Global Cement Newsletter

Issue: GCW573 / 07 September 2022

Headlines


Cembureau called for urgent action on electricity prices from European governments this week to protect cement plants. Its maths was crushingly simple. One tonne of cement takes around 110kWh of electricity to produce. Electricity prices started to top Euro700mWh in some European Union (EU) countries at the end of August 2022. The association says that this represents added costs of Euro70/t of cement and a tripling of the total cost of production. This kind of sudden extra cost to cement production could lead to the widespread closure of cement plants and lead to chaos in the construction supply chain.

Previously, Cembureau reported in 2020 that electricity accounts for about 12% of a cement plant’s energy mix. In a dry production process plant 43% of this is used for cement grinding, 25% goes into raw material preparation, another 25% on clinker production and the final portion is typically used for raw material extraction, fuel grinding and for packing and loading. However, the cost of the electricity can make a big difference to the overall energy bill for a cement plant. When a report by the European Commission’s (EC) Joint Research Centre (JRC) modelled a reference northern European cement plant with a production capacity of 1.0Mt/yr back in 2016, it concluded that the EU cement industry was spending around half of its energy costs on electricity compared to smaller ratios at plants in China, Egypt, Algeria and... Ukraine. That last country in the list is poignant given its unwitting participation in the current energy crisis. One other thing to note is that cement producers, as large scale users, may well be paying less than the wholesale prices Cembureau appears to be quoting.

The timing of Cembureau’s proclamation is pertinent because the EU and individual states have mostly been waiting until the autumn before revealing their energy support plans. However, the dilemma for Cembureau, and other industry lobbying groups, is how to protect their sectors whilst domestic consumers are threatened. The aftermath of the coronavirus lockdowns has shown what can happen when production of key commodities stops: supply chain disruption, shortages and price rises. One ironic shortage in the UK during the lockdown periods was that of CO2, as high gas prices forced the main producer to shut down, leading to unexpected knock-on problems along the supply chain in areas such as food production. The same situation is reportedly at risk of happening again now too.

Cembureau’s wider solution is to link domestic and industrial consumers of electricity. So, some of its suggestions to policymakers are to use all available means of power generation, implement emergency measures such as price caps immediately, change the rules of the electricity market more generally to prevent future price shocks and to promote large scale renewable power source development. These are all things that could help both individual and industrial users of electricity.

Compare and contrast, then, with the MPA’s (Mineral Products Association) approach to the same problem in the UK. Its strategy instead has been to ask the UK government for tax cuts and freezes and to hurry along the forthcoming policy on support for Energy Intensive Industries. That’s not to say that Cembureau’s suggestions don’t also include some sector specific requests. It has asked that the EU temporary state aid framework adopted in late March 2022 should allow all energy intensive industries to have access to state aid covering 70 - 80% of eligible costs. It has also encouraged the wider use of alternative fuels, although it doesn’t link the reason why beyond reducing imports of fossil fuels. Lastly, it bangs the drum for its recent preoccupation, the EU Carbon Border Adjustment Mechanism, this time adding electro-intensity as a main criterion for eligibility for compensation under EU emission trading scheme (ETS) indirect state aid guidelines.

Government support packages for the energy crisis are starting to be announced in European countries but the question for everyone is whether they and other actions will be enough. One problem for the cement industry will be simply staying on the radar of policy makers facing a crisis looming over their citizens. Yet if there is not enough energy to go around then rationing of some kind will be inevitable and heavy industrial users will be the first obvious targets to be told to cut back. Some months later building material supply shortages will hit. One national cement sector to watch in the coming months may be the Spanish one as it has long warned of the risks of high electricity prices.


UK: Tarmac has appointed Craig Kirkland as the plant manager of Tarmac’s integrated Dunbar plant in Scotland. Kirkland first started working for the subsidiary of Ireland-based CRH in the mid-1990s as its Landfill & Recycling Manager. He later became its Commercial Manager in 2015 before becoming the Head of Transformation at the Dunbar plant in 2021.


Finland: Coolbrook, the manufacturer of electrically-powered gas heating technologies, has announced the appointment of Mikko Jaatinen as its first chief financial officer (CFO). Jaatinen was previously heading the Group Treasury's Funding & Markets team at Neste, a renewable fuels and circular solution company.

In his role as CFO at Coolbrook, Jaatinen will ensure that the company’s financial strategies and policies support its growing global partnerships and commercial relationships, including those with Cemex and UltraTech Cement. He will support Coolbrook’s ambitions of international expansion and scaling up its operations, and lead the development of sustainable financial strategies.

