Global Cement Newsletter

Issue: GCW515 / 21 July 2021

Headlines


There has been a significant investment in the South Korean cement industry this week with the news that Hanil Hyundai Cement has ordered a steam-based waste heat recovery (WHR) system from Japan-based Kawasaki Heavy Industries. The 22.6MW system will be used on two of the production lines at the Yeongwol plant in Gangwon Province. The supplier says that installation is expected to generate about 30% of the energy the plant needs and save around 10,000t/yr of CO2 in the process. Delivery is scheduled for late 2022.

This order may be the first investment following the announcement in late June 2021 that the state-owned Korea Development Bank had pledged around US$870m towards supporting the cement sector in making carbon reduction upgrades by 2025. These are intended to include moving away from burning fossil fuels in cement production and increasing the use of recycling materials. At the time of the agreement between the bank and the Korea Cement Association (KCA), Hanil Hyundai Cement noted that the local alternative fuels substitution rate was 24% compared to 46% in the European Union and 68% in Germany.

Graph 1: Cement production in South Korea, 2010 – 2020. Source: Korea Cement Association.

Graph 1: Cement production in South Korea, 2010 – 2020. Source: Korea Cement Association

By European or American standards South Korea kept its coronavirus cases under control in 2020. A robust testing and contract tracing regime (K-Quarantine) managed to prevent the country enforcing stricter measures until late in 2020. A fourth wave of infections, currently underway in July 2021, due to the more contagious Delta variant, has started to change this. Despite being able to keep its economy open though, the construction sector still took a hit although not as bad as initially feared.

Cement production fell by 6% year-on-year to 47.5Mt in 2020 from 50.6Mt in 2019 following a downward trend since 2017. The KCA expected worse after a poor third quarter in 2020 when it was preparing for shipments to fall below the level last seen in the midst of the International Monetary Fund (IMF) crisis in the late 1990s. On top of this the industry was also potentially facing a new tax on production towards the end of 2020. One large local producer, Ssangyong C&E, reported a 5% year-on-year drop in sales to US$864m in 2020 from US$910m in 2019. However, it managed to increase its operating profit over the same period. So far in 2021 the sector faced supply shortages in the spring. The KSA blamed the winter plant maintenance schedule and a lack of railway wagons and trucks.

The timing of the Korea Development Bank investment in the cement sector is interesting given the movement on the European Union carbon border adjustment mechanism. Cement exports seem unlikely to be affected but business lobbyists like the Federation of Korean Industries are well aware of the effects schemes like this might have upon commodities like steel and aluminium in the first phase and then the implications for car production later on. Target markets for cement exports such as the US, Peru, Chile and the Philippines might all become vulnerable should carbon-based trade restrictions become more prevalent. Of course export markets remain vulnerable to more usual hindrances. For example, in March 2021 the Philippines extended its safeguard measures on cement imports to various countries including South Korea.

Following a round of market consolidation in the late 2010s, the South Korean cement sector now appears to be entering a phase of sustainable realignment. In late May 2021 Prime Minister Moon Jae-in announced plans to hasten the country’s carbon reduction targets ahead of the United Nations Climate Change Conference scheduled for November 2021, including a carbon tax. With cement production on a downward trend since 2017 and the coronavirus crisis far from gone it will be instructive to see how far the intervention of the Korea Development Bank will go.


India: Dalmia Bharat Group director Jai Hari Dalmia died on 8 July 2021 at the age of 76.

Dalmia’s father Jaidayal Dalmia founded the company in 1939 before Dalmia and his brother Yadu Hari Dalmia later took charge of the business in the 1980s, according to Forbes. Together they built the cement division up from one cement plant to 13 cement plants in 2020.

Dalmia held a Bachelor of Engineeringdegree in electrical engineering from Jadavpur University and a Master's degree in electrical engineering from the University of Illinois at Urbana Champagne. He had more than 47 years of experience across various industries including refractories, sugar and cement. Dalmia was involved in research and development and had personally received several patents for the company's businesses.


Zimbabwe: Lafarge Cement Zimbabwe has appointed John Stull as a non-executive director. Previously he worked as the chief executive officer of Holcim Philippines from 2018 until 2021. He is currently the Area Manager - East, South Africa & Indian Ocean for Holcim.

