Global Cement Newsletter

Issue: GCW526 / 06 October 2021

Headlines


There have been a couple of news stories worth noting in the Turkish market this week. First, it was revealed that Medcem had chosen Sintek Group to build a new production line at its integrated plant in Mersin. Second, Çimko Çimento agreed to buy two integrated plants and a grinding plant from Çimsa.

The Medcem upgrade project will see the subsidiary of Eren Holding add a second production line, with a clinker capacity of 9000t/day. Sintek Group reportedly has agreed to do this for US$128m. This follows an announcement from Medcem in late May 2021 that it was intending to invest over US$200m towards increasing its plant’s overall production capacity to 6.5Mt/yr from 3.5Mt/yr. The plan at this point was to start construction work in August 2021 with eventual commissioning of the second line in the first quarter of 2023. In addition the cement producer said at the time that it was going to open a new terminal in the US shortly. This was intended to join the company’s existing grinding plants in Cameroon and Tunisia and terminals in Russia and Northern Cyprus. On a side note, Medcem likes to point out that the 11,500t/day clinker production capacity on its existing line at its plant is the biggest in Turkey and Europe.

The Çimko Çimento deal with Çimsa was for US$127m. It includes the Nigde Kayseri integrated plants, the Ankara grinding plant and seven ready-mix concrete plants. As would be expected, the transaction is subject to the approval of the local competition authority.

Graph 1: Domestic and export cement sales in Turkey, January – June 2017 – 2021. Source: Türk Çimento.

Graph 1: Domestic and export cement sales in Turkey, January – June 2017 – 2021. Source: Türk Çimento.

Graph 1 above gives an idea why some cement producers might have decided that it’s time to expand either through upgrades or acquisitions. The general Turkish economy suffered a jolt in mid-2018 when the value of the Turkish Lira dropped and interest rates rose. The coronavirus pandemic hit in 2020 but after a slowdown at the start of that year the economy managed to grow. The growth has continued so far in 2021 but inflation rates have also soared. In the cement sector, annual domestic sales fell consecutively from 2017 to 2019. They started to recover in 2020 and so far in 2021 it looks like they are continuing to grow. As domestic sales fell the sector focused on exports and they have grown steadily on an annual and half-year basis since 2018. Annual exports hit a high of 16Mt in 2020 or 23% of total sales.

Despite this, in June 2021 the Turkish Cement Manufacturers' Association, Türk Çimento, was warning that input costs were mounting, particularly in the last year. It reported that the price of petcoke had nearly tripled in this period. It also warned of mounting production overcapacity, estimated at over 20Mt/yr in 2019 although down to 7Mt/yr in 2020. Coupled with a fall in annual domestic sales from 2017 to 2019, in its words, “The contraction in domestic consumption during that period steered our companies toward exports.” Some of the larger cement producers, including Oyak, Akçansa and Çimsa all reported healthy rises year-on-year in revenue and operating profit in the first half of 2021. They also reported mounting costs which have risen by 35 – 80%.

The other recent stories from Turkey to note are a two week strike organised by the Building Contractors Confederation (IMKON) in September 2021 due to high costs, particularly cement. The confederation claimed that the price of cement had tripled over the last year. Earlier, in late April 2021, the Turkish competition authority Rekabat Kurumu launched a probe into alleged collusion by nine cement producers including Oyak, Çimsa and Limak. We are not saying these two stories are connected. The current state of the Turkish economy is more than enough to cause input costs for cement producers to spike. Yet headlines like this cannot be reassuring to builders wondering why the cost of cement is going up.

In summary, it’s an uncertain time for the Turkish cement industry. Sales are recovering but this has been achieved by pushing exports more than a rally at home. Alongside this, currency instability and high inflation rates are raising costs for cement producers and end-users. This hasn’t been enough though to stop growth activity from a couple of producers in the last week.

