Global Cement Newsletter

Issue: GCW561 / 15 June 2022

Headlines


Coolbrook has been in the news recently with collaboration deals struck with Cemex and UltraTech Cement. First the Finland-based company officially launched its Roto Dynamic Heater (RDH) technology with a memorandum of understanding signed with Cemex in May 2022. Then, this week, it signed a similar agreement with UltraTech Cement.

The specifics of either agreement are unknown but the target is clearly to build an industrial pilot of an electric kiln – or something like it - at a cement plant. Coolbrook says it has run a pilot of its RDH technology in Finland. Further tests are now scheduled to continue for two years starting from September 2022 at the Brightlands Chemelot Campus at Geleen in the Netherlands. Commercial scale demonstrations are scheduled from 2022 with the hope of commercial use from 2024. Links with Cemex and UltraTech Cement seem to suggest progress. At the same time Coolbrook will be testing its RotoDynamic Reactor (RDR) technology, which promises to electrify the steam cracking process used in plastic manufacturing.

Publically available details on the RDH technology are light. In its promotional material Coolbrook says that it can achieve process temperatures of up to around 1700°C. This is crucial to achieve full clinker formation in a cement kiln. Reaching this temperature with non-combustion style kilns, such as solar reactors, has previously been a problem. Notably, Synhelion and Cemex said in February 2022 that they had managed to produce clinker using concentrated solar radiation. Retrofit possibilities and compact equipment size are also mentioned in the promotional material for the RDH. The former is an obvious attraction but size of equipment footprint is increasingly emerging as a potential issue for cement plants looking to reduce their CO2 emissions. Rick Bohan from the Portland Cement Association (PCA) presented a summary of the potential and problems of emerging carbon capture and utilisation/storage (CCUS) technologies for cement plants in the US at the Virtual Global CemCCUS Seminar that took place on 14 June 2022. He noted that installing CCUS equipment makes cement plants start to look different (more like petrochemical plants in the view of Global Cement Weekly) and that they may require more space to install it all.

Coolbrook hasn’t been the only organisation looking at kiln electrification. The installation with the most available information on kiln electrification has been the Decarbonate project, led by the VTT, formerly known as the Technical Research Centre of Finland. The project has built a pilot rotary kiln with a length of 8m inside a shipping container. It has a production capacity of around 25kg/hr. The system reportedly uses fixed radiant heating coils around the kiln, surrounded by insulation materials. Early results presented to the 1st Virtual Global CemPower Seminar in late 2021 were that the kiln started up, sufficient calcination was occurring and the system was operated continuously for three days at a temperature of 1000°C with no problems reported. Further research was scheduled to carry on into 2022 with longer trials planned for three different materials.

HeidelbergCement’s subsidiary in Sweden, Cementa, completed a feasibility study on implementing electrified cement production at its Slite plant in 2019. It then said that it was conducting further study with electricity producer Vattenfall as part of CemZero project. This consists of three projects running to 2025. Namely: heat transfer with plasma in rotary kilns; direct separation of carbon dioxide from calcination of carbonate-based raw materials in the production of cement clinker and burnt lime; and carbon dioxide-free products with electrified production - reactivity of cement clinker with secondary additives. HeidelbergCement has since announced plans to build a full scale 1.8Mt/yr carbon capture and storage (CCS) plant at the Slite cement plant by 2030.

How this would fit with any kiln electrification plans is unknown. However, one attraction of moving to an electrical kiln, for all of the projects above, is to cut out the 40 – 50% of a cement plant’s CO2 emissions that arise from the fuel that is burnt. Taking a kiln electric also makes CO2 capture easier. Much of the remainder of the CO2 released comes from the decomposition of limestone during calcination when clinker is created. Substitute out fossil or alternative fuels and the flue gas becomes much purer CO2.

It is early days for cement kiln electrification but progress is happening both commercially and scientifically. The next step to watch out for will be the first pilot installation at a cement plant. One point to finish with is a comment that Rick Bohan made at the IEEE-IAS/PCA Cement Industry Technical Conference that took place in May 2022: carbon capture is expected to double a cement plant’s energy consumption. Kiln electrification is one potential route for cement production to reach net zero. CCUS is another. If one or both occur then a low carbon future could be a high energy one also.

