Global Cement Newsletter

Issue: GCW544 / 16 February 2022

Headlines


Argos USA announced this week that its integrated Roberta plant in Alabama is set to produce 100% Portland limestone cement (PLC) by June 2022. As part of the transition three of its terminals in North Carolina will also switch over at the same time. The company also expects that all of its plants will convert to PLC in 2023. Cement sites including Newberry in Florida, Harleyville in South Carolina and Martinsburg in West Virginia are already producing PLC.

The change by Argos marks the latest example in an ongoing trend of US-based cement companies moving entire plants to PLC production. In September 2021 LafargeHolcim US said that its integrated Midlothian plant in Texas was preparing to convert to full PLC production and that it would be the first plant in the US to do so. It later confirmed that the plant had done so by the end of 2021. In October 2021 GCC said that its Trident Plant in Montana would fully move to PLC in early 2022. Then in November 2021 Titan America said that its Pennsuco cement plant in Florida would make the change possibly by 2023. Moving into 2022 brought the news that LafargeHolcim US’ Ste. Genevieve plant in Missouri and its Alpena plant in Michigan had each transitioned to PLC production. Lehigh Hanson then rounded up the bunch earlier this month, at the start of February 2022, when it announced that a PLC was the primary product now coming out of its Mason City plant in Iowa. It even invited a US Member of Congress to celebrate!

The current expansionist phase of PLC usage in the US dates back to late 2020 when the Portland Cement Association (PCA) launched a dedicated website to promote the use of the blended cement by discussing its applications and benefits. It then released a new environmental product declaration in March 2021 and PLC received a mention in the PCA’s Roadmap to Carbon Neutrality when it was released a year later in October 2021. Lots of work went into PLC prior to 2020 though, both by the PCA and others. The first commercial production of PLC in the US started in 2005 and PLC gained its own blended cement specification in 2012. Notably, the PCA has been tracking the state acceptance of PLC by the Department of Transportation and it grew markedly during the 2010s.

The US is playing catch-up with PLC. In Europe its usage dates back to the 1960s. Cembureau, the European Cement Association, reported usage of around 30% in 2004. More recently in 2020, the VDZ, the German Cement Association, reported a similar figure domestically with the proportion of blended cement shipments including limestone, shale and multiple additives at 31.6%. In the US it is hard to gauge the scale of the current move towards PLC by producers, due to limited publicly available data. A PCA survey reported PLC production of 0.89Mt in 2016. If all the plants mentioned above convert fully to PLC and maintain their rated production capacity that would be something like 14Mt/yr of PLC in 2023 or 11% of the US’s total cement capacity. For comparison, the United States Geological Survey (USGS) reported total shipments of all blended cements at 3.3Mt in 2020 and a total of 5.4Mt for the first 11 months of 2021. Plus, remember that PLC is just one blended cement among others, like those that use slag or fly ash.

Recent developments show that a large change is coming towards the US cement market in the update of blended cements. It’s been a long time coming but the last six months have seen brisk increases in PLC production at scale. The exact data is not available but one might expect something around triple the current number of production plants making PLC if the US market heads towards European levels. This rough estimate doesn’t take into account existing partial PLC production levels. At the same time the US cement sector should see a fall in its emissions due to PLC’s 10% reduction in CO2 emissions compared to ordinary Portland cement


Russia: Soyuzcement, the national cement manufacturing union, has elected Daria Martynkina as its executive director. She previously worked as the public relations head at Siberian Cement and as an advisor to SibCem’s first vice president Gennady Rasskazov. Martynkina trained as a journalist at Moscow State University and is also a graduate from the Moscow State Law Academy.


Canada: The Cement Association of Canada has appointed Sarah Petrevan as its Director of Sustainability. She previously worked as the Policy Director for Clean Energy Canada and the Friends of the Greenbelt Foundation. She is a graduate of Victoria University in Toronto.


Denmark: The board of directors of FLSmidth has nominated current vice chairman Tom Knutzen as the new chair of the board and Mads Nipper as vice chair. Knutzen will succeed Vagn Sørensen as chair. Sørensen has decided to step down as chair of the board of FLSmidth since his election in 2011. He has decided not to seek re-election. Both nominations will be voted upon at the company’s annual general meeting in late March 2022.

