Global Cement Newsletter

Issue: GCW512 / 30 June 2021

Headlines


Fernando A González and Cemex took to the virtual airways this week with Cemex Day 2021. The investors’ update comprised the usual greatest hits package explaining how well everything is going: earnings growth and leverage levels about to hit desired targets, selective investments and divestments on the way, new production capacity round the corner and punchy sustainability goals turning up earlier than expected. Or at least that’s the way that chief executive officer González and the team told it.

To be fair to Cemex, it seems to be in a good place right now. It weathered 2020 well and now its first quarter results in 2021 compared to the same period in 2019, before coronavirus hit, are looking rosy with cement sales volumes growth of 9%. How much of that is attributable to pent up demand from 2020 remains to be seen though. Its strategy of focusing on markets in North America and Europe appears to have paid off in recent years with its competitors copying it as they have retreated from riskier climes and concentrated on core territories. Its obsession with righting the ratio between its debts and earnings is closer than ever to being realised, with a 4.07x net leverage ratio in 2020 and a target of 3x or lower planned for 2023. That last target is crucial both materially and psychologically for the company as it starts to put it back in the same financial field as its Western multinational competitors and opens up new investment opportunities.

From a production angle, the big news from the event was a 10Mt/yr cement production expansion project between now and 2023. This wasn’t quite as promising as it sounded, as just under half of this was attributed to legacy projects in Mexico, Colombia and the Philippines and some of the new projects had already been announced, but it does bookmark a move from divesting plants to upgrading and building new ones.

The new projects comprise an additional 5.7Mt/yr capacity from on-going debottlenecking, new integrated plants, new grinding plants and reopening idle or mothballed plants. During the event José Antonio González, the Executive Vice President of Strategic Planning & Business Development broke it down into 3.5Mt in Mexico, consisting of 1.5Mt additional grinding capacity at the integrated Tepeaca plant, a 0.5Mt/yr expansion at the integrated Huichapan plant and 1.5Mt/yr from bringing both idled lines back into production at the CPN Hermosilla plant in Senora to support the US market. That last one notably was partly announced in February 2021. In Europe and the US the group plans to add 1.2Mt/yr including expanding grinding capacity at two plants in Europe with details to be announced later. Finally, the company plans to add 1Mt/yr of additional capacity in South American including restarting an idled 0.5Mt/yr kiln at a plant in the Dominican Republic and building a new 0.5Mt/yr grinding mill in Guatemala.

Cemex has also stepped up its target reduction in CO2 emissions to below 475kg CO2/t of cementitious material, an approximately 40% reduction in CO2 emissions compared to 1990 levels, by 2030. The previous target for 2030 of 520 kg CO2 has been brought forward to 2025. This compares to LafargeHolcim’s similar target of 475kg CO2/t by 2030, HeidelbergCement’s target of 500kg CO2/t by 2030 and CRH’s target of 530kg CO2/t by 2030. The group is planning to spend US$60m/yr on its decarbonisation projects. This compares to a spend of around US$140m/yr on its 10Mt/yr cement production capacity expansion drive over the next three years. Or to put it another way, the group is spending more on growing than sustainability.

Unfortunately, it wasn’t all good public relations for Cemex this week with the news in the Colombian press that one of its former executives is set to be investigated by the authorities over his alleged involvement in the ongoing Maceo cement plant corruption case. The background to this one is that in 2016 Cemex fired several senior staff members, and the local subsidiary’s chief executive resigned, in relation to the building of a new integrated plant at Maceo. This followed an internal audit and investigation into payments worth around US$20m made to a non-governmental third party in connection with the acquisition of the land, mining rights and benefits of the tax free zone for the project. Legal proceedings followed in Colombia and the US. Many large companies have legacy problems to deal with. Just take LafargeHolcim’s continued connection to Lafarge Syria’s conduct in the early 2010s. At the time of writing the Maceo plant is still yet to start operation and is likely to be one of the ongoing projects mentioned above.

Cemex’s second quarter results are due to arrive towards the end of July 2021 but the group is presenting an upbeat image. Sales are up, debts are down, divestments are out and expansions are in. Confidence is important for a multinational trying to convince the rating agencies to give it back its investment grade, so whether this is strictly true or not it certainly knows how to talk the talk. One question going forward at least is how strictly Cemex will want to stick to its core markets if the good times really have returned?


