Global Cement Newsletter

Issue: GCW550 / 30 March 2022

Headlines


The economic fallout from the war in Ukraine continued this week with the news that Holcim plans to leave the Russian market. It said that it took the decision based on its “values to operate in the most responsible manner.” The company’s Russian subsidiary added that all of its plants would continue to operate as normal while it considered its divestment options.

Holcim’s road to withdrawal has been staggered. In February 2022 at the start of the war it pronounced its sympathy for any affected colleagues and their families and made a Euro1m donation to the Red Cross. Later it said that it would continue operating its business in Russia by following all regulations and supplying the local market. However, at this time it said it would suspend further capital investments in Russia and that it would “not benefit from our presence in this market.”

It’s unknown what prompted Holcim to take the plunge with Russia one month after the war started. At the very least, making decisions over assets valued this highly takes time. CM Pro has reported that the Russian government has considered introducing reference prices for building materials for infrastructure projects and that the Federal Antimonopoly Service (FAS) has been monitoring prices for ‘unreasonable’ growth over the last month. This follows grumbling by the Ministry of Industry and Trade in late 2021 about an apparent low capacity utilisation rate in the country despite shortages in the Central Federal District.

CRH said that it was leaving its Russian concrete business in early March 2022. Yet the decision by Holcim makes it the first of the three western multinational cement producers with large-scale operations in Russia to publicly say it’s pulling out. Holcim, HeidelbergCement and Buzzi Unicem each operate at least two integrated cement plants in the region.

Lafarge entered the Russian market in 1996. Its successor Holcim runs plants at Voskresensk and Kolomna in the Moscow region, at Ferzikovo in the Kaluga region and Volsk in the Saratov region. Together the plants have a production capacity of around 9Mt/yr. Over the last decade Holcim and its predecessor has invested at least a reported Euro1.3bn in three of the plants. The dry-production line Ferzikovo plant was built in 2015. The Shchurovsky plant in Kolomna was originally founded in 1870 and claims to be the oldest in the country. In 2011 it started commissioned a new dry production line. The Volsk plant started a modernisation project in 2017. The fourth, the Voskresensk plant, was mothballed in 2016. However, in early February 2022 LafargeHolcim Russia said it was aiming to spend Euro23m towards restarting production at the site. This was likely due to a boom in construction in 2021. The subsidiary also owns three aggregate quarries in the Republic of Karelia region of the country, near the border with Finland.

Selling up in Russia looks set to be difficult for Holcim. This is principally due to the European and American economic sanctions and the Russian government’s stated intention to nationalise the assets of any company trying to leave. This is clearly why Holcim has worded its plans so vaguely. If or when a peace deal is reached between Russia and Ukraine, the business environment could change significantly, depending on the terms, complicating any existing sale process. Determining how much Holcim might want to get from such a sale in these conditions is complex. Smikom bought Eurocement from Sberbank for Euro2.1bn in 2021 giving it 10 plants. Could Holcim realistically expect to sell its plants for around Euro200m each in the current environment? As for the hit Holcim might take, in its annual report for 2021 it said that the group’s Russian operations represented around 1% of the 2021 consolidated net sales. This would have been around Euro260m. Its Russian cement production capacity was reported as being 9Mt/yr in 2021 or 3% of the group’s global figure of 293Mt/yr.

Finally, it is worth noting though that Lafarge’s charges of ‘complicity in crimes against humanity’ also continued to be tested in the French courts this week. The legal case relates to the conduct of Lafarge in Syria between 2011 and 2014. This is totally separate from the situation in Russia but it does highlight the issue of corporate ethics for the group once again. Following proceedings in December 2021, Beat Hess, chair of the board of Holcim said, “The described events concerning Lafarge SA were concealed from the Holcim board at the time of the merger in 2015 and go completely against the values of our company.” Consider that use of ‘values’ again. Holcim may be about to find out how much it is prepared to pay for its values as it departs Russia.


Egypt: Suez Cement has appointed Mohamed Hegazy as its chief executive officer (CEO). He succeeds Jose Maria Magrina, who has held the post for six years. Magrina will start a new position as the CEO of HeidelbergCement Trading.

Hegazy is currently the commercial director of Suez Cement. He started his career with HeidelbergCement Group in 2007 as a sales representative for Suez Cement. He took over managerial roles in the sales and marketing departments, before being nominated as commercial director in 2017.


UK: Paul Brogan has started his two-year tenure as the chair of Mineral Products Association Northern Ireland (MPANI). He is the managing director of McQuillan Companies and has worked for the company for over 25 years. Paddy Mohan, the cement sales director of Mannok, will work as vice chair. MPANI is an industry body which represents the mineral products industry in Northern Ireland.