Coolbrook’s chief executive officer Joonas Rauramo said, “The appointment of a CFO is the next logical step in the growth and development of Coolbrook. Mikko’s experience and expertise in a wide range of finance functions and new business development combined with his leadership qualities make him ideally suited to the role.”

Read Global Cement’s interview with Joonas Rauramo in its September 2022 issue


Brazil: Holcim has closed the sale of its business in Brazil to Companhia Siderúrgica Nacional (CSN) for an enterprise value of US$1.025bn. The deal was closed following approvals from the Brazilian authorities. This transaction includes Holcim’s five integrated cement plants, four grinding units, six aggregates sites and 19 ready-mix concrete facilities.

Holcim said that Latin America remains a core strategic growth region for the group. In the first half of 2022 it completed a new cement production line in El Salvador and significantly expanded its aggregates operations in El Salvador, Ecuador and Colombia. The company also continued to expand its Disensa retail network across the region with over 2000 stores now open across eight countries.


Kyrgyzstan: A new cement plant project has been announced for Kyrgyzstan’s Chuy region. The country’s Ministry of Economy and Commerce said that a signing ceremony for an Investment Agreement to implement the project was held between the Cabinet of Ministers of Kyrgyzstan and a consortium comprising representatives from Terek-Tash and ZENIT on 6 September 2022. When built, the plant will have a capacity of 1.5Mt/yr with a total investment cost of around US$150m.


Philippines: Republic Cement has announced that it has become plastic neutral, thanks to the continued efforts of its Ecoloop subsidiary. By collecting and co-processing the equivalent volume of residual plastic waste as it has used in the packaging and transport of its cement products, Republic Cement was able to offset its plastic packaging footprint for 2020, 2021 and so far in 2022. This is equivalent to over 890 dump trucks filled with plastic waste. Ecoloop has already helped a number of other companies to reach plastic neutrality.


Pakistan: Cement sales fell by 24% year-on-year in Pakistan in August 2022, due to increased energy, fuel and transport costs. Total despatches for the month came to 3.3Mt, against 4.3Mt a year earlier, according to data from the All Pakistan Cement Manufacturers Association (APCMA). Local shipments for August 2022 came to 2.9Mt against 3.8Mt in August 2021, a fall of 24%. Exports fell by 26% to 0.39Mt from 0.52Mt in August 2021.

APCMA officials are of the view that the government needs to generate a viable policy for the construction industry, keeping in view the huge damage to national infrastructure after unprecedented recent flooding.


Senegal: Data from the National Agency for Statistics and Demography (ANSD) indicates that cement exports fell by 34% month-on-month in June 2022, although local sales rose by 4%. Overall cement production fell by 2% as manufacturers battle the economic impacts of the war in Ukraine.


Saudi Arabia: Riyadh Cement Company’s net profit after Zakat and tax shrank by almost 47% to US$22.6m in the first half of 2022, compared to US$42.7m in the same period in 2021. The firm ascribed the drop earnings to lower sales, with its revenues standing at US$68.8m in the first six months of 2022, compared to US$107m in the first six month of 2021, a 36% drop year-on-year.


Belgium: Cembureau, the European Cement Association, has called for urgent action to be taken to support cement production due to large increases in the cost of electricity. It said that, if no measures were taken at both the European and national level, the current energy prices would lead to widespread plant closures across the European Union (EU). This in turn could create a crisis in the construction supply chain. It explained that one tonne of cement normally takes around 110kWh of electricity to produce. Therefore, with electricity prices now between Euro700 - 1000mWh, as observed in several EU member states, electricity costs amount to Euro70 – 110/t of cement, tripling the total cost of production.

The association has called for: all available sources of electricity generation to be used to boost power supplies; the immediate introduction of emergency measures, such as price caps; that the EU temporary state aid framework adopted in late March 2022 should allow all energy-intensive industries to have access to state aid covering 70 - 80% of eligible costs; and that co-processing in cement kilns should be actively encouraged and promoted at EU, state and local levels.

It added that further measures should also be considered, including: the electricity market design rules, including the marginal price setting mechanism, should be changed to prevent further electricity price hikes in the future; the cement sector should be made eligible for financial compensation under the EU emission trading scheme indirect state aid guidelines and that indirect emissions should be included in the EU Carbon Border Adjustment Mechanism (CBAM); the large-scale deployment of renewable energy should be supported across the EU; and that the pace of the EU climate agenda ('Fit for 55') should be maintained, and the CBAM should be implemented in a timely manner.


