Global Cement Newsletter

Issue: GCW527 / 13 October 2021

Headlines


In the two and a half years since Calix brought together cement producers across corporate and national boundaries to form the first Low Emissions Intensity Lime And Cement (LEILAC-1) consortium and commissioned a carbon capture installation at the Lixhe cement plant in Belgium on 10 May 2019, carbon capture and storage (CCS) has passed some major milestones. New installations have made Global Cement headlines from Canada (at Lehigh Cement’s Edmonton plant in November 2019) to China (at a China National Building Material (CNBM) plant in July 2021). Twelve other European cement plants now host current or planned carbon capture trials – including the first full-scale system, at HeidelbergCement’sBrevik plant in Norway. A second Calix-led project in Germany, LEILAC-2, attracted Euro16m-worth of funding from the European Union in April 2020.

The work of LEILAC-1 – backed by HeidelbergCement, Cemex, Lhoist, Tarmac and others, with Euro12m in funding – set the benchmark in innovation. Its pilot plant successfully captured 100% of 'unavoidable' process emissions by indirectly heating raw materials inside a vertical steel tube. Called direct capture, the model removes a CO2 separation step, as our subsequent price analysis will reflect.

In October 2021, the LEILAC-1 consortium published its report of the concluded Lixhe trial. It described the three-fold key successes of the study:

1) Both limestone and raw meal may be processed;

2) CO2 is successfully separated;

3) The energy penalty for indirect calcination is not higher than for conventional direct calcination.

Additionally, Calix’s first departure into the cement sector has demonstrated that its model exhibits no operational deterioration, does not suffer from material build-up and has no impact on the host plant when used in cement production. The plant’s clinker capacity remained the same as before the trial. Most importantly of all, the Lixhe cement plant recorded no process safety incidents throughout the duration of the trial.

The study has also put an evidence-based price tag on industrial-scale CCS at a cement plant for the first time: Euro36.84/t. Figure 1 (below) plots the full-cycle costs of three different carbon capture installations at retrofitted 1Mt/yr cement plants using 100% RDF, including projections for transport and storage. Installation 1 is an amine-based carbon capture system of the kind installed in the Brevik cement plant’s exhaust stack; Installation 2 is the Calix direct capture system and Installation 3 consists of both systems in combination. Direct capture’s costs are the lowest, while the amine retrofit and the combination installation are close behind at Euro43.68/t and Euro43.25/t respectively.

Figure 1: Full-cycle costs of three different carbon capture installations at retrofitted 1Mt/yr cement plants using 100% RDF

Figure 1: Full-cycle costs of three different carbon capture installations at retrofitted 1Mt/yr cement plants using 100% RDF

Installations 1 and 3 both entail additional energy requirements for the separation of CO2 from flue gases and air. With the inclusion of the CO2 produced thereby, the cost of Installation 1 rises to Euro94/t of net CO2 emissions eliminated, more than double that of Installation 2 at Euro38.21/t. The combination of the two in Installation 3 costs Euro67.3/t, 76% more than direct capture alone. Figure 2 (below), breaks down the carbon avoidance costs for each one and compares them.

Figure 2: Carbon avoidance costs of three different carbon capture installations at retrofitted 1Mt/yr cement plants using 100% RDF

Figure 2: Carbon avoidance costs of three different carbon capture installations at retrofitted 1Mt/yr cement plants using 100% RDF

The Global Cement and Concrete Association (GCCA)’s seven-point Roadmap to Net Zero strategy puts CCS at the forefront of concrete sector decarbonisation. CCS is expected to eliminate an increasing share of global concrete’s CO2 emissions, rising to 36% in 2050 – by then 1.37Bnt of a total 3.81Bnt. This will depend on affordability. Calix’s model has reduced the capital expenditure (CAPEX) of a carbon capture retrofit by 72% to Euro34m from Euro98m for the amine-based equivalent. When built as part of a new plant, the CAPEX further lowers to Euro27m. Both models may also be retrofitted together, for Euro99m. In future, Calix expects to install direct capture systems capable ofachieving Euro22/t of captured CO2. By contrast, the cost of emitting 1t of CO2 in the EU on 11 October 2021 was Euro59.15.

