Global Cement Newsletter

Issue: GCW551 / 06 April 2022

Headlines


African cement producers have confirmed their interest in calcined clay over the last month with two new projects. The big one was announced last week when FLSmidth revealed that it had received an order from CBI Ghana. This follows the launch of a Limestone Calcined Clay (LC3) project in Malawi in mid-March 2022 in conjunction with Lafarge Cement Malawi.

FLSmidth says that its order includes the world’s largest gas suspension calciner system and a complete grinding station. The kit will be installed at CBI Ghana’s plant near Accra in the south of the country. The new clay calciner system is expected to substitute 30 - 40% of the clinker in the final product, resulting in a reduction of up to 40% CO2/t of blended cement compared to Ordinary Portland Cement (OPC). Overall the equipment manufacturers reckon that the grinding plant will reduce its CO2 emissions by 20% compared to its current output. There has been no indication of how much the order costs but CBI Ghana expects energy and fuel savings, as well as lower overheads from clinker imports.

The public announcement of the Ghana project was also foreshadowed by the visit of Professor Karen Scrivener to the Ghana Standards Authority in February 2022. This was significant because Scrivener is the head of the Laboratory of Construction Materials at the Ecole Polytechnique Fédérale de Lausanne (EPFL) and has been one of the key instigators of the LC3 initiative since the early 2000s. Other calcined clay cements are available such as Futurecem or polysius activated clay (see below) but LC3 is arguably the most famous given its promotion in developing countries.

The Malawi project is at a much earlier stage. The government launched the public private partnership LC3 project in mid-March 2022 in conjunction with Lafarge Cement Malawi and Terrastone, a brick manufacturer. The Ministry of Mining is currently developing a memorandum of understanding with the Gesellschaft für Internationale Zusammenarbeit (GIZ), a Germany-based development agency. India-based Tara Engineering has also been linked to the scheme.

One thing to note about the Malawi project is that it is the first calcined clay project in the cement industry based in East Africa. All the other African ones are based in West Africa. The other two projects in this region are run by Turkey-based Oyak Çimento and its subsidiary Cimpor. The first of these is a 0.3Mt/yr calcined clay and a 2400t/day cement grinding production line that was commissioned in mid-2020. This plant is based at Abidjan in Ivory Coast. The second is a new plant that Germany-based ThyssenKrupp Industrial Solutions is building for Oyak Çimento at Kribi in Cameroon. This unit has a 720t/day calcined clay and a 2400t/day cement production capacity and it will use the supplier’s ‘polysius activated clay’ technology. ThyssenKrupp’s involvement came to light in early 2020 and commissioning was scheduled for late 2021. However, no update on the state of the project has been issued so far in 2022.

As the above examples show, Sub-Saharan Africa has at least one live calcined clay plant, two plants are being built and there’s one more at the development stage. This puts the region neck-and-neck with Europe, which has a similar mixture of current and developing projects. This column has been covering the wider trend of the growing usage of various types of blended cements recently, particularly in Europe and the US, with slag cements, Portland Limestone Cement (PLC) and more. With PLC, for example, note the transition of another two North American cement plants to PLC this week alone. As for calcined clay cement, it is fascinating to see the focus move to a different part of the world. Several commentators have predicted that the future looks set to be dominated by blended cements using whichever supplementary cementitious material (SCM) is most available for each plant. The growth in calcined clay confirms this view.

Global Cement is researching clay calcination use in the cement industry for the next edition of the Global Cement Directory. Email rob@propubs.com with any information on new industrial and research installations.


Mexico: Corporación Moctezuma has appointed Julio Rodríguez Izquierdo as the chair of its board of directors. This follows the resignation of Enrico Buzzi from the post. The change is a planned and periodic rotation of the holder of the role between the company’s two controlling shareholders: Spain-based Cementos Molins and Italy-based Buzzi Unicem. Together, the European cement companies own a 66.7% share of Corporación Moctezuma.

