Global Cement Newsletter

Issue: GCW567 / 27 July 2022

Headlines


Congratulations are due to the National Cement Company of Alabama and Vicat for the inauguration of the new production line at the Ragland cement plant in Alabama. The event took place on 21 July 2022.

The US$300m project was originally announced in late 2019. It then took two years to build with construction starting in January 2020. Key features include a raw vertical grinding mill, a new roller mill, a five stage preheater tower, an automatic clay storage system, a 78m tall homogenisation silo, an alternative fuels storage area for tyre-derived fuel, sawdust and wood chips, a laboratory and a new control room. The new kiln was previously reported to have a clinker production capacity of 5000t/day and it will add up to 2Mt/yr of cement production capacity to the plant. ThyssenKrupp signed up as the principal equipment supplier in 2019 and H&M was the main contractor. The production line is expected to reduce energy consumption by one third. Further change is scheduled with a switch to production of Portland limestone cement (PLC) from Ordinary Portland cement (OPC) by the start of 2023.

Vicat has repeatedly noted its affection for the plant as it was the first cement plant the group purchased outside of France, back in 1974. Indeed, Vicat’s group chair and chief executive officer Guy Sidos personally managed the Ragland plant in 2001. However, rather more prosaic reasons may also have been behind the decision to expand Ragland. According to United States Geological Survey (USGS) data, Alabama, Kentucky and Tennessee’s cement shipments grew by nearly 5% year-on-year to 7.1Mt in 2019 from 6.8Mt in 2018. Shipments are up by 3% year-on-year to 2.5Mt in the first four months of 2022 and the three states were the fifth largest region in the US for cement shipments in April 2022. A shortage of cement was also reported in Alabama in April 2022.

The other big US-based cement plant expansion is Lehigh Hanson’s US$600m upgrade to its Mitchell plant in Indiana. It also celebrated a milestone this week with a ‘topping out’ ceremony to mark the placement of the final section of steel for the stack. Another recent achievement here was the completion of a 169,000t storage dome supplied by Dome Technologies. The supplier says that the 67m diameter and 48m tall dome is the second largest clinker storage facility in Europe and North America, after one it previous built in Romania in 2008.

The Mitchell K4 project was announced in mid-2018 and then ground breaking began in late 2019. However, the start of the coronavirus pandemic delayed construction in early 2020 before it restarted in September 2020. The revised commissioning date was then moved back about half a year to early 2023. The key part of this project is that it will replace the plant’s three current kilns with just one. The new production line will increase the site’s production capacity, reduce energy usage and decrease CO2 emissions per tonne of cement. It was reported by local press back in 2018 that the project would increase the plant’s cement production capacity to 2.8Mt/yr. The project has been linked to supplier KHD with CCC Group as the contractor.

It’s fascinating to see two major new upgrades to cement plants emerging in a mature market like the US and during an unprecedented event like the emergence of coronavirus. No doubt compelling tales will emerge of how both teams coped with managing nine-figure capital expansion projects as a global public health emergency unfolded. The US market has been on a roll in recent years, despite all the uncertainty in the world, and so far it doesn’t seem to be slowing down. With luck both of the projects feature above have timed their opening right.


Pakistan: Dewan Cement has appointed Ishtiaq Ahmed as its chief executive officer (CEO). He succeeds Malik Bilal Omar in the position. Ishtiaq Ahmed was previously appointed as the company’s chair in 2018. Waseem-ul-Haque Ansari has also been appointed as a director in place of the departing CEO.


Switzerland: Holcim increased its consolidated sales by 17% year-on-year to US$15.3bn in the first half of 2022 from US$13.1bn in the first half of 2021. Its recurring earnings before interest and taxation (EBIT) were US$2.26bn, up by 9.6% from US$2.06bn. Cement sales volumes fell by 3.7% to 95.3Mt from 99Mt, and decreased in all regions except North America, where they rose by 9.6% to 10Mt. Meanwhile, the sharpest drop was in Holcim’s home region of Europe, where cement sales fell by 9.5% to 20.1Mt from 22.2Mt. Group operating profit rose by 15% to US$2.15bn from US$1.86bn, while its net debt rose by 7.5% to US$13.9bn from US$12.9bn.

