Global Cement Newsletter

Issue: GCW570 / 17 August 2022

Headlines


Fuels procurement and costs have been weighing on the minds of Indian cement producers since the start of the Russian invasion of Ukraine in February 2022. Two news stories this week show some of this. The first concerns recent imports of petcoke from Venezuela. The second covers the closure of captive power plants due to domestic shortages of coal.

At the same time, as the financial results for cement companies for the first quarter of the Indian 2023 financial year have been released, one constant has been hefty hikes in power and fuel costs. Graph 1 below gives a rough idea of the jump in costs major producers have been contending with. One point to note is that, possibly, the larger cement companies may have been better at slowing down the cost inflation from fuel. However, the prevalence of waste heat recovery installations and alternative fuels usage may also be a factor here. Finally, the company approved to buy Ambuja Cement and ACC, Adani Group, also runs India’s biggest coal trader. It will be interesting to see in the medium term how this might affect the fuel costs for its new cement division.

Graph 1: Comparison of Power & Fuel costs for selected Indian cement producers in first quarter of 2022 and 2023 financial years. Source: Company financial reports.

Graph 1: Comparison of Power & Fuel costs for selected Indian cement producers in first quarter of 2022 and 2023 financial years. Source: Company financial reports.

The Venezuelan story demonstrates the greater lengths that Indian cement producers are now going to secure fuel supplies. Reuters reports that cement companies imported at least 160,000t of petcoke from the South American country between April and June 2022 and that more was on the way. JSW Cement, Ramco Cements and Orient Cement are among them. The Venezuelan oil industry has been under US economic sanctions since 2019 but byproducts such as petcoke are not covered by this. Its petcoke has apparently been discounted by 5 - 10% below the price of US alternatives.

Indian cement producers have been prepared to risk US sanctions further by importing coal from Russia. The Business Standard newspaper, using data from Coalmint, reported that Russia became India’s third largest source of coal imports, at 2.06Mt, in July 2022. Before the war it was the sixth-largest source of coal to the country. Again, Reuters covered how cement companies were doing this in July 2022, when it revealed that UltraTech Cement had used India-based HDFC Bank to purchase coal using Chinese Renminbi, not the US Dollar as is more common for international purchases of commodities. In a conference call for the release of its first quarter results, UltraTech Cement’s chief financial officer Atul Daga confirmed the purchase and described it as “opportunistic.” He added that, “If something more surfaces, we will pick it up.” As the data for July 2022 shows, it may or may not be UltraTech Cement that is buying Russian coal right now but other parties in India certainly are.

Some of the wider economic implications about India buying Russian coal in the face of US and European sanctions include whether any retaliation might be forthcoming and a general sign that the dominance of the US Dollar as the world’s reserve currency is not guaranteed. The former seems doubtful given the size of India’s markets. Yet if the sanctions against Russia drag on then a shift in the global economic status quo becomes more likely, especially if opportunistic purchases become regular ones.

The situation facing captive power plants illustrates one more turn of the screw on energy costs for industrial manufacturers. 30% of captive power plants in India are reportedly closed due to the high cost of coal or an inability to even import it. Although it is worth noting that it is unclear whether, proportionally, more or less of these are serving cement plants. As N Srinivasan, the vice-chairman and managing director of India Cements told the Business Standard newspaper, “Most of our plants have coal based captive power generation. The cost of captive generation is now more than the grid cost. Hence, we shut down all captive power units and resorted to grid power.”

The International Energy Agency (IEA) forecast in July 2022 that Indian coal demand would grow by 3% year-on-year to 1.16Bnt in 2023 due to expanded electrification and economic growth. In its view, global coal demand will be driven principally by China but also by India to a lesser extent. However, unhelpfully, it added that uncertainty was also rising with ongoing developments in the war in Ukraine having a prominent effect. This is unlikely to assist Indian cement producers and their fuel buyers who will be asking themselves: how long will the current situation last and can the prices be passed on to consumers? There is one small silver lining in the current group of economic storm clouds hanging over cement producers at least. The second quarter of the Indian financial year is monsoon season, when economic activity slows down. It won’t slow the trend down but it may reduce the fuel bill a little.


