Global Cement Newsletter

Issue: GCW549 / 23 March 2022

Headlines


From the Nordics to the Mediterranean, European countries lead the field in reduced-clinker cement production using supplementary cementitious materials (SCMs). While consumers, faced with ever-greater choice, continue to opt for sustainability, projects to improve existing SCMs and develop new ones have won government backing and have become a matter of serious investment for other heavy industries beside cement. European cement producers’ decisions are steering the course to a world beyond CEM I. Yet, even in Europe, great untapped potential remains.

Companies generated a good deal of marketing buzz around their latest reduced-CO2 cement ranges in 2021 and the first quarter of 2022: Buzzi Unicem’s CGreen in Germany and Italy, Holcim’s EcoPlanet in six markets from Romania to Spain, Cementir Holding’s Futurecem in Denmark and Benelux, and Cemex’s Vertua in Spain and several other countries. All boast reduced clinker factors through the use of alternative raw materials. This, however, is really a rebranding of a long-established norm in Europe.

Since 2010, cements other than CEM I have constituted over 75% of average annual cement deliveries across Cembureau member countries (all cement-producing EU member states, plus Norway, Serbia, Switzerland, Turkey, the UK and Ukraine). This statistic breaks down differently from country to country. CEM II is the norm in Austria, Finland, Portugal and Switzerland, with deliveries in the region of 90%. Portland limestone cement (PLC) makes up a majority of deliveries in all four. It has been central to Switzerland’s transition to 89% (3.72Mt) of CEM II deliveries out of a total 4.18Mt of cement despatched in 2021. There, the main types of cement were CEM II/B-M (T-LL) Portland composite cement, with 1.38Mt (33%), and two different classifications of PLC: CEM II/A-LL PLC, with 1.28Mt (31%), and CEM II/B-LL PLC, with 888,000t (21%).

A second approach is that of the Netherlands, where CEM III blast furnace slag cement with a clinker factor below 65% predominates, favoured for its sulphate resistance and the protection it offers against chloride-initiated corrosion of steel reinforcement in marine settings. By contrast, the UK has traditionally maintained a higher reliance on CEM I cement. This can be partly explained by the preference of builders there for adding fly ash or ground granulated blast furnace slag (GGBFS) at the mixing stage. Nonetheless, CEM II Portland fly ash cement held a 14% (1.43Mt) market share in the UK’s 10.2Mt of cement consumption in 2021.

The UK Mineral Products Association (MPA) has identified limestone as an underutilised resource in the country’s cement production. Together with HeidelbergCement subsidiary Hanson Cement, it has applied for a change to National Application standards to allow the production of Portland composite cement from fly ash and limestone or GGBFS and limestone. The association has forecast that Portland composite cement could easily rise to 30 – 40% of UK cement consumption, and that this has the potential to eliminate 8% of the sector’s 7.8Mt/yr-worth of CO2 emissions.

Metallurgical waste streams have long flowed into European cement production, primarily as GGBFS, but also as bauxite residue. In 2021, alumina production in the EU alone generated 7Mt of bauxite residue, of which the bloc recycled just 100,000t (1.4%) that year. Two projects – the Holcim Innovation Center-led ReActiv project and Titan Cement and others’ REDMUD project – aim to produce new alternative cementitious materials from bauxite residue.

By collaborating with other industries, cement producers’ investments can most effectively reduce the overall cost of using these materials in cement production. In Germany, HeidelbergCement and ThyssenKrupp’s Save CO2 project aims to develop new improved latent hydraulic binders or alternative pozzolan from GGBFS by producing slag from directly reduced iron (DRI). The Save CO2 team believes that GGBFS substitution for clinker has the capacity to eliminite 200Mt/yr of CO2 emissions from global cement production.

Meanwhile in the world of mining, ThyssenKrupp and others’ NEMO project is investigating the recovery of a useable mineral fraction for cement production from the extractive waste of the Luikonlahti and Sotkamo mines in Finland and the Tara mine in Ireland, through bioleaching and cleaned mineral residue upcycling. This may give cement producers full access to Europe’s 28Bnt stockpiles of sulphidic mining waste, of which mines generate an additional 600Mt each year.