In what it calls the Decade to Deliver, the GCCA aims to achieve a 25% CO2 emissions reduction in global concrete production between 2020 and 2030, in which CCS plays only a minor part of less than 5%. LEILAC-1 presents a visionof affordable carbon avoidance which complements cement companies’ 2030 CO2 reduction aspirations.

Unlike conventional CCS methods, however, direct capture only does two thirds of a job – eliminating the emissions of calcination, but not combustion. This would appear to make it unsuited to cement’s longer-term aim of carbon neutrality by 2050 in line with the Paris Climate Accords’ 2°C warming scenario. On the other hand, direct capture is not designed to work alone. Calix recommends use of the technology in conjunction with a decarbonised fuel stream to eliminate the plant’s remaining direct emissions. This increases the price - by 47% to Euro56.05/t of CO2 avoided for biomassand by more than double to Euro104.48/t for an E-kiln.

The Lixhe cement plant’s carbon capture story is one of a successful crossover from one industry into another: Calix previously applied the technology in the Australian magnesite sector. Realisation of the Calix carbon capture vision in the global cement industry is a challenge primarily due to the scale of the task. It will require continued collaboration between companies and with partners outside of the industry. Further than this, parliaments must continue to enact legislation to make emission mitigation the economic choice for producers.


Australia: AdBri has appointed its chief executive officer (CEO) Nick Miller to its board of directors by making him managing director and CEO. The company said that the move “reaffirms a unified strategic direction set by the board.” It added that, following the appointment in early October 2021, the board would no longer comprise a majority of independent directors as contemplated by the Board Charter or the Board Governance Framework introduced in March 2019, which included an updated Board Protocol – Potential Conflicts and Interests. However, AdBri said that it remained committed to a majority independent board and was looking for an additional independent non-executive director to restore the former makeup of the board.

Miller became the CEO of AdBri in 2019. In 2020 the Australian Competition and Consumer Commission (ACCC) approved Barro Group to buy a 43% stake in AdBri.


US: The Portland Cement Association (PCA) has published a roadmap to carbon neutrality for the cement and concrete sectors by 2050. It says that the strategy document demonstrates how the US cement and concrete industry, along with its entire value chain, can address climate change, decrease greenhouse gases and eliminate barriers that are restricting environmental progress. It added that the document is a ‘major step’ towards engaging US policymakers, industry partners and non-government organisations.

“Cement and concrete have been pivotal in building resilient, durable and sustainable communities that enable people to live safe, productive and healthy lives via structures that withstand natural and man-made disasters,” said PCA President and chief executive officer, Michael Ireland. “The PCA is uniquely positioned to lead the industry-wide ambition to achieving carbon neutrality and enable our member companies and industry partners to continue building a better future.”

The PCA’s roadmap outlines a number of reduction strategies across the various phases of the built environment including production at cement plants, construction including designing and building and everyday infrastructure in use. It also recognises five main areas of opportunity: clinker; cement; concrete; construction; and carbonation (using concrete as a carbon sink).

Notably goals include a reduction of coal and petcoke use at cement plants to 10% in 2050 from 60% at present, a clinker ratio of 75% in 2050 from 90% at present and a reduction of the CO2 intensity of concrete of 60% by 2050. The roadmap also noted the necessity of carbon capture and storage/utilisation (CCUS) for reducing CO2 emissions from cement production. However is pointed out that there are no commercial-scale CCUS installations at any cement plant within the US, location and permitting challenges remained and that infrastructure investment would be required to deal with the captured CO2.