Rodriguez Izquierdo, a 60-year-old Spanish national, is the chief executive officer of Cementos Molins. Prior to becoming the head of Cementos Molins in 2015, he worked for over 30 years at Schneider Electric in a variety of roles before becoming the Executive Vice President Global Operations in 2011.


Pakistan: Power Cement has appointed Irfan Sikander Bawa as its chief financial officer. He succeeds Tahir Iqbal.


South Korea: Seven cement producers have agreed to produce 3.77Mt of cement in the second quarter of 2022, up by 36% quarter-on-quarter from first-quarter 2022 levels, to alleviate a shortage. 380,000t of cement which would previously have been exported will now supply the domestic market instead. The Yonhap News Agency has reported that bituminous coal supply issues have hampered the domestic cement industry's ability to increase its production in line with demand growth. In the first quarter of 2022, South Korea's coal imports consisted of 54% Russian coal and 46% Australian coal, compared to 75% Russian and 25% Australian coal in 2021.

The government plans to invest US$764m between 2023 and 2030 in improving the sustainability of South Korean cement production, including moving it away from reliance on coal through increased alternative fuel use.


UAE: Switzerland-based ABB has carried out an upgrade of the control system for UltraTech Cement subsidiary Star Super Cement at the company's Dubai grinding plant. The supplier says that it installed its ABB Ability 800xA distributed control system (DCS) across three grinding units at the facility. The DCS will communicate between the plant and the company's Ras Al Khaimah clinker plant. ABB previously supplied electric and automation engineering services for the Ras Al Khaimah plant in 2012.

ABB Process Industries global cement lead Max Tschurtschenthaler said that Star Cement's operations will benefit from improved operator visibility, easier maintenance and reduced downtime due to the new systems.


US: Cemex has increased production of Portland limestone cement (PLC) at its Lyons plant in Colorado. PLC is expected to become the plant’s primary product by the summer of 2022. The blended cement has been produced at the site for over 15 years. However, Cemex says it is growing production to meet the company’s carbon reduction goals and meet increased demand for lower carbon materials.

Cemex USA has also increased PLC production at its plants in Brooksville, Florida, and Demopolis, Alabama. The start of PLC production or further increases is planned for other cement plants later in 2022.


US: Drake Cement despatched 80,000t of cement in March 2022, its highest ever figure. The company has congratulated colleagues on the record volumes.


Argentina: Christian Dedeu, the chief executive officer of Holcim Argentina, has warned that there is no guarantee that there will be gas available for his company’s cement plants in the winter of 2022. In an interview with the El Cronista newspaper, Dedeu said that energy prices had risen due to the war in Ukraine and that importing liquefied gas by ship was becoming both harder and more expensive.

He also expressed concern about the government system of price controls on bagged cement, which had made it cheaper to buy bagged instead of bulk cement. Smaller companies are already reportedly buying large consignments of bagged cement and breaking it up to save money.


Japan: Logistics group Tohbu Network has acquired Shiogama-based cement distributor Tohoku Sanko. The Nikkei newspaper has reported that Tohoku Sanko serves the customers of cement producers in Akita and Miyagi Prefectures. The group aims to expand its sales footprint and its productivity through shared use of vehicles, facilities, software and human resources.


Norway: HeidelbergCement, agricultural cooperative Felleskjøpet AGRI and shipping company Egil Ulvan Rederi plan to build what they say will be the world's first zero-emission bulk carrier. The project has also received support of around Euro12m from the Norwegian government-owned sustainability company Enova. The vessel is scheduled for completion and commissioning in 2024. Once operational the ship will be used to transport aggregates products for HeidelbergCement and grain for Felleskjøpet between west Norway and east Norway using hydrogen powered transport.

Egil Ulvan Rederi was selected following a tendering process in 2021. The ship is intended to be highly energy efficient, using rotor sails and has a streamlined design to reduce energy consumption. It will be powered by hydrogen from Norwegian energy supplier Statkraft but will also have small auxiliary batteries and a fuel cell on board to maximize flexibility.