Denmark-based CemGreen, which produces the calcined clay supplementary cementitious material CemShale, is developing a shale granule heat-treating technology called CemTower. This consists of three pieces of equipment vertically integrated into cement plants’ preheaters, kilns and coolers, and brings the processing of waste materials – here oil shale – to the cement plant.

Lastly, cement producers are exploring the possible uses of waste made of cement itself. In Wallonia, HeidelbergCement subsidiary CBR’s CosmoCem project is investigating the production of alternative cement additives from large available flows of local demolition, soil remediation and industrial waste. Similarly, the Greece-based C2inCO2 project seeks to mineralise fines from concrete recycling for HeidelbergCement to use in the production of novel cements in its Greek operations.

In Switzerland, ZND Portland composite cement (produced using fine mixed granulate from building demolitions) is the third largest cement type, with 178,000t (4.3%) of total deliveries – narrowly behind CEM I with 239,000t (5.7%).Holcim Schweiz developed its Susteno 4 ZND Portland composite cement with Switzerland’s lack of any ash or slag supply in mind, demonstrating the potential flexibility of a circular economic approach to cement production.

On 21 March 2022, the University of Trier reported that it is in the process of mapping mineral resources, waste deposits and usable residues ‘on a cross-border scale,’ in an effort to produce new materials for use in cement production. Industry participants include France-based Vicat, CBR, Buzzi Unicem subsidiary Cimalux and CRH subsidiary Eqiom. Vicat is preparing a kiln at its 1Mt/yr Xeuilley cement plant in Meurthe-et-Moselle to use in testing new alternative raw materials developed under the project.

For Cembureau and its members, work continues, with the goal of Net Zero by 2050 constantly in sight. This goal includes a reduction in members’ clinker-to-cement ratios to well below 65%. In this, the association and its members are working towards a world not just beyond CEM I, but beyond CEM II, too. What exactly this will mean remains to be seen.

Sources

CemSuisse, ‘Lieferstatistik,’ 11 January 2022, https://www.cemsuisse.ch/app/uploads/2022/01/Lieferstatistik-4.-Quartal-2021.pdf

WSA, ‘December 2021 crude steel production and 2021 global crude steel production totals,’ 25 January 2022, https://worldsteel.org/media-centre/press-releases/2022/december-2021-crude-steel-production-and-2021-global-totals/

MPA, ‘Low carbon multi-component cements for UK concrete applications,’ July 2018, https://prod-drupal-files.storage.googleapis.com/documents/resource/public/Low%20carbon%20multi-component%20cements%20for%20UK%20concrete%20applications%20PDF.pdf

European Commission, ‘European Training Network for Zero-waste Valorisation of Bauxite Residue (Red Mud),’ 16 July 2020, https://cordis.europa.eu/project/id/636876

European Commission, ‘Industrial Residue Activation for sustainable cement production,’ 16 February 2022, https://cordis.europa.eu/project/id/958208

Recycling Portal, Zement der Zukunft – Forschungsprojekt „SAVE CO2“ gestartet, 28 May 2021, https://recyclingportal.eu/Archive/65677

h2020-NEMO, ‘Project,’ https://h2020-nemo.eu/project-2/

European Commission, ‘Green cement of the future: CemShale + CemTower,’ 14 April 2021, https://cordis.europa.eu/project/id/101009382

CosmoCem, ‘Communiqué de Presse,’ https://cosmocem.org/

CO2 Win, ‘C²inCO2: Calcium Carbonation for industrial use of CO2,’ https://co2-utilization.net/en/projects/co2-mineralization/c2inco2/

Les Echos, ‘Rendre le ciment moins gourmand en CO2,’ 21 March 2022, https://www.lesechos.fr/pme-regions/innovateurs/des-substituts-au-clinker-rendent-le-ciment-moins-gourmand-en-co2-1395002


China: China Resources Cement has appointed Tan Ying as its chief financial officer.

Tan, aged 45 years, joined China Resources Group in 2010 and has worked as the Assistant Controller, the Deputy Controller and the Deputy General Manager of the Finance Department. She holds a bachelor’s degree in economics from the China Institute of Finance and Banking and a master’s degree in business from the University of Sydney in Australia. She holds over 20 years of experience in finance, banking and corporate management.