Kenya: A report by the National Independent Clinker Verification Committee has found that the country has a clinker shortage of up to 3.3Mt/yr. It added that 59% of the imported clinker to compensate for this originates from Egypt without any tariffs, according to the East African newspaper. The committee was originally set up by the government in response to lobbying from industry to increase the duty on imported clinker to 25% from 10% at present. However, the committee also reported that Egypt has benefited from a free trade agreement. Local producers are divided against the proposal to raise tariffs on clinker as some of them reply on imports.

The report found that 3.8Mt of clinker was produced locally in 2020 against a demand of 5.3Mt. Local producers were reported to have been operating at a 65% capacity utilisation rate. Egypt and the UAE accounted for 92% of all clinker imports with a further 7% supplied by Saudi Arabia.


South Africa: The National Treasury has banned the use of imported cement on all government-funded projects from 4 November 2021. The new rules require all tender invitations to use locally produced cement, made from locally sourced raw materials, according to the Business Day newspaper. Trade body Cement and Concrete SA has welcomed the move. The decision follows lobbying by the cement industry to impose tariffs on imported cement.


Kazakhstan: Steppe Cement's revenues in the nine-month period which ended on 30 September 2021 were US$67.6m, up by 8% year-on-year from US$62.6m in the corresponding period of 2020. Sales volumes rose by 4% to 1.38Mt from 1.33Mt.

Kazakhstan Newsline has reported that projected full-year Kazakh cement demand rose by 24% in the period to 11.3Mt, of which Steppe Cement controls a 14% share. The share of imports remained level at 7%. Nine-month cement exports were 1.4Mt nationally.


India: Local press expects UltraTech Cement to be the successful bidder for the 210Mt-capacity Ramstahn Ghunchihai limestone mine in Madhya Pradesh. Sree Jayajothi Cements is the preferred bidder in another auction, for a large limestone quarry in Andhra Pradesh. Nine limestone mines sold at auction in the first half of the 2022 financial year.


India: Ambuja Cement has received validation from the Science-Based Targets Initiative (SBTi) that its CO2 reduction targets conform to a well below zero global warming scenario. India Infoline News has reported that Ambuja Cement is committed to a Scope 1 and Scope 2 CO2 emissions reduction of 21% to 453kg/t of cementitious materials by 2030 from 531kg/t in 2020. Over this period, it aims to reduce Scope 1 emissions by 20% and Scope 2 emissions by 43%.

Ambuja's chief executive officer and managing director Neeraj Akhoury said “We are constantly dedicated and invested in sustainable development and aim to include sustainability in all operational and project planning. With science-based targets developed and validated, Ambuja Cement has now joined the group of global companies promoting an ambitious low carbon economy model for the industry. Being part of the Holcim group and one of the pioneers in the Indian cement industry, we have taken another step towards strengthening our Climate Change adaptability by joining the Race to Zero." He added "Ambuja Cement will continue to implement such best practices and adopt continuous improvement initiatives to achieve our business vision to be most competitive and sustainable company in our industry.


Jamaica: The Ministry of Industry, Investment and Commerce has granted Growth Tech Special Projects a licence to import 50,000t of cement from Turkey before 31 December 2021. The Gleaner newspaper has reported that the nation's other cement importer, Buying House, holds a licence to import 120,000t/yr. Sole producer Caribbean Cement is in the process of expanding its 1Mt/yr Rockfort cement plant's capacity to 1.4Mt/yr.


Finland: The VTT Technical Research Centre of Finland and Finnsementti have revealed work on the Decarbonate project to test a 12m electrically-heated rotary kiln. Other partners on the initiative included Nordkalk and UPM. Precalcination was tested as well as the projection of quick lime. The eventual goal is to use electricity from renewable sources to power the kiln and then capture the CO2 released for utilisation.

The Decarbonate project has been exploring CO2 capture and utilisation concepts that can be commercialised. It has run for two years since late 2019 and has funding of Euro1.2m. It has also looked at oxyfuel and electrolysis experiments.