Knutzen has been a member of FLSmidth’s board of directors since 2012 and is the current vice chair. He is also chair of the Audit Committee and a member of the Nomination and Compensation Committee. His career includes his current role as chief executive officer (CEO) of Jungbunzlauer Suisse, from which he has resigned effective end April 2022, CEO of Danisco, CEO of NKT Holding and non-executive board positions with Nordea Bank, Chr. Augustinus Fabrikker and Tivoli.

Nipper is the current CEO of the multinational power company Ørsted, which develops, constructs and operates offshore and onshore wind farms, solar farms, energy storage facilities, renewable hydrogen and green fuels facilities and bioenergy plants. He brings an international background to FLSmidth including renewable energy, energy efficiency, water management and water conservation. As a member of World Economic Forum's Alliance of CEO Climate Leaders, he leads the Power Working Group. He is also co-chair of the roundtable of hydrogen production under the European Clean Hydrogen Alliance and is vice chair of the international food company Danish Crown.


Thailand: Germany-based Schmersal has appointed Passara Hongwisat as the managing director of Schmersal Thailand. She has 18 years of professional experience in sales and channel management for information technology and industrial products and worked in the automation industry for five years. Hongwisat studied Electronic Engineering at King Mongkut's University of Technology North Bangkok.

Schmersal Thailand was founded in Bangkok in 2019 as a subsidiary of the Schmersal Group and focuses on sales and marketing activities to increase the supply of products for machine safety in Thailand.


US: Lindner Recyclingtech America has appointed Brent Moncrief as its National Sales and Corporate Account Manager for the US West Coast and Michelle Wilshire as its new Operations Manager at its headquarters in Statesville, North Carolina. Moncrief will work on consulting with clients on the company’s portfolio of industrial shredding products to large, multi-location waste handling and processing sites while also supporting Lindner’s participation with industry associations and events.


France: Vicat says it offset rising energy costs by raising its prices in 2021. It reported growth in most places as markets recovered from the start of the Covid-19 pandemic in 2020. It also noted a particular improvement in Egypt as government-mandated changes came into force in July 2021. The group’s consolidated sales rose by 11.3% year-on-year to Euro3.12bn in 2021 from Euro2.81bn in 2020. Cement and concrete volumes increased by 12.4% to 28.1Mt and 12.5% to 10.5Mm3 respectively. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 11.1% to Euro619m from Euro557m.

“Conditions in our markets remained dynamic, supported by favourable pricing trends in a context of sustained demand. This offsets the sharp rise in energy costs and wage increases,” said Vicat group chairman Guy Sidos.


Australia: Boral’s earnings in the first half of its financial year have fallen as it has completed the sales of its North American fly ash business. Its revenue from continuing operations fell slightly to US$1.08bn in the six months to 31 December 2021. However, its earnings before interest, taxation, depreciation and amortisation (EBITDA) for continuing operations dropped by 16% to US$138m from US$164m in the same period in 2020. Cement and concrete sales volumes remained stable and rose slightly respectively.

“With the completion of the divestment of our North American Fly Ash business on 11 February 2022, we have now finalised the strategic realignment of our portfolio to focus on our Australian construction materials business,” said Boral’s chief executive officer Zlatko Todorcevski. “We are focused on building a more competitive and profitable business that is positioned for success and delivers increased returns to shareholders.” He blamed falling earnings on construction shutdowns and growing energy prices despite changes to the business.


Mexico: Cemex says that it will invest a total of US$1.3bn in its business in 2022. US$600m will go towards strategic growth, according to the company.

Chief executive officer Fernando Gondzález said "Overall in 2022, we anticipate a favourable environment with more moderate volume growth in most markets and solid pricing dynamics reflecting high capacity utilisation and input cost iteration. Finally, our objective is to recover margins in line with our goal of operational resilience with our pricing strategy.” He continued "Today, we are very prepared to handle the inflationary change. We have reflected cost pressures in our regular 2022 price announcements scheduled for January and April. We are also assuming that inflation is not transitory and are prepared to respond quickly to changes in the environment."