For more on the Turkish cement sector read ‘Cement in Turkey’ in the October 2021 issue of Global Cement Magazine


Spain: Oficemen, the Spanish cement association, has elected José Manuel Cascajero Rodríguez as its president. He succeeded Víctor García Brosa, general director deputy to the chief executive officer (CEO) of the Cementos Portland Valderrivas Group, in the role. Cascajero Rodríguez has been in post since July 2021.

Cascajero Rodríguez has worked for Cemex for over 20 years in a variety of roles. His international career began in 2005 in the UK, as the Director of Treasury for Europe and Asia, and in 2012 he was appointed Corporate Treasurer of Cemex in Mexico. Since 2016, he has been responsible for Strategic Planning for Europe, the Middle East and Asia, a position he combines with the presidency of Cemex’s Spanish operations. He holds a degree in Business Administration and Management from the Complutense University of Madrid, and a Master of Business Administration degree from ESCP Europe in France.


France: Fives Pillard has appointed Fabien Illy as an executive director. His main role will be to drive the business strategy, the international development of the company and boost its growth.

Illy first started his career at Air Liquide where he worked in its research and development department for combustion and cryogenics. He joined Fives Group in 2015 and has held various positions from sales and business development to management. He holds a master’s degree in thermal engineering from the CentraleSupélec graduate engineering school of Paris-Saclay University in Gif-sur-Yvette, France.

Fives Pillard designs and manufactures burners for the mineral and energy sectors.


Madagascar: Kolos Madagascar has begun importing cement to Madagascar with the aim of staking out a claim in the country’s growing cement demand, which was 1Mt/yr in 2020. The producer says that this figure represents 7% decade-on-decade growth from 935,000t in 2010.In 2020, full-year domestic cement production stood at 150,000t. The L’Express newspaper has reported that the producer intends to establish its own grinding plant in the country. It expects to complete the plant’s feasibility study andnecessary research and obtain environmental and operating permits by April 2023 in order to commission it before 2024.

Kolos Madagascar general manager Tsiry Rasolonjatovo said that ‘quintupled’ sea freight costs were the primary cost of a rise in Madagascan cement prices. He explained “International cement prices haven't budged that much.”Rasolonjatovo added “Madagascar spends US$76m/yr to serve its cementneeds, and another US$7.6m/yr is swallowed up by additional transport costs." He estimated that, along with the realisation of other companies’ planned projects, Kolos Madagascar’s upcoming grinding plantwill increase Madagascan-produced cement’s share of domestic deliveries to 80% from 16%.

Kolos Madagascar is a subsidiary of Mauritius-based construction company Gamma Civic.


Portugal: Cimpor has announced plans for the establishment of 1MW solar power plants at each of its three cement plants in Portugal. The Dinheiro Vivo newspaper has reported that the measure comes under a planned Euro130m investment package in upgrades to its cement operations before 2030. The plans include the expansion of the solar power plants to a total capacity of 10MW by 2025. Additionally, the producer will install two waste heat recovery (WHR) plants with a combined capacity of 8MW at its Alhandra and Souselas cement plants. The company is aiming to reduce its indirect CO2 emissions by 30%. It also has an alternative fuel (AF) substitution rate target of 70% by 2030 - compared to 3% in 2020, when it used 150,000t of AF.

Cimpor has previously invested a total of Euro7.2m in dedicated sustainability-related measures.


Turkey: Medcem has chosen Sintek Group to build a new 9000t/day production line at its integrated Mersin cement plant. Sintek Group’s part of project has a budget of US$128m, according to CemenTürk magazine. The supplier will provide civil works, mechanical equipment manufacturing, supply and assembly, technological manufacturing and assembly, structural steel manufacturing and assembly, auxiliary equipment supply and commissioning services. Medcem, a subsidiary of Eren Holdings, previously said that the overall project to upgrade its Mersin plant has a budget of over US$200m. It originally intended to start construction work in mid-2021, with commissioning scheduled for early 2023.