Zimbabwe: Lafarge Zimbabwe has appointed Shepherd Shonhiwa as a non-executive director. The appointment took effect from 1 January 2022.

Shonhiwa has chaired the boards of companies based in South Africa including Sunday Times Newspapers, Times Media Eastern Cape Newspapers, Dispatch Media and the Institute of Directors South Africa. Over the past 30 years, he held the positions of chief operating officer at Times Media, chief executive officer of Tepco Petroleum, managing director of Shell LPG Southern Africa, managing director of Egoli Gas, general manager of Ford Swaziland and director of TA Management Services (Zimbabwe). He also runs a consultancy in executive leadership coaching, corporate governance, board effectiveness and strategy advisory. He is a Fellow of the Institute of Directors South Africa and the Institute of Personnel Management of Zimbabwe.

The subsidiary of Holcim also announced the retirement of David Leslie Cruttenden with effect from 31 December 2021. Cruttenden had served on the board of Lafarge Zimbabwe since 2006 and was the chair of the Audit and Risk Management Committee at the time of his resignation.


Germany: Australia-based Calix says that its LEILAC-2 carbon capture retrofit of HeidelbergCement's Hanover cement plant has passed its financial investment decision. The company is accordingly proceeding with detailed design and long-lead item purchasing. It will launch construction in 2023. Calix added that, due to a number of project risk flag points given the 'market situation,' it will not buy major components until closer to that time.

When commissioned, the installation will capture 0.1Mt/yr of CO2 and cost an estimated Euro20 - 25/t of CO2 captured.


France: Vicat plans to use a kiln at its 1Mt/yr Xeuilley, Meurthe-et-Moselle, cement plant for trials of cement production using new alternative raw materials developed under the international CO2Redres supplementary cementitious materials (SCM) project. The project brings together Vicat, HeidelbergCement subsidiary CBR, Buzzi Unicem subsidiary Cimalux and CRH subsidiary Eqiom in an effort to map mineral resources, waste deposits and usable residues ‘on a cross-border scale.’ On the basis of this research, the partners will seek to develop new SCMs for use in cement production.


Indonesia: Conch North Sulawesi Cement is receiving 50t/day of fly and bottom ash from the Amurang coal-fired power plant in North Sulawesi. Koran Metro News has reported that the Semen Conch subsidiary uses the ash as a supplementary cementitious material (SCM) in its cement production. The Amurang power plant currently holds 80,000t of the byproduct in stockpiles.


India: The Indian cement industry's sales volumes will rise by 18 - 20% year-on-year in the 2022 financial year and surpass 2020 financial year pre-Covid-19 outbreak levels by 6%, according to ratings agency ICRA. The Press Trust of India has reported that, in the first nine months of the 2022 financial year, fuel and electricity costs rose by 31%, raw materials costs by 12% and logistics costs by 5%. This offset a 5% net sales rise to result in an operating profit before interest, taxes, depreciation and amortisation (OPBITDA) per tonne of cement of US$14.70/t, down by 10% year-on-year. ICRA forecast a further decline in full-year OPBITDA per tonne of 16 - 18% to US$13.50 - 13.80/t in the 2022 financial year.


Brazil: InterCement’s sales revenue grew by 33% year-on-year to US$1.69bn in 2021 from US$1.28bn in 2020. Its cement and clinker sales volumes rose by 6.2% to 20.1Mt from 18.9Mt. All operating regions were reported to have growing volumes. Its adjusted earnings before interest, taxation, depreciation and amortisation (EBITDA) increased by 37% to US$470m from US$343m. The group said that, although input costs kept rising in 2021, it offset this with price increases.


South Africa: PPC expects its group cement sales volumes to increase by 4 - 8% year-on-year for the financial year to 31 March 2022 due to strong performance in Zimbabwe and Rwanda. In an operational update it said that sales revenue is also expected to rise by 11 – 15%. However, sales volumes and sales revenue growth was reported as slower in South Africa and Botswana due to strong demand due to home improvement projects during the previous period.