Stull, an American national, holds over 29 years’ experience with Holcim Group having joined it in 1992 as the operations manager at the Alpena plant in Michigan, US. Since then he has worked in a variety of executive roles around the world. He holds a Bachelor of Science Degree in Chemical Engineering from the University of Akron and an Advanced Management Degree from Harvard University.


Germany: Beumer Group has appointed Jörn Fontius as the managing director of its Germany-based subsidiary Beumer Maschinenfabrik. He succeeded Norbert Stemich in the role in May 2021. Stemich has now moved to the Product Business division of the group.

Fontius joined Beumer Maschinenfabrik in 2013 and managed corporate strategy before becoming the head of global supply chain management. In late 2019 he became the president of the airport division of Beumer’s US subsidiary. Prior to working for Beumner, Fontiuswas a member of the management board of the Bundesvereinigung Logistik, a logistics network.


India: ACC’s net sales rose by 35% year-on-year to US$1.08bn in the first half of 2021 from US$799m in the same period in 2020.Its earnings before interest, taxation, depreciation and amortisation (EBITDA) increased by 56% to US$232m from US$149m. Sales volumes of cement and ready-mixed concrete grew by 31% to 14.8Mt and by 32% to 1.41Mm3 respectively.

“I am proud of the way team ACC has recorded very good performance this quarter. With a strong focus on supply chain efficiencies and cost optimisation, the company has emerged stronger and more resilient. Waste heat recovery system projects at various sites are progressing well. The large cement capacity expansion project at Ametha in Madhya Pradesh has commenced,” said ACC’s managing director and chief executive officer, Sridhar Balakrishnan.

The subsidiary of Holcim Group added that it “believed strongly” in the resilience of the Indian economy following the coronavirus crisis. It expects cement demand to grow due to increased government spending on large scale infrastructure projects.


Peru: Cementos Pacasmayo’s sales have revived following a coronavirus-related lockdown in the second quarter in 2020. It attributed the rebound to sales of bagged cement to the self-construction sector and public sector reconstruction demand. It also noted that sales revenue and volumes in the second quarter of 2021 were ahead of comparable figures in the same period in 2019 before the pandemic started. Its sales revenue more than doubled to US$229m in the first half of 2021 from US$105m in the same period in 2020. Its consolidated earnings before interest, taxation, depreciation and amortisation (EBITDA) nearly tripled to US$49.4m from US$16.9m. Production volumes at the cement producer’s plants grew to 1.79Mt from 0.79Mt.


Brazil: Votorantim Cimentos has started operation of a new production line at its Pecém grinding plant in Ceará. The US$38m upgrade brings the production capacity of the site to 1Mt/yr from 0.2Mt/yr previously. The project was suspended temporarily in 2020 due to the coronavirus pandemic. The producer also operates the integrated 2.2Mt/yr Sobral plant in Ceará and a terminal in Fortaleza. The production sites the company runs in the state are connected by railway and a further line has been extended to connect the terminal.


Russia: SLK Cement is preparing to open a new terminal at its integrated plant in Korkino plant in Chelyabinsk Oblast. The unit will have a cement capacity of 250t/hr for despatch by railway and road. The subsidiary of Italy-based Buzzi Unicem has invested around US$3.4m in the project.


Botswana: Rachit Josh, the managing director of Matsiloje Portland Cement, says that the company hopes to restart production by the end of 2021. The cement producer is currently in talks with an investor to support the move by establishing a partnership, according to the Mmegi newspaper. Joshconfirmed that the company’s integrated cement plant is currently closed. The plant, which is owned by Nortex Textiles, closed in January 2018 due to competition from South African imports. When operational it produced around 30,000t/yr of cement.


Zimbabwe: PPC Zimbabwe has received US$11.2m from the Reserve Bank of Zimbabwe as part of a legacy debts repayment scheme. The debt accrued due toregulations blocking the repatriation of revenue outside the country due to foreign exchange shortages, according to the New Zimbabwe newspaper. The debts were assumed by the central bank between 2016 and early 2019. At the time PPC Zimbabwe was left with a legacy debt of US$21m to its parent company PPC in South Africa. PPC expects the remainder of the debt to be repaid by the end of 2022.