Saudi Arabia: Al Jouf Cement has appointed Abdul Karim bin Muhammad Al Nuhair as its chief executive officer. He succeeds Jamal bin Salem Al Amer in the post who has resigned for personal reasons. Al Amer has now been appointed as president ex-executive advisor to the company.

Al-Nuhair holds a bachelor’s degree in Industrial Management and a master’s of Executive Directors from King Fahd University of Petroleum and Minerals. He holds both management and board-level experience in a number of private and public companies.


Oman: Raysut Cement has appointed Khalid Ramis Mohammed Al Rawas as its chief executive officer. It follows the resignation of Ghose Jotirmoy Pratul Krishna in early August 2022. Al Rawas holds nearly 30 years of experience working in the banking sector. He joined Raysut Cement in 2019.


Taiwan: An-Ping Chan has become the president of Taiwan Cement in addition to his current roles as the group’s chief executive officer and the company’s chair. The concurrent appointment follows the resignation of previous president Jong-Peir Li due to personal health reasons.


New Zealand: Fletcher Building Materials recorded consolidated sales of US$5.37bn during its 2022 financial year, up by 4.7% year-on-year from US$5.13bn in the previous year. Its net earnings also rose by 42%, to US$273m from US$193m.

The group's concrete division, which includes Golden Bay Cement, contributed US$556m-worth (9%) of group sales. The figure represents an 8% increase from 2021 financial year levels. The business recorded 'strong performances' across all key product segments, underpinned by 'robust' demand and pricing. It made capital expenditure investments of US$51.1m, including in a waste tyre recycling system upgrade at the Golden Bay cement plant. The latter increased the plant's alternative fuel (AF) substitution to 50% from 35%. The company also continued to focus on developing low-CO2 concrete binders.

Fletcher Building Materials chief executive officer Ross Taylor said "The 2022 financial year has not been without its challenges. Global and national supply chain disruptions have continued into the third year of the Covid-19 pandemic." He added "The New Zealand Commerce Commission recently published its interim market study report into residential building supplies. The final report and recommendations will be published in December 2022 and in the meantime we will continue to work collaboratively with both the commission and the government."


Turkey: KÇS Kipaş Çimento has placed an order with KHD Humboldt Wedag for a Pyrorotor for its Kahramanmaraş cement plant. The supplier says that the equipment will enable the plant's calciner to achieve an alternative fuel (AF) substitution rate of 90%. It will additionally restrict NOx emissions to 800mg/Nm3. After a short shutdown for assemblage of gas duct connections, KHD expects to commission the upgraded system in mid-to-late 2023.

The company says that the KÇS Kipaş Çimento contract represents its 11th Pyrorotor order globally and the first in Turkey.


Czech Republic: Lafarge Cement says that it has achieved an alternative fuel (AF) thermal substitution rate of 95% at its Čížkovice cement plant. The plant's fuel mix includes contaminant fractions from local plastic recycling. As a result of the move, the plant no longer uses any natural gas in its cement production.

In 2022 as a whole, the producer plans to increase its share of reduced-CO2 cement sales, increase construction waste recycling in its products and reduce its cement's water consumption.


Australia: James Hardie has informed investors that it has frozen all non-critical hiring. The Australian newspaper has reported that the move is designed to counteract the impacts of a rise in costs. The company also plans to announce a new round of price rises on its products.


Tajikistan: Cement production fell by 7% year-on-year to 2Mt in the first half of 2022 from 2.16Mt in the same period in 2021. The Avesta News Agency reports no reason for the decline but it noted that the construction sector had grown so far in 2022. The country’s cement industry exports around 1.5Mt/yr to neighbouring countries including Afghanistan, Uzbekistan and Kyrgyzstan.