Japan: Tokuyama Corporation has signed a memorandum of understanding (MOU) with Mitsubishi Heavy Industries Engineering (MHIENG). Under the agreement, MHIENG will install a carbon capture demonstration plant at the producer's 4.7Mt/yr Nanyo plant in Yamaguchi Prefecture. It plans to commission the trial plant in June 2022 and operate it until March 2023. The supplier hopes to contribute to the early realisation of carbon neutrality in cement and other industrial fields through its work.


Ghana: FLSmidth has secured a contract for the supply of a clay calcination plant at CBI Ghana's 0.6Mt/yr Tema grinding plant in Accra. The supplier says that it will also install a complete grinding station to more than double the plant's production capacity. FLSmidth says that the entire project will reduce the Tema facility's CO2 footprint by 20%. When commissioned, the new clay calcination plant will be the largest in the world, according to the supplier.

CBI Ghana chief executive officer Frédéric Albrecht said “Ghana is the perfect location for using clay as an environmentally friendly alternative to clinker. West Africa is traditionally a clinker and cement-importing region due to the lack of suitable limestone reserves. Developing countries with their young populations and a growing need for infrastructure and housing represent the future in cement consumption. Calcined clay cements are the most sustainable alternative to traditional clinker-based cement."


India: Shiva Cement's board of directors has approved the launch of a shareholders' vote over plans to increase its Odisha cement plant's capacity by 2Mt/yr. The plan also involves the expansion of the same plant's clinker capacity by 3Mt/yr and the installation of a 12MW waste heat recovery (WHR) plant. In addition to this, the company is seeking to open two new limestone mines with a combined capacity of 1.9 - 3.1Mt/yr at Khatkurbahal, also in Odisha. The company has received Ministry of Environment, Forest and Climate Change approval for all of the plans.


World: The Global Cement and Concrete Association (GCCA) has launched new Net Zero Accelerator initiatives under its 2050 Net Zero Global Industry Roadmap strategy in several countries. The new initiatives will identify barriers to decarbonisation and recommend key actions in Colombia, Egypt, India and Thailand. The association will set out national roadmaps with reduction levers, identify funding possibilities and enter into policy dialogues with national governments. Together, the four countries account for 10% of global cement production.

Chief executive officer Thomas Guillot said "Last year, our industry made a breakthrough net zero global commitment. This is the next logical step as we move our focus from a global roadmap to driving decisive local action." He continued "Global cooperation between governments and industry is crucial to ensuring net zero targets are met. Our Net Zero Accelerators will offer collaboration and support to a number of target countries to help them decarbonise and align with the global roadmap. I'm proud to launch the first phase of the Accelerator programme to assist these nations in embracing greener technologies and work towards a more sustainable future together. I now call on more partners around the world to join us and be part of this movement."


India: JK Cement subsidiary Jaykaycem (Central) has secured a contract for the supply of cement for Rail Vikas Nigam's construction of a new line on the West Central Railway network between Devendra Nagar and Puraina in Madhya Pradesh. The line will be 50km in length.


China: CNBM’s sales revenue grew by 7% year-on-year to US$43.1bn in 2021 from US$40.1bn. Its sales volumes of cement and clinker fell by 3% to 332Mt and 13% to 40.4Mt respectively. Concrete sales volumes increased slightly to 112Mm3. Its adjusted earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 7% to US$8.11bn from US$7.6bn. The group increased its average cement prices by 10% in 2021. However, the group’s sales revenue from its engineering division fell by 29% to US$421m from US$590m, although its earnings recovered significantly. The group blamed this on “great uncertainty” in overseas markets due to the coronavirus pandemic although it said that producer’s willingness to invest was starting to recover.

Zhou Yuxian, chair of CNBM, said “The year 2021 was an extraordinary and tough year. In the face of complex environment abroad and numerous risks and challenges, China adhered to the general keynote of seeking progress in a stable manner, coordinating prevention and control of the Covid-19 pandemic and the development of economy and society, continuing the national economic recovery, taking a new step in building a new development pattern and achieving a good start of the 14th Five-Year Plan.”


Germany: ThyssenKrupp Uhde, Holcim and the Technische Universität Berlin have started a joint project to investigate the use of a novel amine scrubbing technology for carbon capture. The goal is to significantly reduce CO2 emissions from existing cement plants and at the same time utilise the captured CO2 for other applications. This includes the development of new mass transfer process equipment that is more efficient and resilient to contaminations. The project is being funded by the German Federal Ministry for Economic Affairs and Climate Action.