Dominican Republic: Domicem has signed an engineering, procurement and construction contract with China-based Sinoma Construction for a 3500t/day clinker production line at its Palenque plant. The scope of the project includes a production line, from raw material feeding to the clinker warehouse and the transformation of the cement mill workshop, according to Digital Cement. The Chinese engineering company previously built the first production line at the site. Domicem’s parent company Colacem said in March 2021 that it was preparing to invest US120m towards doubling the production capacity of the Palenque plant.


US: GCC plans to fully convert production at its 0.35Mt/yr Trident Plant in Montana to Portland Limestone Cement (PLC) in early 2022. The cement producer estimates that the plant’s production change will reduce its CO2 emissions by almost 25,000t/yr.

“We believe that our industry must continue to provide the homes, roads and infrastructure that shape our world while, simultaneously, addressing the challenge of climate change,” said Ron Henley, president of GCC’s US division. “PLC is one piece of the puzzle to reduce greenhouse gases. Concrete made with PLC is a resilient material that easily meets the needs of our customers for generations to come.” He added that GCC signed the Global Cement and Concrete Association’s (GCCA) net zero pledge earlier in 2021.


Taiwan: Taiwan Cement plans to build 87.5MWh and 250MWh large-scale energy storage units at its integrated Suao and Hualien plants respectively. Once complete it will become the largest energy storage field in the country. The company will also install a 4MW solar plant at Hualien.


Australia: Boral plans to run a pilot scale carbon capture and storage unit at its integrated Berrima Cement plant in New South Wales. The project follows an allocation of a US$1.7m grant from the Australian Government’s carbon capture and utilisation and storage (CCUS) Development Fund in June 2021. The pilot intends to develop and test a re-carbonation strategy for CO2 storage. Captured CO2 will be stored in recycled concrete, masonry and steel slag aggregates. In its 2021 sustainability report, the buildings materials company said that, “The relatively low capital and operation costs, abundance of selected waste materials and the financial return potential due to the increased value of processed aggregates are key drivers for adoption of this technology.”


Argentina: Members of the Argentinian Portland Cement Producers’ Association (AFCP) dispatched 8.79Mt of cement in the first nine months of 2021, up by 32% year-on-year from 6.66Mt in the first nine months of 2020. Domestic consumption also rose by 32% to 8.7Mt from 6.6Mt. In 2020, full-year cement sales totaled 9.8Mt.


Australia: AdBri and Barro Group have signed an agreement to acquire Metro Quarry Group’s sand operations. The business consists oftwo quarries, the Lang Lang quarry and the Nyora quarry, in Victoria. The quarries command a total of 50Mt of sand reserves. AdBri will pay US$21.6m to the companies’ joint venture for the purpose of the acquisition and to supplement the business’ working capital. The partners expect to conclude the deal in November 2021.


France: Hoffmann Green Cement Technologies has renewed its strategic partnership with research and testing organization Scientific and Technical Centre for Building (CSTB). CSTB has provided Hoffmann Green Cement Technologies with certification for its clinker-free cements since 2017.It evaluates the products' performance, durability and safety.

The producer said "Hoffmann Green Cement's research and development strategy is to continually invest in the development of new low-carbon technologies. The signing of this partnership agreement will allow the company to benefit over time from optimised deadlines in the processing of its files for the evaluation of its current and future technologies."


Spain: Hanson Spain has agreed to sell its Madrid quarry and three ready-mix concrete plants in the Balearics to Cemex España. The buyer said that the investments promise a high return and are part of the strategic global strengthening of its vertically integrated positions near high-growth urban centres. It expects the deal to close in early 2022.

Europe, Middle East, Africa and Asia regional president Sergio Menéndez said “This acquisition will allow us to better serve our clients by integrating and complementing our portfolio to provide a comprehensive and sustainable offering in Cemex’s high-growth regions of Madrid and the Balearic Islands.” He added “This is another example of the efforts we make to optimise our portfolio and drive earnings before interest, taxation, depreciation and amortisation (EBITDA) growth through high-yield complementary investments."

Hanson has also sold its aggregates and ready-mix concrete assets in Asturias, Catalonia and Madrid to different buyers. Parent company HeidelbergCement had announced a review of its Spanish assets on 22 February 2021. Their total value was Euro300m.