Tanzania: The High Court of Tanzania has ordered G4S Secure Solution to pay Dangote Industries Tanzania US$0.33m for theft and loss of property. In 2018 the security company attempted to sue the subsidiary of Nigeria-based Dangote Cement was for failing to pay for its services, according to the East African newspaper. However, Dangote Cement raised a counterclaim in response due to multiple thefts that it blamed on poor security services.


France/Syria: The Court of Cassation, a court of last resort, has delayed its ruling on the conduct of Lafarge in Syria between 2011 and 2014 until September 2021. It was due to make a decision on a number of appeals related to the case including whether charges of charge of crimes against humanity should be upheld, according to the Agence France Presse. Other indictments include those of financing terrorism, endangering life and violating an embargo. Lafarge has been accused of financing terrorism through indirect payments to extremist groups to keep its Jalabiya cement plant operational after the outbreak of war in Syria.

Lafarge Cement Syria was a subsidiary of Lafarge in the early 2010s. Lafarge and Holcim merged in 2015 becoming LafargeHolcim. LafargeHolcim’s shareholders later voted to change the company’s name to Holcim in May 2021.


Vietnam: The Ministry of Finance has proposed increasing the export tariff for clinker to 10% from 5%. The ministry said that exports of cement and clinker were not sustainable as they use non-renewable resources, according to the Viet Nam News newspaper. It added that cement producers also benefit from low electricity prices. Customs data shows that the country exported nearly 33Mt of cement and clinker in 2020. 22Mt or 73% of this total consisted of clinker.


South Korea: Hanil Hyundai Cement has placed an order with Japan-based Kawasaki Heavy Industries for the design and installation of a 22.6MW waste heat recovery (WHR) unit at its Yeongwol cement plant in Gangwon. The WHR plant will generate power from heat from two of the plant’s production lines when commissioned in December 2022. The supplier says that it will serve 30% of the plant’s energy needs. Kawasaki Heavy Industries says it has previously supplied WHR units to Japan, Germany, South Korea, Turkey, China, Vietnam, India, Pakistan and elsewhere.


India: Nuvoco Vistas has received approval from the Securities and Exchange Board of India to launch an initial public offering (IPO) of shares worth US$670m. The Hindu newspaper has reported that the offering will consist of a US$201m issuance of shares and a US$469m offer for sale. Around US$180m of the funds will be used to reduce the group’s debts and the remainder will be used for general corporate purposes.


Peru: Cement production in the 12 months ending on 30 June 2021 was 12.2Mt, up by 43% year-on-year from 8.54Mt in the previous 12 months. Data from the Association of Cement Producers (ASOCEM) shows that local dispatches totalled 11.9Mt, up by 42% from 8.41Mt.

Cement exports recorded a drop, down by 7% to 0.16Mt from 0.17Mt, while clinker exports rose by 44% to 0.52Mt from 0.36Mt. High demand led to an increase in imports to 0.94Mt of cement, up by 59% from 0.59Mt, and 1.41Mt of clinker, almost triple the previous year’s volume of 0.48Mt.


Georgia: HeidelbergCement Georgia plans to invest in additional grinding capacity at both of its cement plants. The subsidiary of Germany-based HeidelbergCement says that it will complete expansion work at both plants by the 2022 production season. It is also contemplating the possibility of clinker capacity expansions.

In early July 2021, Georgia experienced a cement shortage due to the release of pent-up demand from infrastructure projects and reduced imports from Turkey and Azerbaijan.


Belgium: The European cement association Cembureau says that the European Union’s (EU) upcoming ‘Fit for 55’ emissions legislation must provide an enabling regulatory framework for the cement industry’s carbon neutrality roadmap. Key issues of concern to the association are the prevention of carbon leakage, the retention of free allocation and a carbon border adjustment mechanism (CBAM) until 2030 and the need for a ‘coherent package’ to boost the uptake of low-carbon technologies. It said that the industry supports the European Green Deal and the major challenge of delivering deep emissions cuts by 2030.