Ivory Coast: LafargeHolcim Ivory Coast has appointed Rachid Yousry as its chief executive officer. He succeeds Xavier Saint-Martin-Tillet, who has been in the post since November 2020, according to the Financial Afrik newspaper.

Yousry has worked for LafargeHolcim in a number of supply chain and sales roles since 2011. His last posting was as the Country Commercial & Supply Chain Director for LafargeHolcim Jordan. Prior to working for LafargeHolcim, he held roles at Teleinfo 5, Unilever, AMS Baeshen. Yousry holds a bachelors degree in information technology and a Master of Business Administration (MBA) from the École des Ponts Business School.


India: ThyssenKrupp Industrial Solutions India has appointed Rajesh Kamath as its chief executive officer and managing director. He succeeds PD Samudra. who plans to retire at the end of June 2021 after being in post since 2014.

Kamath is a graduate engineer from Bangalore University. Previously he was the managing director of Air Liquide Engineering and Construction in India. He has also held executive positions with Technip India and Aker Solutions.


Spain: Votorantim Cimentos has agreed to buy Cementos Balboa from US-based investment company KKR for an undisclosed sum. The producer operates a 1.6Mt/yr integrated plant at Alconera in Badajoz, Extremadura that started production in 2005. The purchase is subject to regulatory approval in Spain.

“This transaction exemplifies our strategy for growth and positioning in Spain and reinforces our presence in the country,” says Marcelo Castelli, global chief executive officer of Votorantim Cimentos. The Brazilian-based company has been present in Spain since 2012 and currently operates four integrated cement plants, two grinding plants, a mortar plant and several concrete and aggregates plants, operating in the regions of Andalusia, the Canary Islands, Castile and León, Extremadura and Galicia .


Spain: Cementos Molins has completed the acquisition of a white cement terminal in the Port of Alicante from Turkey-based Çimsa. The unit includes a 10,000t silo and it will be able to supply over 50,000t/yr from the site. The producer also plans to use the terminal to bolster exports from its 0.7Mt/yr integrated white cement plant at Kairaouan in Tunisia, which is operated by subsidiary Société Tuniso-Andalouse de Ciment Blanc (SOTACIB). It distributes products from this plant to over 15 countries.


Pakistan: Bestway Cement and Reon Energy have commissioned a 14.3MW captive solar power unit at the former’s integrated cement plant at Farooqia, Khyber Pakhtunkhwa. The unit is part of a 50MW project deal that is planned to install solar units at the cement producer’s plant at Farooqia, Chakwal, Kallar Kahar and Hattar, according to the Pakistan Observer newspaper. Energy generated at the new solar plant at Farooqia is expected to reduce energy costs and reduce reliance on the national electricity grid.


Bolivia: Fábrica Nacional de Cemento (FANCESA) has agreed to open up where it sells its cement. Previously the producer mostly sold its products through authorised vendors, according to the Correo del Sur newspaper. New vendors will be subject certain conditions under the new marketing policy, including making a request to the cement producer. However, the company has not decided whether it will change its prices. Shareholders of the company have requested a market study to assess the situation. FANCESA is expecting demand for cement to drop by up to a quarter in 2021.


Georgia: Georgian Cement Company (GCC) has warned of cement dumping by Iran and Turkey. The subsidiary of LafargeHolcim is lobbying the government for protective legislation, according to Prime News. GCC operates a 0.3Mt/yr cement grinding plant at Poti. The country consumes 2.5Mt/yr and 1.5Mt/yr of this comprises imports. HeidelbergCement and Eurocement also operate plants locally.


Germany: Two studies looking at how to prepare investments for the conversion to an oxyfuel process have been completed at Hocim’s Germany’s Lägerdorf cement plant. The projects were running with technology partners ThyssenKrupp Industrial Solutions and Linde. Project Oxyfuel100, part of the Westküste100 initiative, was finalised in mid-April 2021. In addition to the oxyfuel process, the technical and economic feasibility of the downstream CO2 extraction, processing and forwarding was examined. The results of the feasibility study were reported as being “extremely positive.”