Giv Brantenberg, general manager HeidelbergCement Northern Europe, said “The project addresses emissions from the transport part of our value chain. It is unique, ambitious and future-orientated. It is fully in line with HeidelbergCement Group's target to be the leading actor in our industry on the path to carbon neutrality." HeidelbergCement estimates that the carbon footprint of the aggregates products can be reduced by 50 - 60% by using the zero emission vessel, as transport accounts for a significant part of the total carbon footprint of these products.


Switzerland: Environmental activists have occupied a forest on private land next to the Gabenchopf quarry that supplies limestone to Holcim Schweiz’s Siggenthal cement plant. The activists are protesting about a planned expansion to the quarry, according to the Blick newspaper. Police have described the mood of the activists as ‘peaceful.’ The occupation follows a similar protest against expansion of another Holcim-owned quarry at Mormont, Vaud, in 2021.


UK: Holcim subsidiary Aggregate Industries has launched an accelerated careers programme for Ukrainian refugees called Jobs for Ukraine. The programme offers a fast and supportive recruitment process with a view to finding Ukrainian refugees suitable employment in the UK. Candidates may access online registration here.


US: Lhoist North America and Mississippi Lime Company have announced price increases for their products subject to existing contractual obligations.

Lhoist North America increased its prices by 10% for lime, limestone and clay products from the start of April 2022. It blamed this on inflation upon the cost of chemical additives, electricity, explosives, diesel, mining equipment, spare parts, inbound transportation, mining services and other inputs.

Mississippi Lime Company has announced that it will increase its prices by 7% from the start of May 2022. It cited a combination of market demand, inflation and supply chain issues.


France: Hazemag has opened an office at Sarreguemines. Its French team will support a growing customer base in France, francophone parts of Europe and some territories in North Africa. The Germany-based group supplies equipment such as screeners, feeders and crushers for raw material markets.


Egypt: Sinai Cement’s consolidated sales were US$78.9m in 2021, up by 62% year-on-year from US$48.7m in 2020. The company recorded a loss of US$19.4m, down by 37% year-on-year from US$30.7m in 2020.


Saudi Arabia: Yamama Cement has signed a US$443m financing agreement with Saudi National Bank (SNB). The company plans to invest the funds in its relocation of a 10,000t/day kiln line to its Northern Halal, Al Kharj, plant from the site of its former plant in Riyadh. This will help towards its aim of increasing the Northern Halal plant’s capacity to 30,000t/day by 2025. The loan consists of US$213m in long-term financing for a period of eight years, US$150m in refinancing of the long-term funding for a duration of four years and US$80m in short-term financing for one year.


Malawi: The Germany-based Gesellschaft für Internationale Zusammenarbeit (GIZ) has launched the construction of a clay calcination plant in Malawi, called the Limestone Calcined Clay Project. The Nyasa Times newspaper has reported that the government has said that increased calcined clay use can reduce domestic cement production’s carbon footprint by a third.


France: Sustainable concrete producer Materrup has shared plans for its upcoming Bordeaux precast concrete elements plant. The L’Usine Nouvelle newspaper has reported that the facility will produce precast elements from Materrup’s cement-free concrete, which it produces from uncalcined clay, an activator and a precursor at room temperature. The technology, called Clay Cement 1 (MCC1), reduces CO2 emissions by 50 – 80% compared to ordinary Portland cement (OPC), according to the producer. It previously opened a Euro7m 50,000t/yr plant in the Atlantisub Business Area in Saint-Geours-de-Maremne, Nouvelle-Aquitaine.


UK: Cemex UK has announced the global launch of its OnPoint coloured cement mortars for off-site and urban architectural applications. The range includes 35 colour palette options.

Europe regional mortars sales manager Mike May said “On heritage projects, we can now accurately colour-match existing mortars for repointing and maintenance work. Our existing buildings account for more than 35% of the world’s energy consumption, so solutions like Cemex OnPoint can significantly contribute to a more efficient built environment and a better future for all.”