Holcim called market conditions “volatile,” but forecast net sales growth of 10% year-on-year on in 2022, upgraded from 8%. It also expects to end the year with accelerated progress towards its 2025 sustainability targets, positive growth in its recurring EBIT and a free cash flow above US$3.12bn.

Chief executive officer Jan Jenisch said “Our record results, from net sales to recurring EBIT and earnings per share, are setting solid foundations to deliver our Strategy 2025 - Accelerating Green Growth.”


Thailand: Siam Cement Group (SCG) recorded sales of US$8.29bn in the first half of 2022, up by 19% year-on-year from US$6.95bn in the first half of 2021. Cement and building materials revenues were US$2.82bn, 34% of total sales, up by 12% from US$2.52bn in the first half of 2021. The group’s earnings before interest, taxation, depreciation and amortisation (EBITDA) dropped by 24% to US$1.15bn from US$1.51bn.

SCG recorded domestic declines in demand for cement and ready-mix concrete of 5% and 7% respectively in the first half of 2022. Cement demand also fell by 10% in Cambodia and by 2% in Myanmar, but rose by 5% in Indonesia and by 1% in Vietnam. In Thailand, SCG expects cement demand to “improve” in the third quarter of 2022, but noted the possible mitigating impact of rising inflation.


UK: Breedon Group recorded sales of Euro798m in the first half of 2022, up by 12% year-on-year from Euro714m in the first half of 2021. Its earnings before interest and taxation (EBIT) increased by 22% to Euro77.9m from Euro63.9m, while its profit after tax increased by 29% to Euro70.7m from Euro54.9m.

The group said “We are optimistic for the remainder of 2022. Our customers’ order books are healthy, the mechanism for passing through cost increases has traction and enquiry levels are encouraging. We therefore expect to deliver underlying EBIT at the top end of the range of consensus expectations.”

Chief executive officer Rob Wood said “We enjoyed a strong start to 2022. Our teams are focused on getting pricing right, our end market exposure is supportive and that has produced excellent results, advancing our margins and returns towards our medium term targets. We completed two in-fill transactions during July 2022, with further mergers and acquisitions activity in the pipeline, and we have continued to progress on a broad range of sustainability initiatives, including a commitment to the Science Based Targets Initiative.”


Spain: Cement consumption grew by 2.5% year-on-year to 7.49Mt in the first half of 2022. Data from the Spanish cement association Oficemen also shows that exports fell by 21% to 2.91Mt. It said that this is the first time since 2011 that Spanish cement exports have fallen below 3Mt in the first half of the year. The association has warned of potential threats to the sector such as inflation and a recession in the second half of 2022.

Aniceto Zaragoza, the general manager of Oficemen, said “Since the Iberian Mechanism began to be applied, there has been a drop in the average price of electricity for industry, although much less significant than expected. The mechanism is capable of moderating the price of the wholesale market, but the lack of wind generation caused by the heat wave and the consequent increase in the use of combined cycles, together with the increase in the price of gas, makes a global reform necessary of the European electricity market.”


Mexico: State police have intervened during a confrontation between rival groups for control of Cruz Azul’s Tula cement plant in Hidalgo. A group of workers, allegedly numbering 1000 people, aligned to the faction that controls the majority of Cruz Azul’s cement plants travelled to the site in Jasso by bus and taxi on the evening of 26 July 2022, according to La Jornada newspaper. Another group defending the plant reportedly blocked local roads and used sticks, pipes and stones to repel the assault. The police managed to deter most of the convoy travelling to the plant. However, eight deaths occurred when some of the attackers made it through.

The Tula cement plant is the sole remaining Cruz Azul unit still controlled by former company director Guillermo ‘Billy’ Álvarez and his associates. The rest of the company is under the command of Cruz Azul’s directors José Antonio Marín and Víctor Manuel Velázquez.


Zambia: China-based Huaxin Cement has increased its stake in Chilanga Cement (formerly Lafarge Zambia) to 81%. The Times of Zambia newspaper has reported that the group previously owned a 75% share of the producer.


Mexico: Beumer Group has won a contract to supply Cooperativa La Cruz Azul’s cement plants with 14 new 5500 – 6000 bag/hr palletisers. The cement company made the decision to modernise palletising operations at its plants following a law change requiring cement to be packaged in 25kg bags, instead of 50kg, from the start of 2023. Beumer Group plans to deliver the first five palletisers in the third quarter of 2022. The other nine machines will follow by 2023.