India: Shree Cement has hired FLSmidth to supply a 11,5000t/day kiln line for its planned Nawalgarh, Rajasthan, cement plant. The line will consist of a six-stage preheater and a three-support kiln. The supplier will also deliver an OK vertical roller mill, which it says has a 5 – 10% lower energy consumption than a standard vertical roller mill. The project focuses on sustainable productivity and emissions control. Shree Cement has opted for JetFlex burners to give the lowest possible nitrous oxide emissions for various fuel types.

Shree Cement managing director Prashant Bangur said “Based on the experience of working with FLSmidth on the installation of a 9,000t/day pyro system at the Raipur, Chhattisgarh, cement plant earlier this year, we felt confident about approaching Carsten Riisberg Lund and his team regarding the Rajasthan project.” He added “Being recognised as a Sustainability Champion by the World Economic Forum is a testament of our emphasis on sustainability at every stage of our operations. The new line will push that agenda even further in terms of lowering the benchmarks on energy consumption and emissions, and thereby reducing our environmental footprint.”

FLSmidth also supplied a second OK mill for Shree Cement’s operations in Kolkata, West Bengal.


World: Forty cement and concrete producers, representing 80% of concrete production outside of China in 2020, have together affirmed their commitment to the Global Cement and Concrete Association (GCCA)’s Roadmap to Net Zero concrete decarbonisation strategy. The roadmap’s seven-point plan consists of increased cement plant efficiency, which should eliminate 22% of emissions, increased concrete production efficiency (11%), adjustments to cement and binders (9%), decarbonisation of raw materials (11%), carbon capture and storage (CCS) (36%), a transition to renewable energy (5%) and the natural recarbonation of concrete (6%).

Besides full decarbonisation by 2050, the strategy provides for a 25% reduction in the global concrete sector’s CO2 emissions by 2030 and the elimination of 4.9Bnt of CO2 emissions by 2030 alone. The GCCA called the new commitment a ‘significant acceleration’ of cement and concrete producers’ on-going decarbonisation efforts, and said that it represented ‘the biggest global commitment by any industry’ to carbon neutrality. Acknowledging the burden on cement producers, the GCCA called on downstream companies and governments to support the industry’s transition.

GCCA member China National Building Material (CNBM) CEO Cao Jianglin said “This is a landmark for industry co-operation in decarbonisation. As part of a global industry, it will need collaboration across our sector to achieve it. As one of the leading cement and concrete producers in China, we will play our part in decarbonising the industry.”


US: The California State Senate has voted in favour of a bill to implement the US’s most advanced statutory framework for cement industry decarbonisation by 74 votes to two. The statute provides for the implementation of lifecycle CO2 emissions reporting for cement produced in the state at an estimated cost of US$220,000/yr. The California Air Resources Board will then implement a ‘programme developed as a result of identified strategies’ at an ‘unknown but significant cost.’ The aim of the strategy will be to facilitate a 40% reduction in cement production’s CO2 emissions between 2019 and 2030 and the attainment of net zero cement production by 2045.


US: Cemex USA has upgraded two Florida cement terminals, the Pensacola and Palm Beach terminals, at a cost of US$8m. The upgraded terminals will serve to increase Cemex USA’s cement supply to the region through marine shipments from its global operations. The Palm Beach terminal is also involved in the distribution of assorted cementitious materials including granulated blast furnace slag (GBFS) and fly ash for cement production.

USA executive vice president Matthew Wild said “Florida is growing rapidly, and Cemex’s strong network makes our company well-positioned to implement supply chain and operational enhancements to meet the high demand for building materials in Florida and beyond.” He added “On the cement side, increased demand has outpaced supply at times, and we expect our supply chain enhancements to help alleviate that issue.”


Mexico: Cemex has announced the release of the collateral on its debt under its main bank agreement and senior secured notes. The release follows Cemex’s reporting of two consecutive quarters with a consolidated leverage ratio of 3.75x or less.

CFO Maher A-Haffar said “We are very pleased with this momentous milestone, which is a culmination of the substantial strengthening of our capital structure and paves the way towards an investment grade rating. This will simplify our debt structure and reduce the cost of managing our debt stack.”


