement for the families of armed forces personnel who died in battle between 1999 and 2019. Under the Naman scheme, the family or the next of kin of a deceased veteran will be given free cement to build a house on a plot of land up to around 370m2, according to the Times of India newspaper. The cement can be obtained in person from any of Shree Cement's manufacturing facilities spread across India.


Pakistan: Cement dispatches in the five months to 30 November 2020, the first five months of the 2021 financial year, were 24Mt, up by 17% year-on-year from 20Mt over the corresponding period of the 2020 financial year. Data from the All Pakistan Cement Manufacturers Association (APCMA) shows that exports grew by 22% to 4.4Mt from 3.6Mt. The Nation newspaper has reported that November 2020’s dispatches were up by 4% year-on-year to 4.5Mt from 4.3Mt, while domestic demand rose by 6% to 3.7Mt from 3.5Mt. Five-month demand also rose, by 16% to 19Mt from 17Mt.


India: The Tamil Nadu Pollution Control Board (TNPCB) has fined ACC subsidiary Madukkarai Cement US$61,000 for fugitive emissions of clinker and cement dust in mid-2020. The Hindu newspaper has reported that inspections found dust in the village Kurumbapalayam, Coimbatore District, located on the eastern side of the cement plant. An ambient air quality survey in September 2020 revealed higher-than-prescribed particulate volumes.

In addition to paying the fine, the producer must comply with 19 instructions of the TNPCB for air pollution control and monitoring by 7 January 2021.


Argentina: A dispute between a supplier and its union has caused Loma Negra to switch off two kilns at its Olavarría cement plant. The Clarín newspaper has reported that the argument is between Minerar, which provides the plant’s raw limestone, and the Asociación Minera Obrera Argentina (AOMA), which represents miners’ interests. The union says that miners are underpaid. They receive US$245/yr less than cement plant workers.

The producer said, “It is the leading Argentine cement company, with approximately 45% of total sales in the country. This shortage will impact the country's economy, which had been recovering after the pandemic." The union rejected a mandatory conciliation on 3 December 2020. Negotiations began in October 2020.


Spain: Mexico-based Cemex plans to merge Spain-based Cemex España with Netherlands-based New Sunward Holding. The transaction will be registered in late 2020 or early 2021 and dated retroactively to 1 December 2020.


Bangladesh: LafargeHolcim subsidiary LafargeHolcim Bangladesh has donated US$117,000 to the Bangladesh Labour Welfare Foundation (BLWF) fund. The New Nation newspaper has reported that State Minister for Labour and Employment Monnujan Sufian received the cheque on behalf of the BLWF, which in 2020 supported 10,500 workers with US$5.2m-worth of financial support.


US: HarbisonWalker International (HWI) has enhanced its Mobile Refractory Tools app based on customer input to increase the ease of refractory products and services optimisation in the field. HWI customers and Contractor/Installer Network (CIN) members can use the free app to access the refractory mix calculator to compute mix ratios and times for HWI products, search safety data sheets, find HWI Global Sourcing Center (GSC) locations, and contact HWI. The company says that CIN members can also gain access to HWI's Pocket Reference Guide (PRG), which contains comprehensive product information, brick sizes, shapes and combinations, sprung arches, anchors, and area and volume data. All business portal account holders receive basic access, along with product data, including datasheets, installation guidelines, curing and dry-out schedules, and the new kiln brick calculator.

Senior vice president (SVP) Mike Werner said, “We are always listening to our customers and the latest advancements in our mobile app reflect what our contractor/installers and customers told us would help them the most on the job.” He added, “HWI app users can find and calculate what they need to know about our products and services when they need them. We're constantly innovating with technology to help our customers and the overall refractories industry, with offerings like our High Temperature Times podcast and our Mobile Refractory Tools app. On-going updates to the app are an important part of our commitment.”


India: The board of directors of Aditya Birla subsidiary UltraTech Cement has approved a planned increase in cement production capacity of 12.87Mt/yr. This will increase its capacity to 136Mt/yr from 123Mt/yr, at a cost of US$743m. The company says that the expansion will consist of new plants and upgrades to existing plants in the ‘fast-growing markets of the east, central and north regions of the country.’ This includes the upcoming Pali integrated cement plant in Rajasthan and capacity expansions at plants in Bihar, Odisha, Uttar Pradesh and West Bengal, that are due for completion in the 2022 financial year (1 April 2021 - 31 March 2022).

The producer said, “Given the company’s history of setting up capacities in record time, commercial production from the new capacities is expected to go on stream in a phased manner, by early 2023. This capacity addition will not impact the on-going deleveraging programme, which is on track to make UltraTech debt-free by the time the expansion program is completed.”

Aditya Birla group chair Kumar Mangalam Birla said, “This significant investment in a core infrastructure sector will accelerate the wheels of economic activity and aid the kick-start of the private investment cycle. The capital outlay, given the current economic backdrop, is aligned with the government’s Atmanirbhar Bharat programme. It is also a marker of UltraTech’s ascent from being India’s No.1 cement player to a national champion. The cement industry has been witnessing healthy volumes post-relaxation of lockdown, on the back of the government’s thrust on infrastructure, underlying demand from the rural economy and individual home builders. Given its pan-India presence, which will be further strengthened by the capacity expansion, UltraTech will be well-positioned to support the rising demand for cement in the country.”