Chief executive officer Koen Coppenholle said “Whilst we welcome that the CBAM will seek to bridge the widening gap in carbon costs between EU and non-EU countries, the proposed phase-out of free allocation and the absence of export rebates would cause significant risks to investments.” He added “The decision not to include indirect emissions at this stage is also regrettable.”


India: Vedanta Aluminium has expressed interest in a long-term collaborative partnership with a cement producer. The Economic Times newspaper has reported that, in such a partnership, Vedanta would supply the producer with fly ash and bauxite residue with which to produced reduced-CO2 cement. The company said that a cement producer could be its ‘perfect circular economy partner.’

Chief executive officer Rahul Sharma said "We hope the Indian cement producers come forth to work with us on this innovative solution, which is a true win-win scenario for the industry and environment.”


India: Shree Cement is on track to commission its 3.0Mt/yr cement grinding plant at Patas in Pune, Maharashtra in September 2021. The plant was originally scheduled for commissioning in late 2020 but this was delayed due to Covid-19 led-disruption. The unit has had an investment of around US$80m and it will source clinker from a group site in Karnataka. The plant is Shree Cement’s first in western India.


India: Larsen & Toubro says that it has won a contract to supply a 1.8Mt/yr grinding unit to a site belonging to a ‘leading cement producer’ at Dolvi in Maharashtra. The supplier said that the scope of the work includes civil and mechanical engineering and equipment installation.

JSW Cement operates a 2.2Mt/yr integrated cement plant in Dolvi. It upgraded the plant’s capacity from 1.2Mt/yr in 2019.


India: Anjani Portland Cement has agreed to acquire a further 3% in Bhavya Cements to bring its stake in the company to 92% from 89%. The group says that its aim is to further consolidate its shareholding. In early June 2021, Anjani Portland Cement completed its purchase of an 83% stake in Bhavya Cements to increase its shareholding to 89% from 6%.


Saudi Arabia: Yanbu Cement’s first-half sales were US$143m in 2021, up by 23% year-on-year from US$116m in the first half of 2020. Net profit fell by 11% to US$30.7m from US$34.5m. The company said that a local price drop and an increased cost of sales offset increased sales to yield the drop in profit.


Germany: Former HeidelbergCement executive director Rainer Nobis’ Illustrated History of Cement and Concrete is now available in hardback online. The book traces the development of artificially produced building materials over 12,000 years, describing both the technical sequence of events and the political and economic environments in which they took place.

An unnamed reviewer said "The book is outstanding and comes at the right time. It has never been more necessary to recall the positive contribution of cement and concrete to mankind or to make it explainable. [Nobis] has more than succeeded!"


Germany: A consortium of Mexico-based Cemex subsidiary Cemex Deutschland, Uckerwerk Energietechnik subsidiary Enertrag and hydrogen specialist Sunfire has announced a cement industry decarbonisation project called Concrete Chemicals. The project will see sequestered CO2 combined with hydrogen to produce hydrocarbons for use as cement fuel. The consortium has submitted a funding application to the German Ministry for Environment, Nature Conservation and Nuclear Safety for a trial at Cemex’s Rüdersdorf, Brandenburg, cement plant. This would help in the realisation of the plant’s 2030 carbon neutrality target. Alongside a 5000t/yr demonstration plant, the site will have a green hydrogen plant, supplied by Sunfire. When commissioned in 2025, the plant will produce synthetic fuels and other hydrocarbon fractions. The consortium is also investigating a methanol synthesis route using synthetic gas.

Europe, Middle East and Africa regional president Sergio Menendez said “We support the urgency of action to address the climate challenge and have committed to a 55% reduction in CO2 from our 1990 baseline in our European operations by 2030. Together with our industry partners, we can collectively transform ourselves into a CO2-neutral world. Concrete Chemicals is a promising project.”


Greece: Titan Cement has received the validation of the Science-Based Targets Initiative (SBTi) for its CO2 emissions reduction targets. The validation confirms that the company’s targets are in line with a well-below 2°climate change scenario.