India: Ambuja Cements and ACC are planning to participate in parent company LafargeHolcim’s ‘Plants of Tomorrow’ programme. The initiative, which aims to make cement manufacturing more efficient through better plant optimisation, higher plant availability and a safer working environment, is part of LafargeHolcim’s ‘Building for Growth’ strategy, which was launched globally in mid-2019.

The four-year programme implemented by LafargeHolcim aims to create a global network of over 270 integrated cement plants and grinding stations in more than 50 countries by applying automation technologies and robotics, machine learning, predictive maintenance and digital twin technologies to the entire production processes. The ‘Plants of Tomorrow’ initiative is also being implemented in other key markets in Switzerland, France, Germany, United Kingdom, US, Canada and Russia.

“As an industry leader we are looking at 'Plants of Tomorrow’ as a big opportunity and responsibility to place India on the map of global cement manufacturing. This path-breaking project will lead to transformative outcomes not just in terms of operational and financial gains but also make cement manufacturing in the country environmentally sustainable and create a safe work environment for our colleagues across all our plants,” said Neeraj Akhoury, the chief executive officer (CEO) of India Holcim and managing director and CEO of Ambuja Cements.


Australia: Calix has joined as a partner of the Heavy Industry Low-carbon Transition Cooperative Research Centre (HILT CRC). The initiative brings together heavy industry players, government and research and aims to boost the capability of Australian companies to remain globally competitive by capitalising on existing mineral and renewable energy resources to become international producers and exporters of low-carbon products. HILT CRC has secured US$29m from the government. This joins funding of US$158m in direct and in-kind contributions from its partners over the last decade.

“It is a chance for us to demonstrate the technology developed for CO2 mitigation in the production of cement and lime through our European LEILAC-1 and 2 projects in an Australian setting, as well as explore other more sustainable applications for our technology in heavy industry, backed by this impressive team of researchers and industrial participants," said Calix’s managing director Phil Hodgson.

As part of the HILT CRC, Calix will continue to develop its technology for the reduction of carbon emissions from lime and cement production, and also use its Calix Flash Calciner (CFC) technology to develop other more processing applications such as for bauxite processing for the aluminium industry and production of calcined clay from kaolinite for use in new lower carbon cements.

HILT CRC’s core industrial partners include Adbri, Alcoa, Boral, Fortescue, Grange Resources, Liberty, Roy Hill and South32. The initiative has its headquarters in Adelaide and it plans to establish hubs in heavy industry regions of Gladstone, the Pilbara, Northern Tasmania, South Australia’s Upper Spencer Gulf, Western Australia's Kwinana and South West regions, the Southern Highlands of Nnew South Wales and Portland in Victoria.


Caribbean: Sweden-based Bruks Siwertell has won a new contract to deliver a Siwertell enclosed screw-type ship loader for cement and clinker. It will serve a new cement plant being built by an unnamed end user in the Caribbean. The type-1B ship loader will deliver cement and clinker handling at a continuous rated capacity of 600t/hr, with a peak loading rate of 750t/hr, for vessels up to 20,000dwt. It will be delivered in 2021 and is scheduled to be operational later in the year.

“This is our first Siwertell loader installation in this particular region and it will have to work in one of the most earthquake-prone zones of the world,” said Axel Dahl, Sales Manager, Bruks Siwertell. “The cement industry in the area is currently undergoing some of its most advanced improvements in decades, and as part of this, environmental protection is very much under the magnifying glass.


India: B K Birla Group subsidiary Mangalam Cement has launched cement and clinker production at its Morak cement plant in Rajasthan following an upgrade. The upgrade has increased the plant’s cement capacity by 400,000t/yr and its clinker capacity by 300,000t/yr. The expansions bring Mangalam Cement’s total cement and clinker capacity to 4.4Mt/yr.


France: Denmark-based FLSmidth has won a contract to supply a 400t/day calcined clay production line to Vicat’s Xeuilley integrated cement plant. The order includes flash calciner technology, an environmental control system and alternative fuel (AF) firing, handling and storage equipment. The line will have a design capacity of up to 525t/day and is scheduled for commissioning in 2023. It will enable clinker substitution in cement of up to 40%, according to the supplier. It says that cement produced using calcined clay will have a 16% smaller carbon footprint than its clinker-based equivalent. The value of the contract is Euro26.8m.