US: The supervisor of Santa Clara County in California has ordered a report by the county council setting out a plan for the acquisition of Lehigh Hanson’s Santa Clara cement plant and its associated quarry. If successful in acquiring the property, the administration would close down all operations there. The Mercury News has reported that the council will have until mid-May 2022 to produce its report. The supervisor called the facilities a ‘historical anachronism’ and said that the land, situated in the county’s Silicon Valley light industry region, might be used for housing.


Spain: Cementos Molins has committed to a 20% reduction in its CO2 emissions between 2020 and 2030. The company has set out its strategy in its 2030 Sustainability Roadmap. The roadmap covers five areas: health and safety, energy and climate change, the circular economy, nature and the environment, and corporate social responsibility. Thus, Cementos Molins aims to achieve an accident-free workplace, to source 55% of its electricity consumption renewably, to increase its alternative fuel (AF) substitution rate to 40% and reduce its cement’s clinker factor to 68%, to halve particulate matter emissions and cut nitrous oxides (NOx) and sulphur oxides (SOx) emissions by 40% and 10% respectively and to have signed official agreements with all host communities and employ women in over 23% of management positions.

Chief executive officer Julio Rodríguez said “Sustainability is the cornerstone of our strategy here at Cementos Molins, and today we are delighted to announce the specific targets that we have set out in our 2030 Sustainability Roadmap. The targets and their corresponding action plans - the result of the hard work and dedication of the Cementos Molins team, together with our stakeholders – will help drive our company forward in actively tackling climate change.” He added “We are deeply committed to achieving zero emissions and building a better world for everyone.”


Colombia: Cementos Argos has successfully commissioned its new cement terminal in Bolívar Department’s Cartagena Free Zone. Semana News has reported that the terminal will export cement to the Caribbean, Central America and the US. It triples Cementos Argos’ cement export capacity to 3.5Mt/yr.


Russia: Eurocement has completed a Euro3.3m maintenance project on the kiln at its Mordovcement plant in Chamzinsky District. The wet-process kiln was reconstructed as part of a large-scale modernisation program. Work conducted included replacement casing bandages, roller supports, the kiln chain curtain and the welding of cracks along the kiln shell. The project included a major relining of refractory material with magnesia bricks produced by the Magnezit Group and aluminosilicate refractory bricks produced by BKO. Maintenance work was also carried out on the plant’s FLSmidth Cross-Bar cooler.


Russia: Siberian Cement’s chair Oleg Sharykin has signed an agreement with the Sergey Tsivilev, the Governor of Kuzbass, to build a lime plant in the Kuzbass Special Economic Zone. The Euro23m project will create a 0.2Mt/yr lime plant with two kilns. The unit will use the Solominskoye limestone deposit, which is being developed by Topkinsky Cement, a subsidiary of Siberian Cement. Around 70 jobs are expected to be created. Russian lime production was reported at around 11Mt/yr from 2014 to 2020.


France/Germany: Cemex has introduced electric vehicles into the concrete mixer truck fleets of its subsidiaries in France and Germany. The El Financiero newspaper has reported that, if successful, the test may lead to continued introductions and tests of new prototype zero-emission concrete mixer trucks in its operations.


Australia: Boral has selected Earlytrade to digitise its supplier payment and progress claim processes. The supplier says that it will help protect Boral's supply chain against inflation and insolvency trends. It will roll out its early payment technology for 5000 suppliers of Boral products, as well as subcontractors, across Australia.


Sweden: Swecem has ordered a 10 000 S type road-mobile ship unloader from Bruks Siwertell for cement handling at the Port of Helsingborg. The unit will have a continuous cement unloading capacity of 300t/hr and is able to discharge vessels up to around 10,000dwt. It will be delivered fully assembled to the operator’s import terminal in May 2022.


US: Eco Material Technologies has successfully completed its acquisition of near-zero carbon cement alternatives producer Green Cement. Eco Material Technologies previously agreed to acquire Boral’s US fly ash business in December 2021, a transaction which it expects to conclude in 2022.


India: ACC has commissioned its Tikaria grinding plant in Uttar Pradesh after completing work to expand its capacity by 69% to 3.91Mt/yr. The plant will help ACC to serve the country’s increasing demand and increase its presence in Central India, according to the producer. The United News of India newspaper has reported that the company commenced the project in January 2021.