Poland: Lafarge Poland says that it has started one of its decarbonisation goals by removing the first of its ordinary portland cement (OPC) products from the market. From the start of September 2022 the subsidiary of Switzerland-based Holcim has stopped producing its bagged CEM I 42.5 R Special cement product. In late 2021 it said it was planning to stop production CEM I OPC by the end of 2025. As it does so it will switch to products in the group’s ECOPlanet range instead.


Romania: Holcim Romania has published four new environmental product declarations (EPD) for its products, including ECOPlanet cement and ECOPact concrete. It says it is the first construction materials manufacturer in the country to do so. The subsidiary of Switzerland-based Holcim first started makings its EPDs available in 2014 for cement, concrete and aggregate products. These were revalidated in 2019 and again in 2022.


Sweden: The Environmental Protection Agency (Naturvårdsverket) and the county administrative board of Gotland have both recommended rejecting Cementa’s application to extend its operating permit for its integrated Slite cement plant by four years. At present the current temporary permit will expire at the end of 2022, according to the Dagens Industri newspaper. The county administrative board has requested more information and Naturvårdsverket has found issues in the application with groundwater and nature protection area issues.

Cementa says that it submitted it application to the Land and Environment Court in April 2022 and that it was deemed complete by the court, which announced the application. In July 2022, opinions were received from around 10 authorities and associations, such as the Geological Survey of Sweden (SGU), Naturvårdsverket and the Norwegian Sea and Water Authority. Cementa added that it has now responded to this feedback.

“There are and must be high requirements for permit applications, so it is natural that there will be many views and questions in this type of examination,” said Karin Comstedt Webb, vice president of HeidelbergCement Sweden. “We have now clarified the application further and are now looking forward to the main hearing in October 2022. We are confident that our application is complete and we have been keen to show even more clearly that the business can be conducted in coexistence with nearby residents, and surrounding environmental and natural values. We see good conditions for the timetable announced by the court to be kept, which is crucial for the Swedish cement supply not to be jeopardised in the coming years.”

Further views on the application will be submitted in September 2022. The Land and Environment Court will then hold a hearing in October 2022 and a final decision is expected the end of 2022.


Finland: Advancetec has changed its name to Schmersal Finland. The company was originally founded in 1993 in Helsinki as a sales company for automation technology. Germany-based Schmersal Group entered into a sales cooperation with Advancetec in the 1990s and eventually fully acquired the company in 2019.

Schmersal Finland sells products from the Schmersal portfolio and the safety services of Schmersal’s services division under the brand name tec.nicum, primarily in Finland and Estonia. Customers include well-known companies from the sectors paper manufacturing, food processing, robotics, marine industry and heavy industry.

Jukka Harmoinen, the managing director of Schmersal Finland, said “The new name will make it easier for us to increase the visibility of the Schmersal brand in Finland. In the future we would like to expand our product range and to develop new projects in cooperation with engineering and consulting companies.”


Indonesia: Semen Indonesia Group has focused on the domestic cement market in the first half of 2022 due to the better availability of coal supplies. Its revenue fell by 2.1% year-on-year to US$1.07bn in the first half of 2022 from US$1.09bn in the same period in 2021. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) remained stable at US$237m. Overall sales volumes of cement dropped by 12% to 17Mt from 19.3Mt. However, domestic sales volumes fell by 2.6% to 14Mt but overseas sales fell by 39% to 3Mt. The group also raised its prices twice in the reporting period to further shore up revenue.


India: Birla Corporation plans to increase its cement production capacity to 30Mt/yr in 2030 from 20Mt/yr at present. It made the proclamation in its annual report for the 2021 – 2022 financial year. Recent developments include the inauguration of its 3.9Mt/yr integrated plant at Mukutban in Maharashtra, run under its RCCPL subsidiary. It is the group’s fourth integrated plant and is reportedly the largest single cement production line in the state. The unit also includes a 40MW captive power plant.

Other developments include plans to expand the capacity of its Kundanganj grinding plant in Uttar Pradesh to 3Mt/yr from 2Mt/yr and a plan to build a new 1.2Mt/yr grinding plant at Gaya in Bihar. The group is also increasing production from its captive coal mines. Output from the Sial Ghoghri coal mine has been increased by 20% above its rated capacity to 30,000t/month. Development of the Bikram coal mine has been advanced and production is expected to start in mid-2023. Finally, the group is adding 8MW of solar power capacity at its Chanderia, Satna and Kundanganj plants in the current financial year and a 10.6MW waste heat recovery (WHR) unit is planned for the Mukutban plant.