Nigeria: BUA Cement recorded consolidated sales of US$619m in 2021, up by 23% year-on-year from US$504m in 2020. Bagged cement sales rose by 23% to US$618m, while bulk cement sales rose by 40% to US$1.48m. Cost of sales was US$328m, up by 19% year-on-year, and the company recorded a profit after tax of US$217m, up by 25% from US$174m in 2020.


France: The European Commission (EC) has awarded funding under its Innovation Fund 2021 for CRH subsidiary Eqiom’s upgrade to its Lumbres, Hauts-de-France, cement plant. The work includes the replacement of a kiln and the installation of a carbon capture, utilisation and storage (CCUS) system at the plant, in collaboration with Air Liquide. The producer says that the project is one of seven selected under the EC’s K6 programme of innovation funding in line with the EU Green Deal.


Tanzania: Tanga Cement has advised investors that it expects a ‘significant improvement’ in its results to a profit before tax in 2021, compared to a loss in 2020. The Daily News newspaper has reported that strong sales during the year contributed to the forecast result, along with a drop in finance costs due to a restructuring of debt facilities.

Tanga Cement said “The improved performance is a result of Tanga Cement’s initiative to optimise the sales, logistics and distribution, as well as its continued cost optimisation initiative.” It added “The company has been able to achieve this despite the challenging global economic and operating environment conditions.”


Pakistan: Three DG Khan Cement workers have been kidnapped by the local Ladi gang from the company’s Dera Ghazi Khan cement plant. The Dawn newspaper has reported that the employees has been inspecting the plant’s raw materials belt when the kidnap occurred.


US: Cementos Argos subsidiary Argos Florida Cement has won the Slag Cement Association (SCA)’s Durability and Infrastructure awards at its 2022 Sustainable Concrete Project of the Year Awards. The producer won the awards for its supply of slag cement to two projects in Florida in 2021. Its involvement in the American Bridge Company’s SR 679 Pinellas Bayway Bridge – Structure E replacement won it the Durability award, while its involvement in Superior Paving’s State Road 52 realignment. Argos Florida Cement congratulated its customers, who also received the awards.


Brazil: Votorantim Cimentos recorded a 37% year-on-year rise in its adjusted earnings before interest, taxation, depreciation and amortisation (EBITDA) to US$1.10bn in 2021. Its sales rose by 33% to US$4.71bn, while its profit more than tripled to US$2.1bn. The group’s sales grew in all of its regions. Its cement volumes totalled 37.2Mt, up by 15% from 2020 levels. Its capital expenditure (CAPEX) investments grew by 30% year-on-year to US$317m. It commissioned a new production line at its Pecém grinding plant in Brazil and continued to work on an upgrade to Cementos Artigas’ Sayago grinding plant in Uruguay, scheduled for completion in 2022. It also completed its acquisition of Spain-based Cementos Balboa.

Cement operations, logistics and adjacent businesses director Osvaldo Ayres Filho, who was serving as group CFO during 2021, said “We had a record financial performance in 2021, despite the challenging environment due to the ongoing effects of the pandemic and global inflationary pressure.” He added that the producer also made ‘significant strategic moves.’


Pakistan: Lucky Cement plans to install a 34MW solar power plant at its Pezu power plant in Khyber Pakhtunkhwa. The Balochistan Times newspaper has reported that the 48GWh/yr installation will be equipped with a 5.59MWh Reflex energy storage system. Both the power plant and energy system will be the country’s largest when commissioned. Fossil fuel generation will remain online, but be shut down in the daytime, saving 26,600t/yr of CO2 emissions.


Russia: The government is ‘working to establish import flows’ of building materials from Uzbekistan. Russian media sources have reported that the construction industry is also hoping to expand import partnerships with China, India, Iran and Turkey. Russian cement production reportedly continues to adequately serve the national demand for cement.