Watch out for Global Cement’s forthcoming interview with Coolbrook in the September 2022 issue of Global Cement Magazine

For more on CCUS, download the proceedings pack for the Virtual Global CemCCUS Seminar 2022

For more on Synhelion and Cemex read the interview in the December 2020 issue of Global Cement Magazine interview


Egypt: Lafarge Egypt has appointed Jimmy Khan as its chief executive officer (CEO).

Khan has worked for Holcim, LafargeHolcim and Lafarge for 18 years. Notable positions include becoming Head of Business Processes, Internal Control and Audit - Nigeria in 2013, CEO of LafargeHolcim Mauritius and Seychelles in 2015 and Country CEO of Zambia in 2018. He is a graduate of the Pamplin College of Business at Virginia Tech in the US.


US: CalPortland has appointed Hamed Maraghechi as its Director of the Central Research Laboratory. He will be based at the CalPortland Center of Technical Excellence in southern California where he will conduct new research and testing related to issues such as carbon reduction and sequestration to help the company achieve its commitment to lowering greenhouse gases. He will also oversee all advanced analytical services for customers and for internal operations, in this newly created position.

Maraghechi holds a PhD in Civil and Environmental Engineering with a materials focus from the Pennsylvania State University, a master’s degree in Civil and Environmental Engineering from the University of Hawaiʻi at Mānoa and a master’s degree in Polymer Engineering from the University of Tehran in Iran. He was most recently a senior scientist at Fortera working on the design and development of low CO2 cement and concrete formulations. Prior to Fortera, he worked as a scientist at Boral IP Holdings and the École Polytechnique Fédérale de Lausanne (EPFL) in Switzerland.


Tajikistan: Fon-Cement has laid the first stone in the construction of its upcoming Ayni cement plant in Sughd Province. Once operational, the plant will create 120 jobs locally.


Egypt: Misr Cement Qena's board of directors has voted for the company to continue operating its Qena cement plant after the end of a management contract with Arab Swiss Engineering Company (ASEC) on 30 June 2022.

Misr Cement Qena reported an operating incomeUS$5.69m in the first quarter of 2022, up by 59% year-on-year from US$3.58m in the first quarter of 2021. Its net profit in the quarter rose by 74% to US$2.56m from US$1.47m.


Liberia: Fouta Cement has secured a US$21.2m financing package for the construction of its upcoming 350,000t/yr Monrovia grinding plant. The International Finance Corporation (IFC) has reported that the package consists of a US$5.4m loan from IFC's own account, a US$10.8m loan from the International Development Association's Private Sector Window Blended Finance Facility (IDAPSWBFF) and a US$5m from Bank of Africa United Kingdom (BAUK).

Fouta Cement's managing director Hamidou Gnan said "IFC's package of long-term investment and advisory services gives us the foundation and support we need to make the switch from reseller to manufacturer, thereby adding more value and creating more jobs in Liberia."


Pakistan: Fauji Cement has ordered three MVR vertical roller mills from Germany-based Gebr. Pfeiffer for its upcoming Salar cement plant in Dera Ghazi Khan/Punjab Province. The supplier says that the order consists of a 520t/hr MVR 5600 R-4 mill for grinding raw materials and two 180t/hr MVR 5000 C-4 mills for cement grinding. China-based Hefei Cement will handle the order.


Pakistan: DG Khan Cement Company is ready to export 50,000t of cement to the US following a certification process. The Tomini Felicity bulk carrier was reportedly being loaded at the Port of Karachi in mid-June 2022 for shipping to Houston in Texas, according to the News International newspaper. The transport is part of a 100,000t deal with a US-based company that was arranged in mid-2021. The intervening period has been spent arranging the necessary certificates. The export is believed to be the first time a Pakistan-based producer has sent cement to the US.


Turkey: OYAK Cement has detailed its progress towards net zero CO2 cement production in its Integrated Report 2021. The report's focus is sustainability and digitalisation. Under itsCement 4.0 CO2 emissions reduction initiative, OYAK Cement has proceeded with efficiency improvements at its cement plants.

OYAK Cement is committed to net zero CO2 cement production by 2050 and reductions in line with the Paris Agreement to limit global climate change to 1.5°C by 2030.The producer is collaborating withthe Science-Based Targets Initiative (SBTi) to realise its emission reduction goals.