Vicat deputy chief executive officer Eric Bourdon said, “EU regulations and increasing demand for more sustainable cement has accelerated the decision to introduce clay as an environmental alternative to clinker in our production. With clay readily available in the area and positive results from pilots at FLSmidth’s test facilities in Denmark, we feel confident about the technology and hope to be able to expand further in the future.”


Mexico: Cemex has forecast full-year earnings before interest, taxation, depreciation and amortisation (EBITDA) of US$3.10bn in 2021, up by 26% year-on-year from US$2.46bn in 2020. The forecast figure is 7% higher than its previous prediction of US$2.90bn in its first quarter 2021 earnings call. The company said that it expects the double-digit growth to continue into 2022. It said that in 2023 and estimated US$400m of additional EBITDA will come from bolt-on investments and its on-going 10Mt/yr cement capacity expansion.


Vietnam: Vietnamese first-half cement production is estimated to have risen by 8% year-on-year to 51.1Mt in the first half of 2021 compared to the same period in 2020. The Viet Nam News newspaper has reported that June 2021 cement production was 10% higher than that in June 2020, at 9.1Mt. Vietnam’s full-year cement production in 2020 was 100Mt.


Colombia: The Colombian prosecution service intends to summon former Cemex Colombia chief executive officer (CEO) Carlos Jacks to face charges in relation to the Maceo cement plant corruption case. Jacks was CEO of the company for 24 years and previously headed Cemex operations in Costa Rica, the Dominican Republic and Puerto Rico, according to the Noticias Caracol television channel. A statement made by Camilo González Téllez, the former Legal Vice President, has been used by the prosecutor’s office to press charges against Jacks. So far González is the only senior Cemex executive to have received a custodial sentence in relation to the affair.

In 2016 Cemex fired several senior staff members in relation to the Maceo project and its subsidiary’s chief executive resigned. This followed an internal audit and investigation into payments worth around US$20m made to a non-governmental third party in connection with the acquisition of the land, mining rights and benefits of the tax free zone for the project. Legal proceedings followed in Colombia and the US.


Ghana: Environmental Protection Agency (EPA) agents and police have raided China-based Empire Cement’s McCarthy Hills cement plant in Accra. The Ghana News Agency has reported that the facility had entered cement production without a licence. The authorities stopped operations at the site and dismissed the staff, including Chinese nationals. Previously, local residents had complained about potential environmental concerns at the site.


India: The Andhra Pradesh branch of the National Company Law Tribunal (NCLT) has approved Sagar Power’s resolution plan for the start of operations at the mothballed Panyam cement plant at Kurnool. Sagar Power intends to pay US$13.5m, together with RV Consulting Services, to settle the debts from the plant’s previous owners, according to the Times of India newspaper. The partners also plan to inject a further US$20.2m of fresh capital into the venture.


US: The Portland Cement Association (PCA) has supported a bipartisan deal between the White House and 21 senators towards a deal on a US$953bn infrastructure package. Sean O’Neill, the PCA’s Senior Vice President of Government Affairs, said that, “America's economic vitality depends on an integrated, national transportation network that moves goods and people safely and efficiently, while ensuring quality of life and economic prosperity for all citizens.” The PCA added that is has continually advocated for a long-term bipartisan infrastructure package and encouraged both parties in the House of Congress to work towards enacting ‘strong’ bipartisan infrastructure legislation.


Jordan: The country’s industrial chambers have made a statement saying that most cement plants are charging ‘average’ prices for cement despite recent rises in energy costs due to imported coal and diesel. In a joint statement the group’s said, that although some plants have increased the price of cement, it does not reflect the increase in real cost to producers, according to the Jordan News Agency. The price of cement has reportedly risen by 12% recently.

The industrial chambers noted that the sector is, “keen to stabilise commodity prices locally and maintain their sustainability." It added that it accomplished this in the interests of citizens during the Covid-19 crisis despite the high price of raw materials. The statement also noted that the country has a cement production capacity of 10Mt/yr but the local market only uses 3Mt/yr.