Afghanistan: Ghori Cement has restarted production at its Baghlan plants near Pul-e-Khumr in Baghlan province after a stoppage of four months. Production halted at the units due to the high price of coal, according to Pajhwok Afghan News. The government is now supplying coal to the plants at a pre-agreed price. Other local news sources report that production has increased to 520t/day from 350t/day previously, following work on a variety of technical issues.


India: Visaka Industries plans to spend US$15m towards building a new fibre cement board plant in the Paschim Medinipur district of West Bengal. The unit will be the company’s fifth cement board plant and the first in the state, according to the Press Trust of India. The project will include solar power generation via roof panels.


Burundi: The government is preparing to allow imports of cement into the country for a designated period in an effort to tackle rising prices. The cabinet announced the plan following a difference being recorded between reference prices and the actual market price, according to the East African newspaper. The measures will also allow for sugar imports. Local cement producer Burundi Cement Company (BUCECO) has called for the government to start a price review first before relaxing import rules. It wants to increase its prices due to growing raw material and transport costs.


China: West China Cement’s preliminary results indicate a profit drop of 40 – 45% year-on-year in the first half of 2022 to US$85.6 – 93.4m from US$156m. The group said that its finance costs rose by US$10.8m, while its foreign exchange gains were just US$4.05m in the half, compared to US$51.2m in the first half of 2021.


Australia: James Hardie recorded sales of US$1bn in the first quarter of its 2023 financial year, up by 19% year-on-year from US$843m in the first quarter of its 2022 financial year. Its net profit was US$163m, up by 34% from US$121m. The group increased its North America fibre cement board sales by 28% to US$740m, its Asia Pacific fibre cement board sales by 9% to US$140m and its Europe building products sales by 7% to US$112. James Hardie launched its new European subsidiary James Hardie Fiber Cement Europe during the quarter.

James Hardie lowered its full-year adjusted net profit forecast to US$730 – 780m from US$740 – 820m. Interim chief executive officer Harold Wiens said "The current calendar year has seen the macro-economic environment change around us quite significantly, with unprecedented levels of inflation, global supply chain disruptions and a war in Europe. The current macro-economic environment is not only creating uncertainty for the housing markets in all three regions we do business in, but it is also putting pressure on our fiscal year 2023 financial results due to increased input and freight costs. That said, we are confident we will be able to deliver growth above market and strong returns in fiscal year 2023, and that is reflected in our updated guidance we provided today, which at its midpoint represents 22% growth in adjusted net income versus the prior year."


UK: HeidelbergCement subsidiary Hanson’s plan for the installation of a carbon capture system at its Padeswood cement plant has proceeded to the due diligence stage for funding from the UK government’s Department for Business, Energy and Industrial Strategy. The project is one of 20 from the East Coast Cluster and HyNet North West Consortium to make the shortlist for this phase of the approval process.

If successful, Hanson will be able to capture 800,000t/yr of CO2 and produce carbon neutral cement at the Padeswood plant by 2027. It will create 54 new skilled full-time jobs.


Egypt: Arab Swiss Engineering Company (ASEC) has won a contract to manage operations and maintenance at Building Material Industries Company (BMIC)’s Asyut cement plant in Asyut Governorate. ASEC previously held responsibility for the plant’s technical management between 2011 and 2019.

The supplier says that both parties look forward to this new phase in their cooperation to maximise the success of the plant’s operations.


India: Indian cement producers imported four shipments with a total of 160,000t of petcoke from Venezuela during the first quarter of the 2023 financial year. Reuters News has reported that a fifth shipment of 50,000t of petcoke is due to arrive in Mangaluru, Karnataka, in mid-August. A further, 30,000t, delivery is also scheduled for shipment from Venezuela during the month. Shipping takes around 50 days.

Ramco Cements enjoyed a US$15 – 20/t discount on its two 50,000t shipments of Venezuelan petcoke in June and July 2022, for which it paid US$10.7m and US$11.1m respectively. Its chief financial officer Sivaraman Vaithiyanathan said
"The quality of petcoke is very good and it has very low sulphur."