The equipment is being tested using exhaust gas at Holcim’s Beckum plant. Various possibilities for using the captured CO2 are also being examined, such as manufacturing methanol or sustainable fuels. The aim is develop a technology that can be retrofitted at existing cement plants.

Ralph Kleinschmidt, head of technology, innovation and sustainability at ThyssenKrupp Uhde said, "Amine scrubbing is already commonly used to recover CO2 from process gases or exhaust gases. Now, we are developing the technology further and optimising it for the cement industry. Additional applications for capturing CO2 direct at source, such as in waste incineration plants, are also possible."Arne Stecher, head of decarbonisation at Holcim Germany added that the company is testing different processes to find the best carbon capture technology.


Japan: Taiheiyo Cement has released its interim carbon neutral goals to 2030. The group intends to reduce its CO2 emission intensity across the entire supply chain by 20% or more compared to 2000. Total domestic CO2 emissions should be decreased by at least 40% compared to 2000. The company intends to invest US$820m towards these goals. Ultimately the cement producer wants to become carbon neutral by 2050.


Russia: Switzerland-based Holcim has announced its upcoming exit from the Russian cement market in line with its corporate value ‘to operate in the most responsible manner.’ The Global Cement Directory 2022 records a total of four Holcim cement plants in the country, commanding a capacity of 9.2Mt/yr.

Holcim’s board of directors thanked all employees currently mobilising to provide shelter, essential goods and medical supplies and other support to Ukrainians.

The group had previously suspended new capital investments into the market on 15 March 2022.


Italy: Buzzi Unicem’s earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 1.8% year-on-year in 2021 to Euro795m. Despite this, its net profit for the year declined by 3.2% year-on-year to Euro542m.

In 2022, Buzzi Unicem forecasts a 10% full-year EBITDA decline due to the impacts of the Russian invasion of Ukraine.


India: Shree Cement has commenced commercial production of clinker with the newly commissioned Kiln 3 of its Raipur cement plant in Chhattisgarh. The kiln has a production capacity of 4Mt/yr.


US: The California Department of Transportation (CalTrans) has approved the use of Portland limestone cement (PLC) in its projects. The California Nevada Cement Association (CNCA) says that the move has the potential to eliminate 25,500t/yr of CO2 emissions.

The CNCA plans to achieve cement and concrete carbon neutrality by 2045 through three priority actions. These are investment in promising and critical long-term technologies (crucially carbon capture, utilisation and storage (CCUS) technologies), increased alternative fuel (AF) substitution and the acceptance of PLC for CalTrans projects. Thus, the latest CalTrans decision marks the establishment of one pillar of the CNCA’s ambitious plan for net zero.


Australia: James Hardie Industries says that it has acquired land in Melbourne, Victoria, on which it plans to establish a fibre cement board plant.

Interim CEO Harold Wiens said "Adding a manufacturing site in the State of Victoria enables James Hardie to continue to meet the strong demand for our high-value building solutions in the Asia Pacific region. As we continue our strategic focus on marketing directly to the homeowner and commercialising market-led innovations, this site will help us not only meet this demand but enable the manufacturing of new innovations and existing high-value products."


Mexico: Cemex has published its 2021 Integrated Report. Under the report’s Climate Action section, Cemex recorded a 4.7% year-on-year decrease in its CO2 emissions per tonne of cementitious material. Alternative fuel (AF) substitution rose to 29%, while its products’ average clinker factor fell to 75%. It was the first company to complete a global roll-out of its reduced-CO2 cement and concrete range (Vertua). It established Science-Based Targets Initiative (SBTi)-verified well below 2°C 2030 climate action goals and joined the UN’s Race to Zero and the Business Ambition for 1.5°C coalition. It also became a founding member of the World Economic Forum’s First Movers Coalition for zero-carbon economic development.

The year also brought major Sustainability and Circular Economy milestones, including managing 57 times the volume of waste it sent to landfill, positively impacting 25m lives through its Social Impact Strategy and processing 61% of global sales through its Cemex Go digital sales platform. For the second consecutive year, its Net Promotor Score was 68, ‘substantially above’ the construction and engineering industry average.


China: Anhui Conch recorded a 4.7% year-on-year decline in its consolidated sales to US$26.4bn in 2021 from US$27.7bn in 2020. Its net profit was US$5.23bn, down by 5.3% from US$5.52bn. Anhui Conch attributed the decline to decreased cement demand. Its fuel and power costs increased by 30% in 2021. The producer forecast continued low market demand and high raw material and energy costs for the duration of 2022.