South Korea: A truck driver strike has ended after seven days. The Korea Herald newspaper has reported that the government has agreed to extend a freight rate-based minimum wage system. The total cost to the cement industry was US$70.6m,


Canada/US: Holcim North America has invested in Blue Planet to support the development and commercialisation of its mineralisation technology. Blue Planet’s process sequesters CO2 with building waste feedstock such as recycled concrete, cement kiln dust (CKD) and slag to produce new aggregate products. Each tonne of Blue Planet’s aggregate can mineralize up to 440kg of captured CO2. Lafarge Canada, Holcim US, and Blue Planet will start a multi-year collaboration to help identify potential to use the mineralisation technology to further lower the carbon footprint of the companies’ cement, aggregates and concrete operations, with the potential to expand to other operations in the Holcim Group around the world.

“This is an important step for us in North America. Our vision is to transform our St Constant Plant in Montreal into a carbon campus that ultimately advances commercialisation of mineralisation technologies, including Blue Planet’s products,” said David Redfern, president and chief executive officer, Lafarge Canada. “We look forward to advancing our Net Zero strategy by leveraging mineralization technology that allows us to use the CO2 from our own cement plants to produce carbon neutral or carbon negative sand and gravel products.”


Saudi Arabia: Arabian Cement says that the Jeddah Commercial Court has ruled in its favour in a lawsuit it filed against Emaar, the Economic City Company, to claim outstanding quantities of limestone it was due in an agreement the companies signed in 2012. The court has ordered Emaar to give Arabian Cement around 4.6Mt of limestone. As part of the deal, from 2012 to 2018, Emaar agreed to provide the cement company with 44.7Mt of limestone. However, Arabian Cement maintains that it did not receive 5.3Mt of the total.

Arabian Cement previously gave land to Emaar in return for a limestone supply deal. Emmar company has been developing the King Abdullah Economic City.


Benin: A local government department covering the Atacora and Donga regions has started forcing the closure of shops and depots that are not following central government-mandated price controls. Other infringements include failure to issue purchasing invoices or display the price properly, according to La Nouvelle Tribune newspaper. The government has implemented controls on certain commodities, including cement and vegetable oil, in reaction to rising prices.


Germany: Menzel Elektromotoren has launched construction work for its new plant in Hennigsdorfon, on the outskirts of Berlin, with the laying of the foundation stone. More than 200 guests and employees attended the event. The new headquarters will be erected on a 24,000m2 plot. All administrative and production workplaces are to be relocated by January 2024.

When complete, the new motor plant with an effective floor space of 8500m2 will increase the manufacturer's production capacities, allow the expansion of the workforce and add efficiency gains through an optimised floor plan. The production area of about 3800m2 will accommodate the assembly, metal processing, fabrication and winding workshops, paint shops and three test fields. In addition, there will be offices, logistics zones and storage areas. The new property is intended to allow for future expansions.


Egypt: South Valley Cement more than tripled its sales year-on-year in the first quarter of 2022, to US$11m from US$3.31m. The company’s net loss during the quarter was US$1.66m, down by 13% year-on-year from US$1.9m in the first quarter of 2021.


Zimbabwe: Fossil Mines plans to keep Lafarge Zimbabwe publicly traded and to recapitalise it through investments after it completes its acquisition of the company. The Insider newspaper has reported that this will lead to an increase in the company’s cement production.

Zimbabwe consumed 1.4Mt of cement in 2021, of which 560,000t (40%) was imported. Switzerland-based Holcim agreed to sell its 76% stake in national number two producer Lafarge Zimbabwe to Fossil Mines earlier in June 2022.


India: The Tamil Nadu Federation of Panchayat Presidents, an overarching organisation for local government leaders, has begun a protest against unlawful cement plant practices in the state. The New Indian Express newspaper has reported that the federation’s president Sellam Kadamban said that limestone mines and trucks are operating illegally, creating pollution and traffic collisions.


Signapore: Researchers at the Nanyang Technological University in Singapore (NTU Singapore) have successfully used bacteria to combine two abundant waste streams into clinker-free biocement. NDTV news has reported that the scientists developed the material from by combining calcium ions with urea in a mixture of industrial carbide sludge and urine. The process takes place at room temperature, reducing CO2 emissions while also offering waste management benefits.

The NTU Singapore team is presently testing the biocement on artificial beaches. It will subsequently investigate other possible large-scale applications around Singapore.