The group aims to reduce Scope 1 emissions per tonne of cementitious product by 21% by 2030 from 2020, and to reduce Scope 2 emissions by 42% within the same parameters. Additionally, it has committed to drive down the CO₂ footprint of its operations and products with the aim of delivering 100% carbon-neutral concrete by 2050. Methods include increasing the use of alternative fuels, accelerating efficiency-improving initiatives, developing low-carbon products, and adopting innovative technologies and solutions. The company says that it will also monitor and independently verify its supply chain emissions.

It said “Through the participation in European and international consortia, as well as through collaborations in research and development, Titan Group will continue to develop low-carbon cementitious products and pilot carbon capture technologies in its plants, actively contributing to the industry’s ambition for a carbon-neutral future.”


Australia: Seven Group has increased its stake in Boral to 52% via a 3% equity swap with Macquarie. the company now has effective control of the building materials producer although it assured Boral that it would retain a majority of independent directors, according to the Sydney Morning Herald newspaper. However, Boral has continued to urge its shareholders to resist the ongoing offer by Seven Group to buy their shares. The takeover bid has been valued at around US$6.5bn. Boral is currently in the process of selling its US fly ash business.


Canada: Progressive Planet and sustainable construction company ZS2 have signed a letter of intent to collaborate on green cement technologies development. The pozzolan-based cement producer will supply ZS2 with 10,000t/yr of natural pozzolan, beginning in late 2021. It will also purchase US$300,000-worth of shares in ZS2. The companies will also explore sequestering CO2 in magnesium-based cements.

ZS2 chief executive officer Scott Jenkins said "The technical collaboration between PLAN and ZS2 continues to grow. The potential to reduce the carbon footprint of innovative cement products is significant with the combination of our mutual research and commercialisation to date. ZS2's growing portfolio of high performance, fire-resistant and sustainable building technologies will be greatly enhanced by our expanding partnership, and we are extremely excited about our shared future potential."


Finland: UK-based minerals group SigmaRoc has acquired Nordkalk for Euro500m. The group says that Nordkalk, SigmaRoc’s sixth platform, adds a core limestone business from more than 30 locations across 10 European countries. Circular economy products comprise 13% of Nordkalk’s sales volumes. It currently makes careful use of by-products and SigmaRoc says it has a clear ambition towards fossil-free and carbon neutral operations in the future.

SigmaRoc Chair David Barrett said “Nordkalk is a well-established and well-respected business with a substantial asset footprint spanning Northern Europe. It has a long history of success and much future potential. This acquisition creates a raft of new opportunities for SigmaRoc to capitalise on in the months and years ahead.”

Chief executive officer Max Vermorken said “The acquisition of Nordkalk, Northern Europe’s leading limestone products company, is a great stepping stone in the evolution of our group, expanding our footprint across Northern European markets. We are purchasing a high-quality business at the right point in the cycle and at an attractive valuation. Nordkalk meets all our stringent investment criteria as a self-contained and asset-backed business which will bring the Group significant earnings growth. We look forward to helping Nordkalk and its experienced management team on its path to continued success as we perpetuate its 120-year history, name and success.”


Mexico: Cemex is set to begin construction of a planned US$250m new stadium for its football team Tigres UANL in Monterrey, Nuevo León. The Récord newspaper has reported that the stadium, on the grounds of the Nuevo León Autonomous University, may host some North America 2026 World Cup fixtures.


Philippines: Holcim Philippines plans to invest US$4.18m in upgrades to its cement plants at La Union, Bacnotan, and Lugait, Misamis Oriental to improve business and sustainability performance.

The subsidiary of Switzerland-based Holcim held a ceremonial signing ceremony on 7 July 2021 to award the contract to Sinoma CBMIPH Construction to install a drying facility at the La Union plant. The project is intended to reduce the fuel consumption of the unit by reusing hot gases from operations to dry materials. The integrated plant was recently awarded an ISO 45001:2018 for Occupational Health and Safety Management System and recertified for ISO 9001:2015 (Quality Management System) and ISO 14001:2015 (Environmental Management System) by certification body TÜV Rheinland. Holcim Philippines has also contracted Sinoma CBMIPH to install a drying facility at its Lugait plant that will reduce moisture of raw materials to improve grinding operations. The La Union and Lugait projects are scheduled to be completed in the first quarter of 2022 and by the end of October 2021 respectively.