During the reporting period the group’s cement sales volumes fell by 9.8% to 409Mt. It increased its clinker, cement and concrete production capacities by 7.2Mt to 269Mt/yr, by 14.3Mt to 384Mt/yr and 10.5Mm3 to 14.7Mm3. It also installed photovoltaic power plants with a capacity of 200MW. By region, it said that market demand remained stable in East, Central and South China, although sales volumes declined slightly. However, it noted insufficient market demand in West China. The group’s export sales volumes fell by 43% but volumes and sales by its international subsidiaries grew by 7.5% and 5.3% respectively.


China: Jiangxi Wannianqing Cement’s consolidated net profit was US$251m in 2021. The figure represents a year-on-year increase of 7.6% from US$232m in 2020.


India: Sagar Cements has received board approval for the preferential allotment of a 10% stake of equity shares to Premji Invest. ET Now News has reported the value of the deal as US$46m.

Joint Managing Director Sreekanth Reddy Sammidi said “We are delighted to partner with Premji Invest and look forward to their inputs towards strengthening our processes and systems and enhancing value for all our stakeholders.”


France: Hoffmann Green Cement Technologies recorded sales of Euro2.38m in 2021, more than four times its 2020 figure of Euro504m. The company’s losses before interest, taxation, depreciation and amortisation (LBITDA) declined by 27% to Euro5.23m from Euro4.13m, while its net loss fell by 9.1% to Euro5.56m from Euro6.12m.

The producer confirmed its global sales target of Euro130m and EBITDA margin target of 40% by 2026, by which time it expects to have achieved sales of 550,000t/yr of its clinker-free cement in France. This would correspond to 3% of the domestic cement market. By 2026, it aims to operate four plants abroad.


Austria/Germany: RHI Magnesita and Horn & Co. Group have announced the consolidation of their recycling activities in Europe under Horn & Co. RHIM Minerals Recovery. The new subsidiary aims to increase the production, use and offering of secondary raw materials for the European refractory industry. The partners say that this will place the new entity at the forefront of the circular economy for customers in cement and other process industries. At the onset, Horn & Co. RHIM Minerals Recovery will process more than 150,000t/yr of secondary raw materials.

RHI Magnesita says that it can save 1.8t of CO2 for every tonne of recycled material used in its refractory production. It now expects to achieve its goal of 10% recycled materials ahead of its previously stipulated target date of 2025. It said that this marks an important step towards achieving a 15% reduction in CO2 emissions by 2025.

CEO Stefan Borgas said “By increasing our focus in this key area, we will make a significant contribution to global climate protection. We will conserve natural resources while at the same time expanding our business.” He added “With the combination of the recycling activities, RHI Magnesita and Horn & Co. Group become the driving force of circular economy in the refractory industry. Going forward, refractory users will benefit from increasing circular economy solutions included in our full line service contracts and customers of Horn & Co. RHIM Minerals Recovery will be able to source sustainable and high-quality raw materials.”


Austria: Lafarge Zement has announced the successful commissioning of a new raw meal mill at its Mannersdorf cement plant in Lower Austria. CEO Berthold Kren congratulated process engineer Nina Wolf and the Mannersdorf plant team for carrying out the Euro23m project.


Pakistan: DG Khan recorded sales of US$151m in the first half of its 2022 financial year, up by 25% year-on-year from US$120m in the first half of the 2021 financial year. Its profit for the period more than doubled to US$12m from US$4.41m. Its cement exports were valued at US$968,000, more than triple its US$230,000-worth of exports recorded in the first half of the 2021 financial year.


Turkey: Members of Türkçimento produced 78.9Mt of cement in 2021, up by 9.2% year-on-year from 2020 levels. Capacity utilisation for the year averaged 71%. Cement sales also rose, by 8.2% to 60.2Mt. Exports fell by 1.9% year-on-year to 30.8Mt, with a value of US$1.26bn, 23% of total sales.

Türkçimento chair Fatih Yücelik said that the sector has ‘rapidly and heavily’ felt the effects of the Russian invasion of Ukraine on its operations. Yücelik said “We continued our activities in 2021 under difficult conditions, following 23% year-on-year growth in 2020. We predict 4% growth in our sector in line with the economic growth target in 2022.”


Finland: Betolar has signed a letter of intent with Australia-based RISAB and the Vanadium Recovery Project to research the use of steel slag from which vanadium has been extracted in concrete production. Dow Jones Institutional News has reported that the company says that, through it Geoprime alkali-activated additive technology, the new slag source could replace 10% of the cement used in concrete production in Finland.