Bangladesh: The high rate of the US Dollar against the Bangladeshi Taka is forcing local cement producers to raise their prices despite an increase in imports of volumes of raw materials. The country imported 5.12Mt of clinker, granulated slag, limestone, gypsum and fly ash in July and August 2022, a rise of 34% year-on-year, according to the Daily Star newspaper. Golam Kibria, the general manager of Premier Cement, said that the negative currency exchange effect was the main cause of local price rises for cement since the cost of raw materials on international markets had remained stable in recent months.

The country imported 36.1Mt/yr of raw materials for cement production in the 2021 – 2022 financial year. These materials mostly came from Thailand, Vietnam and China through ports in Chattogram and Mongla. This compares to imports of 16.8Mt in the 2017 – 2018 financial year.


China: Sichuan Yadong Cement’s plant in Sichuan has restarted production following a suspension of electricity to industrial users due to a heat wave. The local authorities stopped supplying industrial plants in late August 2022. The subsidiary of Taiwan-based Asia Cement Corporation also reduced staff levels at the plant to cope with the extreme weather event.


Australia: BGC has cancelled its latest attempt to sell the company, blaming the decision on labour shortages and supply chain disruption. It said it had received “very strong interest from a range of parties” but had made the decision based on poor market conditions, according to the West Australian newspaper. A shortage of skilled tradespersons in West Australia is negatively affecting the local home construction sector and reducing BGC’s value consequently. A second attempt to sell the company started in April 2022 with Macquarie Capital appointed to run the process. The company plans resume its sale in 2023 when market conditions have improved.


Mexico: Cooperativa la Cruz Azul’s Tula cement plant in Hidalgo has agreed with the Federal Electricity Commission (CFE) that electricity supplies will restored no later than 7 September 2022. Federico Sarabia, cooperative chair and leader of a dissident group claiming to own the plant, said that the plant has made losses of over US$15m due to the outage, according to the El Sol de la Laguna newspaper. The electricity supply to the site was reportedly cut in mid-August 2022 at the request of Víctor Manuel Velázquez, the head of the board of directors of the group.

State police intervened during a confrontation between rival groups for control of the Tula cement plant in late July 2022. The plant is the sole remaining Cruz Azul unit still reportedly 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. This group started asserting legal control of the cooperative’s cement plants in Puebla and Aguascalientes from mid-2020.


Cameroon: The Minister of Trade, Luc-Magloire Mbarga Atangana, has announced cuts to the price cement. He attributed this to a substantial increase in the production capacity of Mira SA’s plant to 1.5Mt/yr from 0.5Mt/yr, according to the Cameroon Tribune newspaper. Prices of some products have reportedly fallen by up to 12%.


China: Tangshan Jidong Cement’s operating income rose by 3% year-on-year to US$2.44bn in the first half of 2022 from US$2.36bn in the same period in 2021. However, its net profit fell by 7% to US$165m from US$178m. Its sales volumes of cement and clinker dropped by 20% to 38.4Mt from 48Mt. It has a reported clinker and cement production capacity of 110Mt/yr and 176Mt/yr respectively. The cement producer said that demand for cement was weak, especially in April and May 2022, with no seasonal rebound. It blamed its falling profits on geopolitics, coronavirus and a downturn in the real estate sector.


China: Dongwu Cement recorded consolidated sales of US$25.9m in the first half of 2022, down by 26% year-on-year from US$34.8m in the first half of 2021. The company’s loss was US$2.54m, compared to a US$3.76m profit in the previous period. At 30 June 2022, Dongwu Cement’s cement segment’s borrowings were US$14.8m, down by 4.5% from US$15.5m at the beginning of the year.


Morocco: LafargeHolcim Maroc’s sales were US$377m in the first half of 2022, consistent with its first-half 2021 sales, according to the L’Economiste newspaper. In the second quarter of 2022, the producer’s sales fell by 7% year-on-year to US$181m. It attributed this to a drop in its cement sales volumes, amid a national decline in demand of 10% year-on-year during the quarter. During the first half of 2022, Moroccan cement demand declined by 4.5% year-on-year. LafargeHolcim Maroc said that this was the result of global economic factors.

The producer’s net debt was US$590m on 30 June 2022, up by 5% year-on-year.


US: The Boulder County Planning Commission has recommended that county commissioners should reject Cemex USA’s application to extend its licence to mine limestone at its Dowe Flats quarry until 2037. Local press has reported that Cemex USA previously agreed to shut down its Lyons cement plant at the expiry of its extended licence in 2037. The company says that it will be able to continue operating the plant without use of the mine.