India: Cochin Port Trust has announced plans for expansion projects to the Port of Cochin in Kerala worth around US$420m. The Times of India has reported that the new developments are to include a cement terminal and bagging facility. Other initiatives covered by the memorandum of understandings include a hospital, an oil refinery, a petrochemical terminal and a multi-modal logistics hub. The projects are scheduled for completion by the end of 2023.


India: Visaka Industries plans to establish a US$10.8m cement boards plant at Coimabatore, Tamil Nadu. The Hindu newspaper has reported that the plant will be the company’s fourth to produce its Vnext product range of cement boards.

Joint managing director Vamsi Gaddam said that, together with a new US$6.74m roofing plant, the Coimbatore will add US$27.0m-worth of additional turnover in their first full year of operation. She added, “While the company passed through a tough phase due to Covid-19 led disruption, we managed to do well after the lockdown with volumes coming back to normality. We are adding these two plants due to the demand for our sustainable products.”


Mexico: Cemex says that it will invest US$925m in 2021 – 2023 in production capacity expansions and upgrades, as well as in other projects to improve financial margins. Chief executive officer Fernando González said at its Cemex Day 2021 business update that the group is planning a 10Mt/yr cement capacity expansion consisting of an extra 7.5Mt/yr in the Americas, 1.5Mt/yr in the Philippines and 1.0Mt/yr in Europe. It expects a total increase in 2023 full-year profit of US$520m as result of the investments. Around US$425m will be spent on the cement capacity additions and the remainder will go towards projects on urbanisation and its other business lines.

Strategic planning and business development executive vice president José González said “We focus on high-growth metropolitan areas, where our products and solutions nurture the urbanisation needs of these markets. These areas represent around 70% of the population and around 80% of the gross domestic product (GDP) of construction.”


Pakistan: Cherat Cement’s board of directors has approved plans for a US$215m integrated cement plant at Dera Ismail Khan, Khyber Pakthunkhwa. The company has already invested US$8.24m in acquiring land and leases for the plant. When commissioned in mid-2024, it will have a capacity of 11,000t/day.


Mexico: Cemex has launched a new brace of CO2 emissions reduction targets. The group is now targeting CO2 emissions below 475kg/t of cement and 165kg/m3 of concrete by 2030. These represent decreases of 40% and 35% respectively compared to 1990 levels. The group plans to invest US$60m/yr in efforts to meet its 2030 targets. It had previously targeted CO2 emissions below 520kg/t of cement by 2030. It now aims to achieve the previous target by 2025. The group says it intends to reach the new targets through the use of alternative fuels with high biomass content, hydrogen injection, low temperature and low CO2 clinker, decarbonated raw materials, optimisation of the kilns’ heat consumption and the reduction of clinker factor through the higher utilisation of blended cements in the market.

Chief executive officer Fernando Gonzalez said, “Climate action is the biggest challenge of our times, and Cemex is taking decisive action to address it. We commit to continue leading the industry in climate action.”


Europe: The European cement producers’ association Cembureau says that a possible reduction of European Union (EU) Emissions Trading Scheme (ETS) free allowances would endanger cement producers’ investment decisions and projects. It says that this in turn might produce competition distortions with third parties. The EU is planning to implement a carbon border adjustment mechanism (CBAM) but the association is concerned that its ‘Fit for 55’ 55% CO2 emissions reduction target for 2030 may have negative implications for the cement industry. However, the association said that it supported the concept of a CBAM.

Cembureau has called for a transition period until 2030 whereby free allocation under the EU ETS will continue fully alongside the introduction of the CBAM. It added that this is compatible with World Trade Organisation rules and avoids any form of ‘double protection’ provided the free allocation is taken into account when calculating the levy paid by any third-party importers. It further stated that the CBAM must cover both direct and indirect emissions. It has also continued to press the legislators to provide for a CO2 charge exemption for EU exporters to third countries, if the country in question is not covered by an equivalent carbon pricing mechanism. The association asked the EU to consider implementing secondary legislation before any CBAM enters force, and to ensure consistency of ‘Fit for 55’ legislative initiatives, applied across a sufficient breadth of sectors to preclude market distortions.