CEO Matti Löppönen said "We see a huge opportunity for Betolar here. If successful, we would be able to offer our customers a specific, currently unused slag of the steel industry to replace cement in concrete. Our customers already have experience in utilising other types of slag in the production of concrete using Geoprime. Utilising new side streams will expand the reach of our solution as planned.”

Betolar launched Geoprime in September 2021. It is currently developing a recipe-optimising artificial intelligence (AI) and data platform to bring together concrete producers and suppliers of slag, ash and other materials.


World: Market Research Future has forecast a 15% composite annual growth rate (CAGR) in global green cement demand between 2018 and 2023, where green cement is defined as fly ash cement, slag cement, geopolymer cement and other cements produced using alternative raw materials. Market Research Future predicts that fly ash cement’s global growth will be the sharpest due to its abundant availability. Its report concluded that cement sector strategies in response to the growth would include mergers, joint ventures and acquisitions.


Cambodia: Conch International Holding (HK) subsidiary Conch KT Cement has completed the feasibility study for its upcoming US$250m Kampong Speu cement plant at Monorom in Horng Samnan Commune. The Phnom Penh Post newspaper has reported that the company is collaborating with stakeholders to develop a ‘masterplan’ to manage all potential impacts revealed in the feasibility study. The plant is Conch KT Cement’s second in the country, with the help of which it hopes to secure a reliable domestic cement supply for Cambodians, making use of the kingdom’s abundant raw materials.

In the first 10 months of 2021, Cambodia imported US$40m-worth of cement, down by 33% year-on-year from US$59m in 2020.


Thailand: Siam Cement Group (SCG) has secured a contract with Denmark-based COBOD to provide Thai distribution services for the company’s COBOD 3D construction printers. SCG says that it will help the supplier to launch a construction sector transformation. It says that it chose COBOD’s printer as the option with the most in-market experience.

SCG International managing director Abhijit Datta said “3D construction printers have been widely used in many parts of the world with excellent results. The technology helps reduce waste and increase construction times with foolproof simulation and minimal numbers of labourers.” He continued “Together with COBOD, we will improve Thailand’s construction market with the future expectation of extending cooperation in the ASEAN. With our regional expertise and domestic solid business alliance relationship, we are ready to assist our partner in achieving long-term success.”


France: The Scientific and Technical Center for Building (CSTB) has certified Hoffmann Green Cement Technologies’ clinkerless H-UKR alkali-activated slag cement for structural use in buildings of all types. BusinessWire News has reported that the certification confirms the product’s safety, sustainability, lifespan and performance in conformity with Eurocode 2 and Eurocode 8 design standards.

Co-founders Julien Blanchard and David Hoffmann said “In the midst of ongoing frenetic communication regarding carbon neutrality, Hoffmann Green Cement is as usual endeavouring to back its announcements with verified and evaluated elements. The granting of these evaluations further objectifies the quality of our cement, notably with the awarding of a lifespan of 100 years. In this regard, we would like to thank the CSTB’s teams for drafting this unprecedented technical appraisal and our own teams who are working tirelessly on seeking innovative decarbonised solutions to preserve tomorrow’s world.”


UK: Concrete admixture producer Oscrete UK has appointed Matthew Gabriel to the role of new product development and sustainability manager. The company says that the appointment strengthens its commitment to sustainable construction.

Gabriel said “With the environment at the forefront of everyone’s minds, and customers looking to increase their use of supplementary cementitious materials (SCM), my priority is to develop products and processes which support our customers’ own route towards low carbon concrete.” He continued “Finding cost effective green solutions without impacting performance is key to the future of the construction sector. We are now looking to develop products that can help our customers to use or increase the use of products with a lower eCO2, hence the creation of a role dedicated entirely to this arena.”


Poland: The Building Research Institute has issued environmental product declarations (EPDs) for all six cement types produced at its Chełm and Rudniki cement plants and Gdynia grinding plant. The products in question were two CEM I cements, two CEM II Portland fly ash cements, another CEM II cement and a CEM III slag cement. Cemex Poland additionally obtained EPD certification for its Vertua Classic and Vertua Plus concrete products.

Materials director Michał Grys said “For us, product certification is another important step towards sustainable construction and a sustainable future. EPD declarations provide our clients with additional confirmation of the properties of products offered by Cemex Poland. They also improve their chances of obtaining LEED or BREEAM certificates for their investments.”