The cement producer noted that it had yet to experience any ‘meaningful uplift’ in cement sales following the government’s decision to only use locally produced on infrastructure projects. It said that cement sales in coastal regions of South Africa were behind those in the previous reporting year. It said that cement imports, mainly from Vietnam, increased by 11% and accounted for approximately 10% of the local market.


Malaysia: Sharuddin Omar Hashim, the managing director of Cement Industries of Malaysia Berhad (CIMA), says that rising input materials, especially coal, are driving up the cost of cement. He blamed the mounting price of coal on Indonesia’s export ban and the war in Ukraine, according to the Malaysian National News Agency. Sharuddin said that coal had previously cost up to US$70/t but it was now US$200/t, with the possibility of reaching US$400/t. Other raw material costs were also reported to have risen sharply due to logistic problems following the Covid-19 pandemic. Sharuddin added that his company is trying to optimise production and reduce production costs through the use of other alternative materials.


Oman: The Ministry of Commerce, Industry and Investment Promotion has held a meeting with cement companies, importers, distributors and related government departments to discuss cement shortages in some regions of the country. One local plant has suspended production due to high input costs, according to the Oman Daily Observer newspaper. However, Oman Cement Company says it is prepared to boost its production by 10% to meet local demand. Following the meeting the ministry has taken several steps to ensure the availability of cement across the country and maintain prices. These include increasing the production output at some cement plants and increasing imports.


US: Argos USA has agreed to sell a total of 23 US ready-mix concrete batching plants to Smyrna Ready Mix Concrete for US$93m. 18of the plants are situated in North Carolina and the remainder in Southwest Florida. The El Colombiano newspaper has reported that the deal includes a five-year cement supply agreement for all 23 plants. Cementos Argos said that the divestment is part of its plan to divest assets in suburban markets or that are not already integrated into its production and logistics chain.


China: China Shanshui Cement has forecast full-year consolidated operating revenues for 2021 of US$3.88bn, up by 18% from 2020 levels. Its profit meanwhile dropped by 13% to US$437m.


Pakistan: Maple Leaf Cement’s first-half standalone sales were US$121m in the 2022 financial year, down by 33% year-on-year from a first-half 2021 financial year figure of US$91.5m. Export sales fell by 46% to US$2.63m, 2.5% of total sales. Its main export markets were Afghanistan, the Seychelles, Oman and Tanzania. The company reported a 70% increase in its consolidated net profit to US$15.2m from US$8.97m in the first half of the 2021 financial year. The producer said that it expects the domestic cement market to remain ‘stagnant’ for numerous reasons, including high inflation, increased interest rates and decelerating implementation of projects under the Public Sector Development Programme.


Australia: Boral has updated the market that ‘exceptional’ wet weather on the East coast of Australia ‘significantly’ disrupted its New South Wales and South East Queensland operations in February and early March 2022. The Australian newspaper has reported that CEO Zlatko Todorcevski has forecast that the disruption to cement production and deliveries will have a negative impact of US$17.1m on the producer’s earnings in the first quarter of 2022. Coal and diesel costs have also risen ‘sharply’ so far in the quarter, to partly offset which the company has raised its cement prices. It now forecasts full-year earnings from continuing operations, excluding property, of US$108 – 115m.


India: TRA Research has named Ambuja Cements as India’s Most Trusted Cement Brand in its Indian Brand Trust Report 2022. The company also secured fifth place on the report’s Manufacturing category list.


China: China Resources Cement’s profit was US$993m in 2021, down by 13% year-on-year from 2020 levels. Its cost of sales grew by 22% to US$3.81bn from US$3.12bn. The group noted that the average cost of coal increased by 54% in 2021. It also pointed out that infrastructure investment growth slowed down in 2021. The company increased its turnover for the year by 9.7% to US$5.62bn. Sales volumes of cement and clinker fell by 7% to 81.3Mt and 7% to 3.3Mt respectively. Concrete sales volumes grew by 11% to 14.8Mm3.