Cyprus: Vassiliko Cement’s Vassiliko cement plant was the site of a tyre fire in an alternative fuel (AF) storage area on 11 June 2022. The Cyprus Mail newspaper has reported that the fire begun due to a mobile shredder malfunction. Enerco Energy Recovery operates the shredder at the 2.5Mt/yr cement plant. Local residents protested the incident at the site of the plant’s former quarry on 13 June 2022.


India: Shree Digvijay Cement plans to more than double the capacity of its Digvijaygram cement plant in Gujarat’s Jamnagar District to 3Mt/yr from 1.2Mt/yr. Projects Today News has reported that the project will begin by mid-2023, and will also include the establishment of a waste heat recovery (WHR) plant.


Argentina: The National Commission for the Defence of Competition (CNDC) has concluded an investigation into the cement industry with the finding that all four Argentinian cement producers colluded to maintain high prices between 2013 and 2018. Cementera Avellaneda, Holcim Argentina, Loma Negra and Petroquímica Comodoro Rivadavia (PCR) reportedly increased their sales by US$178m between 1 July 2017 and 30 June 2018 through cost overruns generated by their control of local markets.

The CNDC ordered the Portland Cement Manufacturers Association (AFCP) to refrain from distributing competitively sensitive information production, dispatches and imports information between its member companies.


Japan: Taiheiyo Cement plans to introduce a coal surcharge for its cementitious products in September 2022 due to rising energy prices. It will use a surcharge system linked to the price of coal for one year until the end of August 2023. The first surcharge will be determined based on the price of coal in June 2022 and then disclosed in mid-August 2022. It will be revised every two months. The surcharge will be charged separately from the product price.

The cement company said that, “Although we are trying to further reduce costs, it is not possible to absorb the unprecedented rise in costs only by corporate efforts.”


Germany: Beumer Group has completed its acquisition of conveyor systems and loading technology supplier FAM Group.

Beumer Group says that the acquisition expands its portfolio and complements its competence in the project planning of plants with FAM Group’s know-how and global positioning throughout the entire value chain, including aftersales service.


Nigeria: BUA Cement has donated a solar motorised borehole and medicines worth US$59,600 to eight host communities in Wamakko, Sokoto State. The company says that the efforts are aimed at alleviating the effects of local water scarcity and medicinal supply issues.


US: The Global Cement and Concrete Association (GCCA) hosted chief executive officers (CEO)from across the global cement industry at its CEO Gathering in Atlanta, Georgia, on 9 June 2022. The event explored the best ways for the sector to progress towards net zero CO2 emissions. Speakers included: UN special advisor on climate Selwin Hart, US Department of Energy assistant secretary for fossil energy and carbon management in the Brad Crabtree, architecture firm Gensler CEO Diane Hoskins, Chair of Oil and Gas Climate Initiative (OGCI) executive chair Bjorn Otto and climate economist Gernot Wagner.

GCCA CEO Thomas Guillot said “To achieve net zero and enable the delivery of the sustainable built environment of the future, there needs to be ongoing engagement and deeper collaboration between our industry and government in the years ahead. Targeted government policy will be vital to removing barriers and to expediting our industry’s decarbonisation plans.”


Russia: Local Press has reported that Altai Cement plans to start up Kiln 2 at its Altai cement plant. When operational, the kiln will double the plant’s capacity to 2400t/day.


Canada: Progressive Planet Solutions has successfully produced a new supplementary cementitious material (SCM) called PozDE from diatomaceous earth. The company says that it developed PozDE using calcium bentonite-containing diatomaceous earth from the Red Lake mine in Kamloops, British Colombia. The SCM’s seven-day and 28-day strength activity index (SAI) values are 101% and 120% those of ordinary Portland cement (OPC) respectively, while its water demand is lower at 98%.

Chief operating officer Ian Grant said “It is uncommon to see SCMs exceed the 7-day strength of the control Portland, so we are excited to see better strength while indicating lower water demand."


Europe: The European cement association Cembureau has expressed its disappointment in the outcome of European Parliament votes on the EU Emissions Trading Scheme (ETS) and Carbon Border Adjustment Mechanism (CBAM). The parliament voted against an amended proposal to introduce a carbon border tax and to phase out ETS allowances from 2028 to 2034, against a previous proposal of 2025 – 2030. Groups including The Greens – European Free Alliance voted against the proposed legislation as they believed it did not go far enough.