Chile: Unacem has completed its acquisition of Spain-based Cementos La Unión’s Chilean cement business. The value of the asset, including assumed debts, was US$23m. The business consists of the 0.3t/yr San Antonio grinding plant and two ready-mix concrete plants with a total capacity of 336,000m2 /yr.


Germany: Scientists at the University of Kassel in Hessen have launched a study into the use of ash from waste incinerators in precast concrete production. The Hessische Allgemeine newspaper has reported that a waste-to-energy plant in Kassel will provide the ash for concrete production in partnership with local companies Kimm Baustoffe and Gebäudeke Baustoff-Recycling. The study aims to produce pre-cast concrete elements containing at least 30% ash, beginning with paving slabs and noise barriers.

Project leader David Laner said that ash has the potential to help lower concrete’s carbon footprint. He said “So far, it has been put to lesser-value uses; we make a product out of it - upcycling instead of downcycling.”


Canada: Habitats for Humanity has again partnered with Lafarge Canada for its annual affordable housing fundraiser in Kingston, Ontario. This year, the partners will attempt to raise US$21,700 over 27 days to support the construction of sustainable housing in Eastern Canada. Lafarge Canada has pledged 80m3 of its ECOPact reduced-CO2 concrete to the project.

Eastern Canada regional head of environment and sustainability Rob Cumming said "Our sustainability goals overlap safe housing with reduced climate impact.” He added "We are excited about this first milestone and are looking forward to the future supply of our ECOPlanet solutions.”


Azerbaijan: Cement companies increased the total volume of cement produced in the first eight months of 2021 by 1.5% year-on-year to 2.2Mt from 2.17Mt in the corresponding period of 2020. Meanwhile, ready-mix concrete production increased sharply, by 39% to 1.7Mt from 1.3Mt.

On-going large-scale state construction projects the new territories East of Zangazur and Karabakh are anticipated to increase full-year cement production in 2021 and into subsequent years.


US: The US Department of Energy has selected Central Plains Cement to receive US$5m-worth of funding to realise its plans for a cryogenic carbon capture (CCC) installation at its Sugar Creek, Missouri, cement plant. Contify Energy News has reported that the system will initially have a capacity of 30t/day of CO2, with a view to eventually capturing 95% of the plant’s flue gas’ CO2 content. The Eagle Materials subsidiary will receive US$5m in funding from the US Department of Energy for the project. The sum is part of a raft of a total US$45m-worth of grants to help towards decarbonising heavy industry and natural gas power. Chart Industries will carry out the work.

Chart Industries CEO and President Jill Evanko said that the company’s CCC model increases cement production costs by just 24%, compared to 38% - 130% for other types of system. She added “We are delighted that public and private entities recognise Chart as a leader in carbon capture technologies and products; we view this award as well as our third quarter 2021 commercial activity as meaningful steps and accelerators toward capturing - pun intended - a significant share of our anticipated US$6bn total addressable market for carbon and direct air capture in 2030.”

The St Louis Post newspaper has reported that Holcim US’s Ste-Genevieve, Missouri, cement plant is also among facilities chosen to receive funding for carbon capture and storage (CCS) installations.


Mexico: Cemex CEO Fernando Gonzalez has estimated that the impacts of the Covid-19 outbreak will cost the group US$100m in 2021. Gonzalez attributed the anticipated negative effect on full-year earnings before interest, taxation, depreciation and amortisation (EBITDA) to supply chain disruptions and currency effects, especially on the Mexican Peso, as well as delays to projects globally.


China: Tangshan Jidong Cement has announced plans to issue a tranche of bonds with a total value of not more than US$155m. Reuters News has reported that the issuance is the second by the company.


Finland: Wärtsilä has announced that its upcoming Capital Markets Day event will take place at 1pm – 4.30pm, Eastern European Time (EET), on 18 November 2021. The supplier says that attendees will be able to follow proceedings via a webcast. President and CEO Håkan Agnevall together will host the event, during which members of the board of management will provide information on the company's business operations, strategy, and financial development.