India: The Competition Commission of India (CCI) has approved Adani Group’s US$10.5bn deal to acquire Holcim’s Indian business. Holcim holds a 63% stake in Ambuja Cements, which holds a 50% stake in ACC. Holcim also holds a direct 4.5% stake in ACC.

Adani Group launched a new company, Endeavour, to assume ownership of the new share capital from Holcim’s holding company Holderind Investments.


Egypt: Arabian Cement’s first-half sales were US$111m in 2022, up by 121% year-on-year from US$50.4m in the first half of 2021. The company recorded a profit of US$6.25m during the reporting period, compared to a loss of US$1.22m one year previously.


India: 30% of plants in India’s 78GW captive power plant network have temporarily closed due to high coal prices. 40GW-worth of capacity (55%) is coal-fired, with an annual consumption of 200Mt/yr. The Business Standard newspaper has reported that total Indian coal imports fell by 10% to 23.8Mt in July 2021 from 26.3Mt in June 2021. Deliveries of coal to non-power sector consumers fell by 33% year-on-year at the beginning of August 2021. The Indian Cement Manufacturers Association (CMA) and nine other national industry associations have contacted the government to urge the formation of policies for the equitable distribution of available coal.

India Cements has imported two shipments of Russian coal for use in cement production. The company’s power and fuel costs rose by 54% year-on-year in the first quarter of its 2023 financial year, which began on 1 April 2022. Its vice-chair and managing director Narayanaswami Srinivasan said “Most of our plants have coal-based captive power generation. The cost of captive generation is now more than the grid cost. Hence, we shut down all captive power units and resorted to grid power.”


Vietnam: The State Audit Office of Vietnam (SAV) has uncovered limestone mining activity above licensed levels by multiple subsidiaries of the Vietnam Cement Industry Corporation (VICEM) between 2017 and 2022. In 2021, Vicem Bim Son’s Yen Duyen quarry yielded 499,000t of limestone, 14% above its licensed capacity. That same year, Vicem Hoang Mai extracted 154,000t of limestone from its Hoang Mai B quarry, 8.5% above capacity, while Vicem Tam Diep extracted 111,000t from its Hang Nuoc quarry, 6% above capacity.

The Viêt Nam News newspaper has reported that the SAV has asked Vicem to review the causes of the discrepancy between production and licences and clarify its responsibility.


Poland: Poland produced 9.3Mt of cement in the first half of 2022, up by 8.6% year-on-year from the same period in 2021. The Polish Association of Cement Manufacturers (SPC) recorded an 11% increase in national cement consumption to 6.8Mt during the reporting period. The Institute of Economic Forecasts and Analyses has estimated that full-year demand will reach 20Mt in 2022.


Brazil: Votorantim Cimentos recorded consolidated sales of US$1.17bn in the first half of 2022, up by 22% year-on-year from US$961m in the first half of 2021. Its cost of sales rose by 36% to US$1.05bn from US$777m. As a result, the group made a loss during the half of US$29.6m, compared to a US$85m profit in the first half of 2021. Group cement volumes grew by 1.1% year-on-year to 17.6Mt from 17.4Mt.

CFO Bianca Nasser said “Despite the slowdown in the world economy, Votorantim Cimentos continues to operate within solid financial metrics and with high liquidity, maintaining its investment grade status with a stable outlook attributed by the credit rating agencies Moody’s and Fitch. The company’s leverage remained at stable levels and in line with our financial policy. In May, we carried out a transaction in the international market that repurchased the most expensive debt in our portfolio, taking advantage of attractive market rates. And we used funds from debt issuances in the local market with more attractive rates to finance our operation.”


Argentina: Loma Negra recorded first-half 2022 sales of US$357m, up by 1.2% year-on-year from US$353m. Its cement sales rose by 13% to 3.15Mt from 2.79Mt in the first half of 2021. The producer more than doubled its net profit to US$45.4m from US$19.3m.