Pakistan: The All Pakistan Cement Manufacturers Association (APCMA) recorded a 5.7% year-on-year decline in overall cement sales in the first quarter of the 2022 financial year to 12.8Mt from 13.6Mt in the corresponding period of the 2021 financial year. Intensified local construction activity increased domestic cement sales by 4% to 11.3Mt/yr from 10.9Mt/yr.

Costs increased – notably the price of coal, which more than tripled year-on-year to US$210/t from US$68/t. Its transport costs from South Africa more than doubled to US$30/t from US$11/t. Currency effects exacerbated the rise in costs. The Dawn newspaper has reported that exports fell by 44% in the period to 1.55Mt from 2.74Mt. Afghanistan had previously received 606,000t of Pakistani cement exports, 22% of the total. This figure fell by 36% year-on-year to 389,000t, 25% of the first-quarter 2021 total, due to political unrest and increased transport costs.


India: JK Lakshmi has temporarily suspended dispatches of cement from its Durg cement plant in Chattisgarh. India Infoline News has reported that the producer had previously reduced its dispatches on 19 September 2021. This is due to disruption caused by a strike by the Chattisgarh Cement Transport Association. The producer has called the strike action ‘illegal.’ It said “Industry-wide negotiations are being held with State Government and we are hopeful of an amicable solution shortly.”


Russia: Holcim Russia has committed to realising a 15% CO2 emissions reduction in its cement production between 2019 and 2030 to 475kg/t from 561kg/t. It plans to further reduce its cement’s CO2 emissions to 453kg/t by 2050, and to implement further measures to ensure its net carbon neutrality at that time.

Corporate relations director Vitaly Bogachenko said “The company's goal is to drastically reduce carbon emissions, and there are two working solutions for this. The first is the use of alternative fuels (AF) obtained from different types of waste: residues of municipal solid waste after sorting and extraction of all useful fractions from them, used tyres and others. The presence of biomass in them makes such fuels carbon neutral, so emissions during production are significantly reduced. The second solution is to replace carbon intensive raw materials. For example, instead of limestone, we use slags. The 'recipe' for cement is completely different: thanks to the new composition and the lower temperature during the firing process, the carbon footprint in the production of cement is reduced.”


Bangladesh: Seven Rings Cement has secured a contract for the supply of cement to the site of the upcoming Sylhet Osmani Internation Airport in Sylhet. Chief marketing officer Gautam Chatterjee signed the contract with Beijing Urban Construction Group on behalf of the company.

Seven Rings Cement is currently also supplying cement for the new Hazrat Shahjalal International Airport Terminal 3 in Dhaka.


Mozambique: West China Cement has signed a memorandum of understanding with the Mozambique government for four upcoming ‘industrial investment and development’ projects including a cement plant worth a total of US$800m. Local press has reported that another of the projects will be the construction of a power plant.

President Zhang Jimin said Zhang thanked the government for its past support of subsidiary Dugong Cimentos. He added “Due to this support we have, we are confident to continue the implementation of the development projects in Mozambique, as the government shows its concern to improve the investment conditions and environment.”


US: Martin Marietta Materials has completed its US$2.3bn takeover of Lehigh Hanson’s West Region business. The acquisition enlarges the company’s cement assets by two new plants and related distribution terminals, as well as targeted downstream operations, in California and Arizona.

Chair, president and CEO Ward Nye said "We are pleased to complete the Lehigh West Region acquisition and welcome a talented group of new employees to the Martin Marietta team. These assets serve as a new growth platform for our continued geographic expansion and are uniquely positioned to benefit from favourable market dynamics and accelerating public and private construction activity in California and Arizona.” He added “We are confident in our ability to quickly realise the benefits of this transaction and deliver significant value creation for our shareholders, customers and employees following the same proven approach we took with our acquisitions of TXI and Bluegrass."