Registration is open until 11 November 2021 and may be accessed here.


India: NCL Industries recorded a 10% year-on-year rise in cement production to 677,000Mt in the second quarter of the 2022 financial year from 615,000t in the second quarter of the 2021 financial year. Its cement dispatches also increased by 10% to 678,000t from 617,000t. The company's cement board production during the quarter was 19,200t, while its cement board dispatches were 18,800t.


Oman: Oman Cement Company will spend US$300m on the new 10,000t/day Line 4 as part of the upcoming upgrade and expansion of its Rusayl cement plant in Muscat governorate. The Oman Observer newspaper has reported that Switzerland-based PEG Resources will carry out the work. Oman Cement Company CEO Salem bin Abdullah al Hajri said that the new line will help Oman to achieve cement self-sufficiency by 2024.

The company said “The new 10,000t/day production line will be the largest in Oman and will have more cost-effective production, for the company to sustain its success and competitiveness in the local and international cement markets in a long run.” It added “The company will focus on utilising state-of-the-art production technology resulting in lower power consumption, potential for waste heat recovery (WHR), higher fuel efficiency, realisable use of alternative fuels (AF), improved productivity and the best environmental standards.”

Oman Cement Company is also expanding the Rusayl plant’s Line 3 by 25% to 5000t/day from 4000t/day, prior to decommissioning its other two lines.


Belgium: The low-emissions intensity lime and cement (LEILAC) consortium has published the results of its LEILAC-1 carbon capture and storage (CCS) study at HeidelbergCement’s Lixhe cement plant in Visé. The study found the cost of CCS to be Euro14 – 24/t of CO2 captured. It found that full-chain CO2 mitigation projects incur costs are Euro39 – 80/t, depending on transport and storage selections.

EU Emissions Trading Scheme (ETS) credits currently cost Euro62/t.


Germany: Aumund has announced the launch of its PREMAS 360° packages. The three packages – basic, advanced, premium - combine quality Aumund all-around maintenance and inventory management support, extended warranties, physical inspections, cutting-edge Industry 4.0 monitoring of Aumund and other conveying equipment, technical training, emergency remote support and consultation programmes.

Managing Director Pietro de Michieli said “With PREMAS 360°, Aumund puts customer service to the forefront. Our goal is to reassure machine availability and reliability through the simplicity and flexibility of a fully bundled maintenance solution, to be a partner to our customers assisting them to reach operation excellence.”


Poland: Cemex Poland has established a new 50kW solar power plant at its Pruszków ready-mix concrete production plant in Masovian Voivodeship. The company says that it is planning other investments to retrofit renewable energy systems into its operations across Poland.

Materials director Michał Grys said “Cemex is actively addressing the climate challenge by decarbonising our processes. The key to realising our ambitious goals is finding and implementing new low-emission products as well as more sustainable technologies and construction solutions.” He added “Photovoltaic farms are another investment by Cemex Poland in renewable energy sources. Currently, much of the electricity used in our aggregate quarries, cement plants and many concrete plants comes from renewable sources."


Mexico: Cemex has received validation from the Science-Based Targets Initiative (SBTi) for its 2030 global CO2 emissions reduction targets. The validation attests that the targets conform with the Paris Agreement’s well-below 2°C global warming limit. Under its Future in Action programme, Cemex aims to reduce its cement’s carbon footprint to 40% compared to 1990 levels and achieve 55% renewable energy use by 2030. The company says that it has the global cement industry’s most ambitious 2030 targets.

CEO Fernando Gonzalez said “Climate action is the biggest challenge of our times. Cemex is taking decisive action to address it by defining ambitious emissions reduction targets in line with the SBTi, and executing against those targets.” He added “We commit to continue leading the industry in climate action not only because it creates value, but more importantly because it is the right thing to do. Cemex is building a better future, and that future must be sustainable.”