CEO and managing director Sridhar Balakrishnan said "ACC's strong belief and resilience in these difficult times enabled the team to commission the additional capacity at the Tikaria grinding plant. Meticulous planning and the collaborative approach of the Tikaria team has been the driving force in ACC’s setting a new benchmark in these unprecedented times."


Thailand: The Securities and Exchange Commission has approved Siam Cement Group (SCG)’s planned debenture issuance. Reuters News has reported that the value of the debenture is US$926m.


US: Argos USA has announced the upcoming transition of its Roberta, Alabama, cement plant to Portland limestone cement (PLC) Type IL production. By mid-2022, the company plans to produce 100% PLC at the 1.7Mt/yr plant. Its Durham, Statesville and Wilmington cement terminals in North Carolina will also transition to the exclusive distribution of PLC. The Roberta plant will directly serve customers in Alabama, Florida, Georgia and Mississippi.

Argos USA has also launched PLC production at its Harleyville, South Carolina, Newberry, Florida, and Martinsburg, West Virginia, cement plants. It aims to begin producing PLC at all of its cement plants nationally by 2024.

CEO Bill Wagner said "We are excited to announce the transition of the Roberta plant to 100% (PLC) Type IL. With this transition, we continue to support our customers and the industry on its road to lower greenhouse gas emissions. With PLC, we are supplying a more environmentally friendly building solution for our customers, engineered to deliver an outstanding quality and performance while lowering our carbon footprint.”


US: United States Lime & Minerals has announced its acquisition of Mill Creek Dolomite from InterRock Minerals. The value of the deal was US$6.4m.


Thailand: Sales from Siam Cement Group’s (SCG) cement business rose by 6% year-on-year to US$5.61bn in 2021. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 13% to US$145m. The company said that demand for cement improved gradually in the fourth quarter of 2021 following Covid-19 related shutdowns in the third quarter. Overall group sales were US$16.5bn in 2021, up by 33%, and net profit rose by 38% to US$1.4bn, boosted by the company chemicals division performance.

President and chief executive officer Roongrote Rangsiyopash said that its integration of environmental and social governance, along with a digital transformation, during the year contributed towards growth, along with a demand rise in line with the decline in Covid-19’s ongoing impacts.


Thailand: Siam City Cement's (SCC) sales, volumes and earnings picked up in the second half of 2021 following the easing of Covid-19-related lockdown measures in Thailand and Vietnam. Price rises, especially outside of Thailand, also reportedly helped to compensate for higher raw material, energy and transportation costs.

The group’s full-year consolidated sales fell slightly to US$1.28bn in 2021 from US$1.29bn in 2020. Sales revenue from its cement division rose by 3% year-on-year to US$842m but dropped by 19% to US$166m from its concrete division. Its overall earnings before interest, taxation, depreciation and amortisation (EBITDA) dropped by 6.8% to US$289m from US$310m. Net profit rose by 15.4% to US$131m from US$113m.


US: Eco Materials Technologies has finalised its US$1.05bn acquisition of Boral’s US fly ash business and launched an oversubscribed US$525m green bond issue. The issue will help it to become a global green cement production leader, according to the group. The Australian Financial Review newspaper has reported that subscriptions were four times the available bonds.


South Africa: A fuel tank explosions at a cement facility on Neptune Road in Gqeberha (formerly Port Elizabeth), which Global Cement believes may be Cemza’s Coega grinding plant, has killed a 40-year-old worker. Algoa FM News has reported that there were no other casualties or injuries. Police have launched an inquest into the tragic incident.


India: Nuvoco Vistas plans to increase its installed cement production capacity by 21% to 26.9Mt through capital expenditures of more than US$253m. The Hindu BusinessLine News has reported that the company will invest US$200m in the establishment of its upcoming 2.18Mt/yr Kalaburagi cement plant in Karnataka. It will invest a further US$53.1m in upgrading its Bhiwani, Haryana, blending plant to make it into a 2.4Mt/yr grinding plant. Additionally, Nuvoco Vistas will establish alternative fuel (AF) processing plants at its Nimbol, Maharashtra, and Risda, Chhattisgarh, cement plants.