India: Ambuja Cements has commenced commercial production at its new 3Mt/yr Marwar cement plant in Nagaur, Rajasthan. The plant has and an additional 2Mt/yr of grinding capacity. The Orissa Diary newspaper has reported that the producer invested US$316m in its construction. The Marwar cement plant increases Ambuja Cement’s installed capacity by 20% to 29.7Mt/yr.

Managing director Neeraj Akhoury said “Ambuja has ambitious growth plans to expand its capacities in India, and the Marwar plant is a step in that direction. We are very proud that it is a ‘green plant’ designed to meet our ambition for a sustainable future. The plant has deployed all modern equipment and technology to produce cement in a more environmentally friendly manner. It has a waste heat recovery (WHR) system that converts waste heat derived during the production process into energy.”


France: France-based Saint-Gobain has acquired Chryso from financier Cinven for Euro1.02bn. The Le Moniteur newspaper has reported that the group will operationally integrate Chryso into its high performance solutions division. It said that it intends to develop Chryso in markets already served by Saint-Gobain, and to accelerate cross-selling between Weber and Chryso.

CEO Benoit Bazin said "Chryso strengthens us significantly in the growing construction chemicals market, in which we have made 10 acquisitions and opened 16 plants in 18 countries over the past three years to now exceed more than Euro3bn in turnover in 66 countries.”


Brazil: CSN Cimentos is reviewing alternative options to raise funds to pay for its acquisition of LafargeHolcim Brasil’s cement assets after cancelling its planned initial public offering (IPO). The O Estado de São Paulo newspaper has reported that the producer abandoned the planned IPO of US$500m – US$1bn-worth of shares due to stock market turbulence. The value of the deal was US$4bn.


Benelux: Belgium-based building supplies chain EcoBati has signed a distribution agreement with France-based Hoffmann Green Cement Technologies. The producer will supply its H-Iona clinker-free cement for EcoBati to sell online and in its shops in Belgium, Luxembourg and the Netherlands.

Hoffmann Green Cement Technologies owners Julien Blanchard and David Hoffmann said "Signing a distribution agreement with an international specialist in ecological materials shows the competitive edge and relevance of our H-Iona cement within the context of the fight against global warming. We are therefore delighted with the signing of this partnership that allows us to benefit from the EcoBati network’s strategic retail outlets and provide a response to the exponential demand for sustainable cement. We intend to sign more such partnerships in the future in order to spread our responsible vision of the construction sector and contribute to the environmental transition."


India: Udaipur Cement Work plans to increase its reliance on renewable power with the installation of a new 4.15MW solar power plant at its cement plant in Udaipur, Rajasthan. When operational, the installation will increase the Udaipur plant’s solar power capacity by 42% to 14.3MW. The producer says that its entire solar power apparatus will facilitate a reduction in CO2 emissions of 14,000t/yr. In the 2020 and 2021 financial years, the producer consumed 13,000MWh of solar power, reducing CO2 emissions by 10,000t.


Vietnam: Vietnam National Cement Association (VNCA) members sold 77.5Mt of cement in the first nine months of 2021, up by 3.5% year-on-year. Vietnamese cement exports rose by 19% over the same period, to 31.9Mt. This corresponds to 41% of total sales. State-owned Vietnam Cement Industry Corporation (VICEM) exported 14.5Mt of cement, 45% of national cement exports. Viet Nam News has reported that the country ended the nine-month period with 3.6Mt of cement and clinker in inventory.


Spain: Consumption of cement in the first eight months of 2021 was 9.58Mt nationally, up by 13% year-on-year from 8.48Mt in the first eight months of 2020. The Spanish Cement Industry Association (Oficemen) says that consumption remains 2% below pre-Covid-19 outbreak levels in the corresponding period of 2019. The El Economista newspaper has reported that the association has forecast full-year cement consumption of 14.6Mt in 2020, slightly below the full-year 2019 figure of 14.7Mt.

President José Cascajero said "These levels put us on the path to have a growth in future years that is hopeful. The recovery of infrastructure, which has returned to being the primary source of demand, and residential building, has allowed both consumption and expectations to be substantially improved since April 2021.”