India: Jaiprakash Associates has defaulted on its scheduled repayments of loans worth US$381m. Dion News Service has reported that the debt consists of US$203m-worth of overdue payments and a further US$178m in principal. The group’s total indebtedness is reportedly US$3.63bn. Its lenders include
HDFC Bank, Bank of India, Union Bank of India and over 30 other institutions.


US: Summit Materials subsidiary Continental Cement’s 1.1Mt/yr Davenport, Iowa, cement plant has become the latest US cement plant to transition to 100% Portland limestone cement (PLC) production.

Summit Materials executive vice president Tom Beck said "Our transition to PLC at Davenport aligns with the Portland Cement Association (PCA)'s Roadmap to Carbon Neutrality.” He continued “It is critical that the industry comes together and acts now to create sustainable building solutions for decades to come. The US cement and concrete industries can collectively address climate change, decrease greenhouse gas emissions and eliminate barriers that are restricting environmental progress through the continued adoption of product and manufacturing innovations."


US: Holcim has announced the rebranding of its US-based LafargeHolcim US subsidiary to Holcim US. The name change is the first in any region since parent company LafargeHolcim became Holcim in July 2021. The producer says that this regional rebrand marks a ‘significant milestone’ towards establishing a shared purpose and vision across its global operations.

Holcim will continue to work towards becoming the global leader in innovative and sustainable building solutions through building progress for people and the planet.


India: ACC has launched its new Concrete Direct app for booking and live tracking concrete deliveries. The producer says that the app reduces operational follow-up calls.

Managing director and CEO Sridhar Balakrishnan said “At ACC, we recognise the need to improve and lead through digitalisation. We are happy to launch Concrete Direct, a premium digital tool that saves time and money for our customers. With such innovations, we want to enhance customer experience and build a strong ecosystem of partners to support them.”


Peru: Unacem’s sales were US$655m in 2021, up by 43% year-on-year from US$458m in 2020. It sold US$598m-worth of cement, up by 41% year-on-year from US$425m-worth, and exported US$30.3m of clinker, up by 35% year-on-year from US$22.5m-worth.

The producer said “2020 and 2021 have been years of great challenges for the world and our country because of the Covid-19 pandemic. In this context, the company implemented a plan of measures that has allowed it to cope with this crisis, having as a fundamental pillar ensuring the safety and health of its employees, the sustainability of the company and all its shareholders. Likewise, the Peruvian government continues to take the necessary actions to mitigate the effects of the third wave of Covid-19 as well as to safeguard the payment chain of companies.”


India: RCCPL, a subsidiary of Birla Corporation, has commenced cement despatches from its 2.7M/yr Mukutban cement plant in Maharashtra. The plant has a further grinding capacity of 1.2Mt/yr and a 40MW captive power plant. Switzerland-based ABB previously delivered electrification and automation systems to the site of the new plant in June 2020.


Canada: Lafarge Canada has converted its Richmond, British Colombia, cement plant to 100% OneCem Portland limestone cement (PLC) production. OneCem cement’s CO2 emissions per tonne are 13% below the Canadian PLC average. The Richmond plant has supplied OneCem cement to the Western Canada and US Pacific Northwest customers since 2011. Since that time, it has eliminated 1.18Mt of CO2 emissions, according to the producer.

President and CEO Brad Kohl said "Collaborating with local government and stakeholders was key to ensuring OneCem PLC’s uptake in the market, and conversion away from traditional high-intensity cement products. As industry leaders, we want to facilitate access to low carbon cements across Canada, and starting with Richmond is a big step towards making that happen."


UK: Edie has named Holcim’s chief sustainability and innovation officer Magali Anderson as laureate of its Sustainability Leader of the Year award at the Sustainability Leaders Awards 2022. The awards recognise leaders from across all sectors of UK industry. Naturalist Chris Packham hosted the event in Westminster, London.


Morocco: The Professional Association of Cement Manufacturers (APC) has recorded domestic cement deliveries of 14Mt in 2021. The figure corresponds to 58% of the industry’s 25.8Mt/yr capacity.