During 2021 the group started construction of a second clinker production line and two cement grinding lines at its plant in Wuxuan, Guangxi. Once the upgrades are completed the plant will have a total cement and clinker capacities of 2.4Mt/yr and 1.4Mt/yr respectively. The group also acquired a 51% stake in Hunan Liangtian Cement in January 2022 to enter into the market in Chenzhou, Hunan. This company has cement and clinker production capacities of 1.6Mt/yr and 2Mt/yr respectively. An ongoing upgrade will increase the cement production capacity of 2.1Mt/yr. In March 2022 it sold its 72% stake in Shanxi China Resources Fulong Cement to Tangshan Jidong Cement to enable it to leave the northern market.

China Resources Cement has also been growing its co-processing capabilities in 2021. At the end of the year it reported 10 co-processing projects with a total capacity of 1.7Mt/yr. The projects, mostly based in Guangxi and Yunnan provinces, process municipal solid waste, urban sludge and industrial waste.


El Salvador: Cementos Fortaleza is establishing a new 0.3Mt/yr cement plant at Acajutla in Sonsonate Department. The Diario El Mundo newspaper has reported that the subsidiary of Grupo Regalado and Mexico-based Elementia plans to commission the plant in eatly 2023. The company will invest US$40m in its construction. The plant will produce its cement from 20% El Salvadorean-produced raw materials and will primarily serve local consumption, with the possibility of also exporting some cement.

Grupo Regalado representative Marcos Regalado Nottebohm said “It is challenging to invest in a project of such magnitude. This has been a natural step between two large business groups of great renown.”


Nigeria: BUA Cement’s Sokoto cement plant has resumed operations following a fire that killed three workers. The Sun newspaper has reported that the fire began at a diesel storage tank depot near to the plant, where third-party contract workers were welding a diesel storage tank. The group said that it activated a swift response in order to prevent any escalation of the incident.


US: New industrial nitrous oxide (NOx) emissions limits under the Environmental Protection Agency (EPA)’s proposed Good Neighbour Plan will cost US$1.1bn by 2026, according to the National Association of Manufacturers. US Political and Economic Organizations News has reported that the association claims that the cost of implementing the regulations may harm US manufacturing and the country’s economy.


Tanzania: Dangote Cement has signed an agreement with the Tanzanian Ports Authority whereby it will ship cement from its Mtwara cement plant and raw materials for its Tanzanian operations via the Port of Mtwara. Ecofin Agency News has reported that the company previously used the road network for both materials. This had a negative impact on local roads and prevented it from exporting the Mtwara cement plant’s cement overseas.


China: Fujian Jianfu Cement has hired Citic Heavy Industries to carry out engineering design, procurement, construction and delivery of its upcoming 4500t/day ‘green smart’ cement plant. Process Worldwide Online News has reported that the plant will cost US$136m and operate with a high degree of process automation. As such, Citic Heavy Industries will rely on 3D parametric equipment design and digital twin technology in order to generate equipment models, incorporate artificial intelligence (AI) and maximise data potential for lifecycle operations.


US: Buzzi Unicem has announced the upcoming transition of its 1Mt/yr Stockertown cement plant in Pennsylvania’s Northampton County to 100% Type IL Portland limestone cement (PLC) production in 2022. Local press has reported that Buzzi Unicem and its subsidiary Alamo Cement Company will have fully converted to PLC production at ‘several locations in the US’ before the end of the year, according to the group.


Spain: FYM-HeidelbergCement’s Málaga cement plant has temporarily ceased to produce clinker due to high electricity costs. The La Razón newspaper has reported that the effects of the Russian invasion of Ukraine have made clinker production economically unfeasible at the plant.


India: Employees of a contract firm working at Dalmia Cement’s Bokaro grinding plant in Jharkhand have allegedly killed a worker in an attack on 15 March 2022. The deceased’s roommate has also been missing since then. Both workers had been in trouble with their employer for refusing to work overtime. Operations reportedly continued as normal at the plant until other loading workers began a protest on 16 March 2022.

Dalmia Cement spokesperson Shyamlal Sahu said “The matter was brought to the notice of local police and they have started their probe. We are cooperating with them to bring the culprits to justice. We will work with the contractor – Durga Enterprises – to extend support to the bereaved family. We, at Dalmia Bharat, accord highest priority to maintaining internal harmony and a healthy working environment, and will work with our contractors towards ensuring that such untoward incidents do not happen in the future.”