India: Birla Corporation plans to raise US$20m through redeemable non-convertible debentures (NCD). It has allotted 1500 NCDs with a value of around US$13,500 on a private placement basis. The producer announced plans in August 2020 for an upgrade to its Durgapur grinding plant in West Bengal.


India: Orient Cement has entered into a share purchase, subscription and shareholder’s agreement with AMPTechnology and AMPSolar Systems. It will acquire a 26% stake in the latter for around US$0.6m. The Press Trust of India has reported that AMPSolar Systems is establishing a 13.5MW solar power plant in Maharashtra, where Orient Cement operates an integrated cement plant.


Nepal: Four explosions at Saurya Cement’s Udayapur quarry in Province No. 1 have injured five workers. The Republica newspaper has reported that the cause was allegedly a bombing campaign by an unidentified group, which also destroyed two vehicles. Police described the conditions of the victims, who are receiving treatment in Katari Hospital, as ’normal.’ The incident follows a similar event at the Tapli rural municipality office in the district in November 2020.


India: Police have made arrests in Ujjain, Madhya Pradesh where cement was being bagged in falsely branded UltraTech Cement bags. The Free Press Journal has reported that the authorities confiscated over 1000 bags in the raid. They believe that the plant has been operative since 2018. Investigations continue, including a manhunt for suspected ringleader Jitendra Singh.


Argentina: Cement producers in Argentina shipped 1.13Mt of cement in November 2020, up by 28% year-on-year from 0.88Mt in November 2019 and by 4% month-on-month from 1.09Mt in October 2020. The Economista newspaper has reported that the figure is a high-water mark for monthly production since September 2017. Consumption also rose to 1.09Mt, up by 25% year-on-year from 0.87Mt and 2% month-on-month from 1.07Mt.


India: Switzerland-based LafargeHolcim plans to invest US$112m in implementing waste heat recovery (WHR) plants across six of its cement plants in India by the end of 2022. The group has estimated a net carbon dioxide (CO2) emissions reduction of 0.5Mt/yr as a result of the installations, towards its target of a 65% total reduction between 2018 and 2030.

Chief Sustainability Officer (CSO) Magali Anderson said, "On our net zero journey, we set ourselves an ambitious scope-two target. I am very excited to see India leading the way by investing US$112m in WHR. This major step forward builds on our procurement teams’ work in renewable energy."

When commissioned, the new plants will double the group’s WHR power generation capacity in India.


Germany: The German Cement Works Association (VDZ) has published a study entitled ‘Decarbonising cement and concrete: a CO2 roadmap for the German cement industry,’ detailing the planned transformation to cement industry-wide carbon neutrality by 2050.

The study says that a decarbonisation scenario based on conventional reduction measures would cut carbon dioxide (CO2) emissions by 36% between 2019 and 2050. Chief executive officer (CEO) Martin Schneider said that the sector is already “reaching the limits of its potential for any further reduction in the volume of CO2, particularly as the process-related emissions specifically associated with clinker production cannot be lowered by employing conventional means." As such, the association proposed a “completely new approach to the production of cement and its use in concrete” in order to realise full climate neutrality. It proposes that cement producers help to reduce concrete’s clinker factor, capturing the remaining CO2 from necessary cement production.

Schneider said, "We have placed the decarbonisation of cement and concrete at the heart of our activities. It will be essential to achieve an integrated approach, incorporating the entire construction value chain.” In order for this more radical scenario to work, he added, “Another essential factor will be to involve society as a whole in this process."


Spain: Cementos Cosmos has partnered with France-based EDF energy to establish a 6.2MW solar power plant in Toral de los Vados, León, at a cost of Euro4m. The Diario de León newspaper has reported that the plant intends to use 9.0GWhr/yr of energy from the new unit. This will provide 15% of the electrical power requirements at the cement plant. The 14,000-panel project is scheduled for completion in mid-2021.


Italy: The Italian cement and concrete association Federbeton says that investments in sustainable technologies in domestic cement production totalled Euro110m between 1 January 2017 and 31 December 2019. This reduced carbon dioxide (CO2) emissions by 311,000t in 2019 alone, up by 12% year-on-year from the reduction in 2018. An increased alternative fuel (AF) substitution rate of 6.7% in 2019 contributed to the reduction, up by 0.7% from 6.6%. Producers’ full-year AF consumption was 1.6Mt.


Kenya: LafargeHolcim subsidiary Bamburi Cement has made a donation of personal protective equipment (PPE) worth US$46,800 to coronavirus rapid response teams and 11 health facilities in Kajiado, Kilifi, Kwale, Machakos and Mombasa Counties. The company said that the donations include “N95 masks, surgical gloves, coveralls, goggles, face shields and shoe covers.” This will constitute part of the US$140,000 donations promised by the company to “support the fight against the spread of Covid-19.”

Group managing director Seddiq Hassani said, "During the cheque handover to the Covid-19 Emergency Response Fund Board earlier this year, we committed to continued support to Covid-19 management efforts and therefore, with the escalating numbers of Covid-19 cases, today we fulfil our promise with this donation to our frontline healthcare workers who continue to serve with fortitude by ensuring that they remain safe while serving Kenyans. We value their priceless role in battling Coronavirus.” He added, “We care for the community and we are determined to be part of the solution to this pandemic and make a difference for the benefit of us all.”