UK: The UK government has announced Euro58.2m-worth of funding to support infrastructure spending, targeting innovation and technology projects. This will include a scoping study into developing a CO2 storage testbed that will look at carbon capture and storage on an industrial scale. Other projects include a new radio telescope network, laboratories and Euro18.8m-worth of new digital research infrastructure. The government says that the new infrastructure aims to provide ‘strategic direction’ in the use of science and technology to overcome societal challenges and increase global prosperity. It said that the upgrade will secure the UK’s position as a ‘science superpower’ globally.


Israel: Archaeologists have identified a new precursor species of humans dated to 130,000 years ago among discoveries from a quarry run by Nesher-Israel Cement Enterprises site at Ramla. Called Homo Nesher Ramla, the species’ antiquity and proximity to Homo Neanderthalensis suggest it as a possible ancestor of Neanderthals, according to Reuters. This would contradict previous theories of European origins of our sister species. Researchers from the Hebrew University of Jerusalem and Tel Aviv University say that Homo Nesher Ramla may have lived alongside Homo Sapiens for hundreds of years at the important junction of Africa and Eurasia now occupied by modern Israel, and could have interbred with our own ancestors.


Fiji: The Fijian Competition and Consumer Commission has issued a price control order for cement with effect from 22 June 2021. It applies to the ex-factory, wholesale and retail supply of cement products in all qualities, quantities, grades and classes, according to the Fiji Times newspaper.


Guyana: Vas Energy subsidiary Georgetown Cement Company has broken ground on construction of its upcoming La Resource, Essequibo Coast cement plant. The Guyana Chronicle newspaper has reported that the company plans to spend US$100m in establishing the plant.  When commissioned in mid-2022, it will supply all of Guyana with the possibility of export to neighbouring countries. This will reduce the cost of imported cement by 30%. Georgetown Cement Company plans to employ 180 – 200 people at the plant.


India: NCL Industries is planning to expand its 2.7Mt/yr Mattapalli plant in Suryapet district, Telangana, to 3.6Mt/yr capacity at a cost of US$13.5m. The work includes the installation of vertical roller mills to replace the plant’s ball mills. Times of India newspaper has reported that the company says that it will complete the expansion by 2022.

Its plan also involves the establishment of a new 660,000t/yr grinding plant at nearby Anakapalle, at a cost of US$26.9m. The producer will invest a further US$810,000 in setting up three new ready-mix concrete plants in Hyderabad and Vizag, bringing its total number of concrete plants in the state to eight.


Mexico: Holcim subsidiary Holcim Mexico has inaugurated its new 650,000t/yr cement grinding plant at Umán in Yucatán. The cost of the project was US$40m. The plant will receive clinker from its integrated plants at Macuspana in Tabasco, and Orizaba in Veracruz. The producer says that the plant will optimise delivery times for cement customers in the area. It says that it will create 400 local jobs.

General director Jaime Hill Tinoco said, “At Holcim we are very proud to continue growing with the community, as well as to continue promoting well-being in the region through the creation of direct jobs, infrastructure and investment with this new grinding plant that, as I pointed out on the day that the first stone was laid, will strengthen national and foreign investments in benefit of the growth of the region.”


Vietnam: State-owned Vicem produced 10.5Mt of cement in the first five months of 2021, an increase of 9% year-on-year. Total cement and clinker sales rose in the period by 8% to 12.8Mt, according to the Viet Nam News newspaper. The company is targeting 26Mt-worth of cement production in 2021, up by 8% year-on-year.


Switzerland: Holcim has launched its Transport Analytics Center (TAC) software platform across its logistics fleets in 50 countries. The centre optimises route mapping, increasing deliveries’ predictability and safety, according to the company. This enables transport emissions tracking, including those of its third-party suppliers. Holcim says that the platform will cover 1.4bn kilometres of journeys by over 60,000 trucks annually. The producer hopes to use the software to reduce its Scope 3 emissions related to transportation and fuels by 20% in 2030 compared to the 2020 baseline of 29Mt of CO2.

Chief information officer Jochen Werling said, “TAC is a great example of how we are becoming a data-driven organisation. With our extensive industry expertise and advanced technologies we are developing cutting-edge digital solutions that are tailored to our specific business needs. TAC is a breakthrough for us as well as for our broader industry.”