India: Grasim Industries recorded consolidated sales of US$3.52bn in the first quarter of its 2023 financial year, up by 41% from first-quarter sales of US$2.5bn a year previously. Dow Jones Institutional News has reported that the group’s cement business contributed a net profit of US$402m, down by 8.8% year-on-year from US$441m.


Taiwan: Hsing Ta Cement says that it has cancelled a planned repurchase of US$266m-worth of its shares. The purchase was the company’s fourth successive planned transaction of that kind. It retains a total shareholding worth US$114m.

In the second quarter of 2022, Hsing Ta Cement recorded sales revenues of US$100m and a net profit of US$2.23m.


Mexico: Cemex’s North American logistics subsidiary Cemex Servicios Logísticos has changed its name to Alliera. Alliera will continue its 15-year tradition of operating as an independent third-party logistics company, serving customers across various industries.

Cemex Mexico president Ricardo Naya said “For Alliera, Cemex’s strategic priorities are ensuring our collaborators’ health and safety, sustainability and innovation. Within this package of priorities, we always seek growth, as we do now with Alliera, which is part of Urbanisation Solutions, our most recently created business branch.”


Thailand: Siam Cement Group has received approval to issue a new lot of debenture worth US$426m on 3 October 2022. The group says that the debenture replaces its existing lot, which will retire for redemption on 1 October 2022. The new lot has an interest rate of 3.25% and matures on 1 October 2026.


India: UltraTech Cement has received US$94.6m-worth in commitments on a planned sale of its commercial papers. Reuters News has reported that the papers will reach maturity in November 2022.


Germany: Loesche has published its Sustainability Report of its performance in 2021. The supplier’s Scope 1 and 2 CO2 emissions declined by 6.1% year-on-year to 229t from 244t in 2020 and by 19% over the two years from 2019, when they totalled 282t. It reduced the share of Scope 2 emissions in the figure to 40% from 41% in 2020 and 45% in 2019.

Loesche offers emissions-reducing products to the global cement industry under the label Greenkey Solutions. These include its A/Fuel and H/combust ranges for alternative fuels and green hydrogen upgrades, its C/Clay range for clay calcining and grinding, its Digital/Ready 4.0! range for predictive process optimisation and smart asset management, its E/Slag range for ground granulated blast furnace slag upgrades and its S/Crete range for waste concrete recycling, as well as audits for retrofits. Together, Loesche says that its products can reduce the global cement sector’s carbon footprint by 90%. Within this, Loesche believes that calcined clay technology alone can reduce cement’s CO2 emissions by 40% and its energy demand by 21%.

Loesche said that its launch during the year of its H2Optimum grinding bed spraying system can reduce grinding mills’ water consumption by 50%.


Philippines: Holcim Philippines has launched its ECOPlanet 30% reduced-CO2 cement range in the city of Davao on Mindanao. The producer also introduced its Balik-Plastic waste cement bag recycling programme, offering a collection service to customers in order to reuse waste bags as alternative fuels and raw materials in cement production at its Davao plant.


Canada: Lafarge Canada has installed its first electric vehicle charging stations at its Kent Avenue ready-mix concrete batching plant in Vancouver, British Columbia. The company’s Vancouver team built the four stations with US$39,200 in funding from Lafarge Canada and US$15,700 in funding from BC Hydro’s CleanBC Go Electric Vehicle charger rebate programme. Dow Jones Institutional News has reported that the company plans to establish 96 further stations at 30 sites in British Columbia, Alberta, Manitoba and Saskatchewan. It says that the electric vehicle charging network will enable it to eliminate 188t of CO2 emissions by 2028.

Lafarge Western Canada chief executive officer Brad Kohl said "We are thrilled that Western Canada has opened the first electric vehicle charging stations to kick-start this exciting effort planned across our Canada operations to advance our goal of net-zero as part of our environmental commitments."