The supplier said “Cruz Azul and Beumer Group have had a trustful and successful partnership for decades. The system provider has convinced with its highly developed and sustainable technology and a sophisticated concept, which will enable the cement manufacturer to achieve the required performance in its packaging terminal” It continued “Covid-19 presented a particular challenge in this project. Due to the pandemic, it was not possible for Beumer experts to be on site with the customer in person. All concepts were discussed, debated and agreed online and with the support of the local group company in Mexico City.”


India: UltraTech Cement plans to increase its installed cement production capacity to 154Mt/yr by the beginning of the 2026 financial year on 1 April 2025. The increase represents a composite annual growth rate of 10% from 115Mt/yr at the start of the 2023 financial year. The Economic Times newspaper has reported that the producer plans to carry out the expansion in two phases.

Indian domestic cement consumption is forecast to continue growing by 5% year-on-year over a five-year period to July 2027.


India: Kesoram Industries plans to raise fund through high-cost fixed deposits at an annual coupon rate of 12%. The Business Standard newspaper has reported that the producer will use the funds to support its 10.8Mt/yr cement plant network’s working capital requirements.


India: The Indian Coal Ministry has deducted Jaypee Cement’s bank guarantee for a lease for a planned coal mine. The Hindu newspaper has reported that the project is among 44 others penalised for delays in operation or missing production targets. UltraTech Cement also received a show cause notice regarding adherence to its timeline at one of its coal blocks.


India: UltraTech Cement increased its sales by 28% year-on-year to US$1.9bn in the first quarter of its 2023 financial year, from US$1.48bn in the first quarter of the 2022 financial year. The company’s net profit during the quarter was US$198m, down by 7% year-on-year from US$213m in the first quarter of the 2022 financial year.

Dow Jones Institutional News has reported that UltraTech Cement recorded increased cement demand in June 2022 and forecasts full-year year-on-year consumption growth nationally. The producer said that state-backed investment in infrastructure and industrial development will support high housing demand momentum, while pressure will remain on its profitability due to high costs.


US: National Cement Company of Alabama has reported that the new kiln line at its Ragland cement plant will reduce the plant’s CO2 emissions by 40%. Its energy consumption will also fall by 30% as a result of the upgrade. The new line includes a 78m-high homogenisation silo, vertical crusher, five-stage preheater and automated clay storage system. AF used in the kiln will include waste tyres, woodchip and sawdust. The new kiln will help in the Ragland cement plant’s transition to 100% Portland limestone cement (PLC) production by 2023, further diminishing its carbon footprint.

Vicat CEO Guy Sidos said "Our ambition is to use AF in all our cement plants around the world. In addition to eliminating fossil fuel energy and replacing it with recycled regional waste, our investments contribute directly to local development. We are proud of the modernisation and transformation of our Ragland site, which was our very first acquisition outside France in 1974."


Spain: Cemex España has signed a 10-year renewable energy supply deal with Acciona Energía. The producer expects the contract to cover 30% of its power consumption. It used 30% renewable energy in 2021, and is aiming to achieve 55% renewables use by 2030.

Cemex Europe, Middle East, Africa and Asia president Sergio Menendez said "Increasing clean energy consumption plays a key role within our decarbonisation plan." He concluded "This agreement shows commitment to our clean energy transition, adding to the success of similar agreements in other geographies."


Namibia: 200 Cheetah Cement employees have gone on strike to protest low wages and lack of pensions and medical aid. The Namibia Press Agency has reported that salaries have fallen behind inflation, having remained level for four years.

Cheetah Cement general manager Kevin Lee called strikers’ demands ‘unrealistic’ and said that the producer had done everything in its power, but now ended in a ‘deadlock’ with workers.


US: A 43-year old worker died after sustaining severe injuries at Giant Cement’s Harleyville, South Carolina, cement plant on 21 July 2022. Local press has reported that the cause of the tragedy involved a conveyor belt at the plant.


Philippines: Cemex subsidiary Solid Cement is installing a new US$356m, 1.5Mt/yr line at its Antipolo cement plant. When operational in April 2024, the line will increase the plant’s capacity by 79% to 3.4Mt/yr. Over the first four months of the project since March 2022, Solid Cement invested US$197m in silos and mechanical installation. The new 1.5Mt/yr line will use Low Temperature Clinker technology to reduce its CO2 emissions, and will also recycle waste hot gases for raw materials drying.