In January 2021, Holcim Philippines also started projects worth US$2.42m to raise the efficiency of converting qualified waste materials to alternative fuels of its cement plant in Bulacan, Norzagaray. These will enable its Geocycle subsidiary to support the Bulacan plant to increase its thermal substitution rate by using more post-consumer and municipal solid wastes as alternative fuels.


South Korea: Korea Cement Association (KCA) members have agreed to reduce their net CO2 emissions to zero by 2050. To help them achieve this target, the state-owned Korea Development Bank has pledged US876m in investments in emissions reduction and green production upgrades by 2025, according to the Maeil Business Newspaper. The KCA says that 90% of local cement producers have increased their environmental, social and corporate governance investment and reduced their use of coal.


India: Synergy Metals Investments Holding has received the Competition Commission of India’s approval via the accelerated ‘green channel notice’ to acquire a minority stake in JSW Cement. The Press Trust of India has reported that the accelerated procedure aims to improve merger regulation through transparent review with a minimal waiting period.


Egypt: Tamer Magdy, the country manager for Sinai Cement, says that parent company Vicat is keen to continuing to invest in the local market. He noted that noted that the France-based building materials producer is a long-term investor with confidence in the Egyptian economy and that it has no plans to leave, according to the Daily News Egypt newspaper.

He praised the government’s decision in early July 2021 to introduce reduced cement production quotas. The group is also keen for the authorities to develop the Sinai region more, where its main market is based. Vicat has operated in Egypt since 2003 when it acquired Sinai Cement. However, Magdy also called on the government to provide subsidies for exports.


Ethiopia: China-based Sinoma International Engineering’s subsidiary Suzhou Sinoma has signed an initial deal with Western International Holdings to build a 10,000t/day clinker production line at Lemi in Amhara Region for around US$326m. The line includes entry of raw materials to the packaging of finished cement. Once Western International Holdings establishes a company to carry out the project Suzhou Sinoma will sign a further contact to confirm the deal. At this point construction is expected to take around 20 months.


US: ForneyVault has partnered with Command Alkon to improve the quality control process for a mutual customer, Titan Virginia Ready-Mix. The concrete producer, a subsidiary of Greece-based Titan Group, previously relied on both suppliers’ products separately. Now, ForneyVault has integrated Command Alkon ‘s quality control technology into its own data collection software. It says that the integration will benefit the concrete producer’s testing capabilities. Titan Virginia uses Command Alkon’s CommandQC software product to validate the quality for its own internal ready-mix concrete products.

Command Alkon software product owner James Shilstone said “Forney’s decision to place their data in the cloud makes it easy to interface with CommandQC. Sharing data between the two programmes eliminates the need for double entry and makes the test results available to the QC manager more quickly.” ForneyVault vice president, platform development Scott Grumski added “Integration with Command Alkon’s software allows Titan’s quality control technician to lose the clipboard and pencil... The integration partnership reduces risk and advances compliance for Titan’s quality assurance programme.”


UK: Cemex UK says that use of MP Connect contractor and haulier cards will be mandatory across its operations by the start of 2022. The Mexico-based Cemex subsidiary is presently rolling out the cards in its London and Southern ready-mix locations. It previously launched them at aggregates sites in its Central and Southern business areas. The system is now live at 39 sites and is used over 2000 times weekly, according to the company. It said that the initiative will help to streamline internal processes and enhance management of hauliers and contractors, legislative and site requirements are complied with.

Supply chain director Dave Hart said “Safety is Cemex’s number-one priority and we are always looking for ways to make our processes in this area more streamlined and effective. Implementation of the MP Connect system across our business will ensure that all drivers meet the standards set through checks of qualifications and competencies, while also providing them with more support and making their visits to different sites easier.” Cemex said that this will ‘enable the business to continually raise standards and lead the industry in safety and compliance.’

The MP Connect system was launched by the Mineral Products Qualifications Council (MPQC) in late 2020. It is intended to provide a single unified record of driver and operator working achievements that, when presented on a reader at site, can be viewed by logistics personnel. The information on the card then allows the logistics team to grant access, safe in the knowledge that the correct safety criteria applicable to the site, have been met by the person carrying the card.