Mexico: Cemex recorded consolidated net sales of US$14.5bn in 2021, up by 14% year-on-year. Sales rose by 10% to US$4.83bn in Europe, Middle East, Africa and Asia, by 9% to US$4.36bn in the US, by 23% to US$3.47bn in Mexico and by 16% to US$1.57bn in South, Central America and the Caribbean. The group’s operating earnings before interest, taxation, depreciation and amortisation (EBITDA) also rose, by 18% to US$2.86bn.

CEO Fernando González said “We are very pleased to report exceptional financial and strategic performance during 2021, despite the unprecedented challenges from Covid-19 and cost inflation.” He continued “In 2021, under our Future in Action programme, we accelerated our climate action ambition, establishing more aggressive 2030 decarbonisation goals as well as a detailed plant-by-plant roadmap to reach the targets. With our enhanced roadmap in place, we achieved our lowest carbon emission level on record and our largest annual year-on-year decline. And we pushed the boundaries on innovation, introducing new sustainable products and developing breakthrough decarbonisation technologies. Our performance gives me great confidence that we can reach not only our 2030 climate goal but also our Net Zero ambition.”


Philippines: Southern Concrete Industries Corporation says that it has doubled the planned capacity of its upcoming US$195m Davao del Sur cement plant in Davao Region to 4Mt/yr. The Philippine Fiscal Incentives Review Board (FIRB) approved a two-year income tax holiday and five years of enhanced deductions for the plant and duty exemptions for its equipment on 18 January 2022. The tax breaks will come into effect when the company commissions the plant in July 2022. CEO Ramon Ang said that the enlarged capacity will help to reduce the region’s reliance on imported cement and support infrastructure development on Mindanao.


India: ACC has announced its successful purchase at auction of the Kannur limestone block mineral reserve in Wadi, Kalaburagi District, from the Karnataka government. The producer plans to use the block to supply limestone for its Wadi cement plant.


Germany: Vecoplan Group has recorded its highest ever new order intake of Euro180m in 2021, up by 60%. The company said that its earnings before interest, taxation, depreciation and amortisation (EBITDA) for the year also set a company record.

CFO Michael Lambert said “Internationalisation is picking up speed. In line with this, we are implementing new sales and service centres throughout the world. Additional locations in various countries and regions are being planned.” He added “In 2022, we will be putting the spotlight on our digitalisation strategy and investing several million euros in software and hardware.”

CEO Werner Berens added a note of caution: “In spite of the good prospects for the new year, supply chains will continue to be disrupted by global factors like supply bottlenecks, raw material shortages and logistics problems. We too must show that we are able to deal with these big challenges.”


Japan: Sumitomo Osaka Cement recorded sales of US$1.19bn in the first nine months of the 2022 financial year, down by 22% year-on-year. The company’s net profit was US$71.7m. For its full-year 2022 financial year, the group forecast sales of US$1.61bn, down by 22% from full-year 2021 financial year levels. It expects full-year net profit to drop by 32% to US$69.2m.


Italy: Buzzi Unicem’s full-year consolidated sales rose by 8.9% in 2021 to Euro3.45bn. The group also increased its cement sales, by 6.7% to 31.2Mt.

Buzzi Unicem’s net financial position for the year was Euro231m, compared to a loss of Euro242m in 2020.


Spain: The Catalonia government has received a court order to close down LafargeHolcim España’s Montcada i Reixac cement plant in Barcelona. The Spanish Collection newspaper has reported that the plant failed to conform to new environmental regulations. LafargeHolcim España has appealed the decision.

The Montcada i Reixac plant currently employs 300 people. A union involved in the issue said that the alleged breach is formal rather than substantive and that an administrative error by the regional government caused the plant to breach the regulations.


Pakistan: Cement producers have reported a rise in operating costs. The News International newspaper has reported that costs have risen due to a hike in the price of imported Afghan coal. The price of the coal rose by 13% to US$170/t from US$150/t in the week leading up to 10 February. The rise brings it to just 23% below the price of imported coal from South Africa, which is currently US$236/t.

The Pakistani cement industry depends on imports of coal, of which 30 – 40% came from Afghanistan in Northern Pakistani cement production in 2021.


Pakistan: Power Cement has received the International Standards Organisation (ISO)’s ISO 50001:2018 certification for the energy performance of its management systems.

The producer said “We are on a never-ending quest to improve the environment for future generations by promoting the usage of sustainable energy.”