Cembureau chief executive officer Koen Coppenholle said “The EU cement industry needs a strong CBAM to support our decarbonisation efforts and fight carbon leakage. Both draft European Parliament texts on ETS and CBAM contain significant improvements on some key issues – such as CBAM’s watertightness or industrial innovation – which are essential to support our transition to carbon neutrality.” Coppenholle continued “We encourage MEPs to resume negotiations as soon as possible and reach a reasonable compromise on the remaining divisive issues, thereby providing a predictable regulatory framework for the industry.”


Indonesia: The Indonesia government says that it will ask for compensation if the Philippines Tariff Commission extends tariffs on cement. The Manila Bulletin newspaper has reported that the government suggested that the fellow Association of Southeast Asian Nations (ASEAN) member state should take more targeted measures against any country responsible for cement dumping, in line with the bloc’s rules.

In 2019 – 2021, Indonesia exported 532,000t of cement to the Philippines, constituting 2.7% of the country’s cement imports. Vietnam, meanwhile, exported 15.8Mt (80%).


US: Prometheus Materials has successfully developed cement-free blocks from a material produced by biomineralising cyanobacteria. Dezeen News has reported that the American Society for Testing and Materials (ASTM) has approved the materials for construction applications.

Director Wil V Srubar III said "Coral reefs, shells and even the limestone we use to produce cement today show us that nature has already figured out how to bind minerals together in a strong, clever and efficient way. By working with nature to use existing microalgae to bind minerals and other materials together to create new types of sustainable biocomposite building materials, we can eliminate most, if not all, of the carbon emissions associated with traditional concrete-based building materials."


India: UltraTech Cement has entered into a collaboration with Finland-based Coolbrook to implement the latter’s roto dynamic heater (RDH) electric kiln technology in Indian cement plants. RDH technology uses renewable power to heat kilns to up to 1700°C.

UltraTech Cement managing director Kailash Jhanwar said “UltraTech is a forerunner in utilising renewable energy in its manufacturing operations. We are constantly looking at opportunities to improve process efficiency and reduce greenhouse gas emissions from our operations.” Jhanwar concluded “We believe that our collaboration with Coolbrook will help to further accelerate the decarbonisation of our operations.”

Coolbrook executive chair Ilpo Kuokkanen said “India is one of the most important potential markets for Coolbrook, as we want to make a global impact on CO2 emission reductions. Cooperation with India’s largest cement producer UltraTech is a significant step in our strategy to decarbonise heavy industry processes globally. UltraTech is also an excellent addition to our comprehensive and responsive partnership ecosystem spanning across leading industrial actors, academic institutions, and the public sector.”


India: Ramco Cements plans to make capital expenditure (CAPEX) investments of US$154 – 167m in the 2023 and 2024 financial years. At the beginning of the 2023 financial year on 1 April 2022, Ramco Cements’ net debt was US$489m. It plans to pay back US$64.3m during the current financial year, with the ultimate aim of becoming net debt-free before the 2026 financial year.


Belgium/France: Ciments Calcia plans to transition 60% of its truck transport of cement in Belgium and France to rail. The company says that the shift will eliminate 5% of its CO2 emissions. 400 rail cars currently distribute cement from Ciments Calcia’s 10 production sites. The producer said that the planned increase became possible due to logistics solutions developer Everysens’ transport digitisation software.


UK: The UK Department for Business, Energy and Industrial Strategy (BEIS) has granted Carbon Clean Euro701,000 under its Carbon Capture, Utilisation and Storage (CCUS) Innovation 2.0 programme. Carbon Clean says that it will partner with energy engineering company Doosan Babcock and Newcastle University to develop carbon capture systems which apply non-aqueous solvent (NAS) and rotating packed bed (RPB) technology together for the first time. The partners seek to overcome the challenges of scale and cost in order to advance the widespread deployment of CCUS systems.

The CCUS Innovation 2.0 programme is part of the UK government’s Euro1.17bn Net Zero Innovation Portfolio scheme.


South Korea: Korea Cement Association (KCA) members’ cement shipments fell by 90% over two days to 13,000t on 8 June 2022 from 180,000t/day prior to a truck driver strike which began on 7 June 2022. The association claimed that producers lost US$23m-worth of sales in the first two days of the strike, which also affects other industries. 17 ready-mix concrete batching plants in the Seoul area have suspended operations. The Korea Herald newspaper has reported that the association representing the construction industry has also voiced concerns about the supply situation.