Solid Cement is building the plant using 6000t of its own Vertua reduced-CO2 cement, which it says will further reduce its net carbon footprint by 564t.

Philippines president and CEO Luis Franco said “We will maintain our active role in supporting the development of this nation, as we have done in the past 25 years.”


US: Vicat subsidiary National Cement Company of Alabama inaugurated its new US$300m production line at its Ragland cement plant on 21 July 2022. Local press has reported that the line includes a new rotary kiln, equipped for alternative fuel (AF) use.

President Spencer Weitman said “This puts us into the next 40 or 50 years. And it’s prolonged the life of the plant to move us forward into the next century hopefully.”


Poland: PGE Group is ordering a feasibility study for a planned new cement production facility in Bełchatów county. Polish News Bulletin has reported that the plant will take advantage of locally available fly ash from coal-fired power plants.


China: Tangshan Jidong Cement plans to raise US$148m through an issuance of bonds. Reuters News has reported that the producer will use some of the funds to repay its debts, and the remainder to replenish its capital.


Malaysia: Cahya Mata Sarawak says that it has no plan to double the capacity of its Bintulu, Sarawak, grinding plant, Reuters News has reported. The company, however, noted the potential ‘opportunity’ offered by the construction of a new Indonesian capital in Nusantara, East Kalimantan, on the opposite side of Borneo.


Australia: Boral announced the expiration of its tender offer for up to US$300m-worth of guaranteed senior notes on 21 July 2022. The producer recorded a total principal amount tendered of US$425.7m. The 3.75% notes are due in 2028.


Canada: The provincial government of Alberta has signed a contribution agreement for US$3.87m in funding towards Lafarge Canada’s planned carbon capture installation at its Exshaw cement plant. The cost of the system is US$20.9m. Offshore Energy News has reported that it is one of 11 carbon capture projects in the province which Alberta Minister of Energy Sonya Savage said will be operational by 2030. Ultimately, project partners plan to establish a CO2 sequestration hub and transport network connecting the capture sites of various industry partners.


India: Sagar Cement’s net sales were US$69.8m in the first quarter of the 2023 Indian financial year, up by 42% year-on-year from US$49.1m in the first quarter of the 2022 financial year. The quarter, which ended on 30 June 2022, saw an 82% year-on-year increase in costs to US$72.7m from US$40.1m. As a result, the company recorded a net loss for the quarter of US$1.64m, compared to a net profit of US$6.08m in the first quarter of the 2022 financial year.


Colombia: Federación Interamericana del Cemento (FICEM) and the Global Cement and Concrete Association (GCCA) have announced their next steps to accelerate the decarbonisation of cement production in Latin America and the Caribbean. The partners have named Colombia as the region’s first Net Zero Accelerator host country. The initiative works to identify barriers to decarbonisation and to recommend policy changes to make an immediate impact. Along with fellow Net Zero Accelerator host countries Egypt, India and Thailand, Colombia brings the total coverage of the initiative to 10% of global cement capacity.

GCCA chief executive officer Thomas Guillot said “The urgency of addressing climate change becomes clearer every day. Last year, our industry made a breakthrough Net Zero global commitment to reduce our carbon footprint, and we are now driving action in Latin America to make real change in one of the regions predicted to use the most concrete and cement in the coming decades. Our Roadmap Accelerator programme, previewed today by our members and affiliate (FICEM) at Latin America and the Caribbean Climate Week, highlights the tailored policies and tools we will use to ensure that Net Zero concrete and cement is achieved by 2050.”


Canada: The Canadian government’s Environment and Climate Change department has granted an extension to St Mary’s Cement to an order regarding alleged sticky dust emissions from its McInnis cement plant. The Journal de Québec newspaper has reported that the producer now has until 8 August 2022 to submit its observations on the situation. Environment and Climate Change Canada has identified 12 different equipment failures as contributors to the alleged illegal emissions. On 20 July 2022, it had received a total of 80 reports from the public about the situation.


India: Visaka Industries commissioned its Udumalpet cement panel plant in Tamil Nadu’s Tirpur district on 20 July 2022. Capital Market News has reported that the plant has a capacity of 10,000t/yr.