Cemex USA executive vice president Trpimir Renic said "We do always try and consume the raw materials that are available to us at the existing site where we are currently operating. We think that operating that quarry for the next 15 years - supplying Lyons cement plant - is the most responsible resource management operation that we can undertake."


Europe: RHI Magnesita is heading a European Union Horizon project called ReSoURCE. The project seeks to develop a sensor-based refractory waste sorting and powder handling system. It involves academic partners in Austria, Germany, Ireland, Norway and the UK. The European Health and Digital Executive Agency (HADEA) supplied Euro6m in funding for the study, while the UK government supplied Euro1m. Global refractory waste generation is currently 28Mt/yr.

RHI Magnesita chief executive officer Stefan Borgas said “On average, 60% of all spent refractories generated by refractory-consuming industries go to landfill, while only 30% are recycled. With the ReSoURCE project, we aim to increase it up to 75%. This means we can achieve significant savings of CO2 emissions per annum. With this research project, we have the chance to make a difference in the world.”


US: Royal White Cement has leased a site on the Houston Ship Channel in Houston, Texas. Local press has reported that the company plans to build its second cement terminal in the city there. Houston Peninsula Terminals will operate unloading systems for the storage of cement across three facilities at the site. It is also equipped with multiple railway tracks and heavy truck loading facilities. Royal White Cement owner Marcel Fadi said that the move would help the producer to expand its footprint in Houston and beyond.

Fadi said "We have long operated in the Houston market, but this direct access to storage and bulk unloading along the channel will provide greater efficiencies and flexibility, allowing Royal White Cement to handle and store approximately 100,000t of multiple cementitious products such as slag, grey cement, and white cement."


Mexico: Cemex has successfully closed its sale of its Costa Rica and El Salvador subsidiaries to Cementos Progreso for US$329m. Cemex plans to use the proceeds from the divestments to fund its bolt-on investment growth strategy, reduce its debt and for other general corporate purposes.


US: Lehigh Hanson has secured US$3.7m-worth of funding from the US department of energy for its planned front-end engineering design (FEED) installation of a carbon capture system at its Mitchell cement plant in Indiana. The funding was part of a total US$31m pot awarded to 10 different carbon capture projects across multiple industries. All of the projects have the capacity to capture over 95% of emissions from their respective plants.

Mitsubishi Heavy Industries America is supplying its carbon capture system for use at the Mitchell cement plant, at a total project cost of US$4.8m.


Canada: Lehigh Cement has initiated the administrative process to begin the use of alternative fuels (AF) in cement production at its Picton cement plant in Ontario. Under the company’s plans, the plant will substitute 200t/day of AF for coal and petcoke at the plant. Possible AF sources include excess seed from farm feed production in Ontario. The Picton cement plant previously reduced its CO2 emissions per tonne of cement by 20% through assorted sustainability initiatives.

Picton plant manager Carsten Schraeder said that the move will support Canada’s 2030 emission reduction plan, and also take pressure off landfill sites.


US: Argos USA has invested US$40m in 200 new ready-mix concrete mixer trucks, as the first phase of a five-year fleet expansion and replacement plan. The company says that the vehicles have a useful life of 8 – 10 years, or 53,500m3. It expects to make its next truck purchases in early 2023.

Argos USA ready-mix president Richard Edwards said "With the acquisition of these new assets, we continue our dedication to delivering extraordinary solutions to customers, helping facilitate the progress and development of the cities and communities where we have a presence. Our new trucks have a capacity of around 7.5m3 of concrete, are approximately 15% more fuel efficient than our previous trucks, and result in lower atmospheric emissions. They are also vehicles with the latest safety equipment, to continue ensuring the safety of our employees and everyone we share the road with daily."


UK: Cemex has bought 10 Volvo 460 8x4 tipper trucks for use at its Angerstein Wharf aggregates depot in Greenwich. From there, the trucks will deliver sand and aggregates all around London. The trucks’ bodies are made of lightweight aluminium, and they conform to Euro 6 emissions standards. This corresponds to 80% NOx emissions reduction and 50% particulate emissions reduction compared to Euro 5 standards.

Cemex UK fleet engineering manager Nigel Ponton said “The addition of these new trucks to our fleet will enable us to better meet customer demand, safely and efficiently. Safety is the number one focus whenever we add new trucks to our operation and these Volvos tick every box in that respect.” Ponton continued “These trucks will all be working in busy streets across London so it’s imperative we provide our drivers with the best tools possible to do the job and help protect any vulnerable road users. Moreover, thanks to the improved fuel efficiencies and enhanced payload these new Volvos are the most sustainable vehicles we’ve ever had and will help decarbonise our delivery footprint.”