India: The India Cements has launched Concrete Super King, a general application cement, and Halo Super King, a cement exclusively developed for use in the production of precast hollow dense concrete blocks.

Vice chair and managing director Narayanaswami Srinivasan said that many of the company’s customers already rely on its products in their precast hollow dense concrete block production. With the launch of Halo Super King, it hopes to further increase the ease of application.


Greece: Titan Cement recorded Euro1.71bn in net sales in 2021, up by 6.7% year-on-year from Euro1.61bn in 2020. The company attributed the boost to higher demand and ‘supportive pricing’ in all of its regions. Cement sales volumes were 18.3Mt, up by 7% year-on-year from 17.1Mt. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) dropped by 4.6% to Euro272m from Euro286m, due to an ‘unprecedented’ second-half costs increase. The group’s net profit was Euro89.6m, compared to Euro1.1m in 2020. During the year, Titan Cement increased the digitisation of its cement production and continued its on-going share buyback programme. Its Scope 1 and 2 CO2 emissions declined by 4% year-on-year, in line with its 2030 target trajectory.

Titan Cement said “Having already achieved the 2025 targets for energy efficiency and zero waste-to-landfill certification, the group’s attention is now focused on empowering business ecosystems to incorporate sustainability considerations in their decision making. To ensure that key suppliers meet the group’s environmental, social and governance (ESG) standards, Titan Cement developed a sustainable supply chain roadmap and published the first Titan Group Procurement Policy.” In the coming year, the group plans to ‘continue to harness the advantages offered by decarbonisation, digital transformation and business model innovation to benefit our customers, employees, suppliers and communities, aspiring to deliver to society carbon-neutral concrete by 2050.’


India: Shree Cement has fired up the kiln of a new clinker line at its Raipur cement plant in Baloda Bazar, Chhattisgarh. The Business Standard newspaper has reported that the company funded the project, involving the reactivation of the Raipur plant’s Kiln 3, from its internal accruals. It has also installed a new waste heat recovery (WHR) plant alongside the kiln. The line will augment Shree Cement’s supply of clinker to its grinding plants in Eastern India. It hopes thereby to contribute to growth and development in Chhattisgarh and beyond.


France: Lafarge France has announced a total planned investment of Euro46m in upgrades to its 1.6Mt/yr Saint-Pierre-la-Cour, Mayenne, cement plant and its 1.2Mt/yr La Malle, Bouches-du-Rhone, cement plant. The Holcim subsidiary will invest Euro40m to convert the Saint-Pierre-la-Cour plant to low carbon cement production. Meanwhile, it will invest Euro6m in the La Malle plant’s conversion to ultra-low carbon cement production. The L’Usine Nouvelle newspaper has reported that the transitions will complement the company’s strategy of over 25% EcoPact reduced-CO2 ready-mix concrete sales by 2025.


Ireland: CRH says that it completed another phase in its on-going share buyback programme on 16 March 2022. The group purchased US$300m-worth of shares, bringing its total cash returned since the beginning of the programme in May 2018 to US$3.2bn. On 17 March 2022, it concluded an agreement to begin the purchase of a further US$300m-worth of its shares by 27 June 2022. The producer instructed investors that any decision in relation to any future buyback programmes will be based on an ongoing assessment of the capital needs of the business and general market conditions.


New Zealand: Holcim Australia and New Zealand plans to establish a new low carbon cement import and distribution facility next to its existing cement terminal at Ports of Auckland. The company says that the facility will have the capacity to replace 100,000t/yr of ordinary Portland cement (OPC) used in New Zealand. In 2021, the country consumed 1.6Mt of cement, generating 1.3Mt of CO2 emissions.

CEO George Agriogiannis said “I’m pleased Holcim Australia and New Zealand is progressing to the building phase of a facility that will import and distribute low carbon cement replacement products. Once operational, the site will enable the reduction of carbon emissions via a cement replacement which can be used for applications such as infrastructure, commercial and residential projects.” He concluded “This initiative is a positive step toward the New Zealand government’s Zero Carbon ambitions and Holcim’s Net Zero climate pledge.”