In 2022, he forecast year-on-year demand growth of 3 - 5%, due in part to the positive impacts of the EU post-Covid-19 outbreak recovery fund. Cascajero warned of the increasing burden of rising electricity prices and CO2 emissions fees and called for ‘structural reforms’ to mitigate their drag on growth.


France: Ciments Calcia says that it will move into its new headquarters in La Défense, Hauts-de-Seine department, in early 2022. The Les Echos newspaper has reported that the Covid-19 pandemic previously delayed the move, which the company announced in late 2019. It will leave ‘part of its services’ at its existing Guerville, Yvelines department. Some staff will work at the new headquarters ‘two or three days a week’ due to the benefits of remote working.


Thailand: Siam Cement Group (SCG) has received approval for the issuance and offering of debentures up to US$2.97bn in its subsidiary SCG Chemicals. Reuters News has reported that the group is offering the shares under a medium-term note programme.


UK: The Mineral Products Association (MPA) has announced the successful completion of a trial of cement production using a net-zero fuel mix consisting of hydrogen and refuse-derived fuel (RDF) at Hanson’s Ribblesdale, Lancashire, cement plant. The RDF in the mix consists of meat and bone meal (MBM) from the food industry and glycerol from biodiesel production.

Increased alternative fuel (AF) substitution is one of seven key levers in the MPA’s Roadmap Beyond Net Zero emissions reduction strategy. The association says that the fuel will eliminate 180,000t/yr of CO2 emissions from the Ribblesdale plant’s operations when fully implemented. The project received Euro3.71m in government funding.

Hanson’s environmental sustainability manager Iain Walpole said “We are delighted to be involved with this world-leading project, which is a further example of our commitment to cutting CO2 emissions.” He added “It will also contribute to our ambition of supplying net zero carbon concrete by 2050.”


India: JK Cement has successfully completed an upgrade of Line 3 of its Nimbahera, Rajasthan, cement plant. The upgraded line has a 30% expanded capacity of 6500t/day, compared to 5000t/day previously.

The plant produces some cement for export to countries including Bahrain, the UAE, Nigeria, South Africa and Tanzania.


Croatia: Holcim Croatia plans to invest Euro1.28m to upgrade the dosing equipment of its Koromačno cement plant’s kiln line. The planned upgrade will enable the line to increase the proportion of alternative materials used in its cement production, thus equipping the plant for low-carbon cement production. Innovation Norway has granted the producer Euro441,000 towards the cost of the project.

Managing director Nikola Kovačević said “Mineral admixtures in cement have a threefold benefit: on the one hand, different characteristics are created in the cement to meet the requirements of different types of construction; on the other hand, the exploitation of natural resources decreases. Thirdly, the carbon footprint of the cement is thus reduced through the lowering of the clinker factor.”


India: Birla Corporation has announced plans for a 92% increase of its installed cement production capacity to 30Mt/yr by 2027 from 15.6Mt/yr. The company’s upcoming 3.9Mt/yr Mukutban cement plant near Nagpur, Maharashtra, is scheduled for commissioning in early 2022. The impacts of the Covid-19 outbreak increased the project’s cost by 12% to US$370m from US$330m. The Times of India has reported that the group’s next phase of expansion will focus on the operations of the former Reliance Cement Company. Birla Corporation acquired the company in 2016.


US: Lhoist will raise the price of its lime products by US$0.2/t for every US$0.05 rise in its natural gas costs above US$2.6/MMBtu from 1 November 2021. The producer says that the price rise reflects supply challenges and increased costs, of which energy costs have risen most significantly.

The producer said “We regret having to implement this energy surcharge, but believe it necessary in the face of these energy-related cost increases. Additionally, please note that this surcharge is independent of and in addition to 2022 price increases that will be necessary for Lhoist to keep pace with general inflationary factors impacting its cost structure.” It added “We appreciate your business and cooperation during this difficult time. If you have any questions regarding the above, feel free to contact your Lhoist sales representative.”