Global Cement Newsletter

Issue: GCW608 / 17 May 2023

Headlines


The two largest cement producers in Japan released their results for their 2023 financial years this week. Much like manufacturers elsewhere in the world they reported mounting sales revenues, but they also noted losses. Input prices such as coal rose in 2022 and these were passed on to consumers in the form of higher prices. However, this was insufficient to stop them making a loss.

In the case of Taiheiyo Cement, its domestic sales volumes of cement remained stable at 13.4Mt in the year to 31 March 2023. It made a loss at home in Japan but still reported a profit in its overseas businesses, despite export volumes falling by 41% year-on-year to 2.44Mt. The group also noted delays at construction sites due to a lack of workers. Recent domestic developments for Taiheiyo include an agreement in October 2022 to buy the cement business of chemicals company Denka. Outside of Japan, in China, the group suspended the production and sale of cement from its Jiangnan-Onoda Cement subsidiary in February 2023 citing a 'tougher competitive environment,' although it justified this decision as part of its strategy to refocus on Southeast Asia. Then, in late April 2023, the company was forced to stop its proposed acquisition of the Tehachapi cement plant in the US due to an inability to obtain regulatory approval.

Sumitomo Osaka reported a similar situation, with cement sales volumes also down year-on-year. Again, cement price increases were unable to catch coal prices made worse by negative currency exchange effects. Having got the bad news out of the way, it then it took the opportunity to outline its medium term strategy to 2035. It said that becoming carbon neutral was the key to this. In its 2022 financial year cement accounted for around 70% of total sales. However, it is now aiming to reduce this to 65% by 2025 and 50% by 2035. If this sounds familiar this is because it is similar to what Holcim is doing with its growing light building materials division and its diversification away from the heavy building materials trio of cement, concrete and aggregates. Sumitomo Osaka plans to invest over US$3.5bn towards this goal by developing its presence in the semiconductors sector, building its business in Australia and starting new ventures in decarbonisation.

Of the other cement producers, Tokuyama Corporation said in late April 2023 that it was considering suspending operation of one of the three kilns at its 4.54Mt/yr Nanyo cement plant as part of measures to strengthen profitability. It reported a growing loss for the current financial year that it blamed on raw material and fuel costs. Mitsubishi Materials and Ube Industries formed their merged cement businesses in April 2022 known as Mitsubishi UBE Cement Corporation. Ube said, as part of its latest financial results, that, despite a gradual decrease in the domestic market, cement sales had remained stable but that the business was “heavily affected” by rising energy prices such as coal. It added that demand for cement and concrete remain strong in its overseas market in North America.

Graph 1: Sales and exports of cement in Japan from 2013 – 2022. Source: Japan Cement Association.

Graph 1: Sales and exports of cement in Japan from 2013 – 2022. Source: Japan Cement Association.

The Japanese cement market peaked in the 1990s. Domestic sales of cement in Japan have declined over the last decade, as can be seen in Graph 1 above, but at a slower rate. Exports rose to a peak of just under 12Mt in 2017 but have slipped a little since then. Data from the Japan Cement Association placed production at 53.2Mt in 2022 compared to 61.7Mt in 2013. This trend explains the move by the cement producers towards decarbonisation, offshoring, diversification and consolidation. The bump in fuel prices over the past year may have accelerated this process, as examples such as Taiheiyo Cement’s takeover of Denka and Sumitomo Osaka’s new business strategy suggest. The race continues to keep cement production profitable in a changing business environment.


Colombia: Empresa Colombiana de Cementos has appointed Martha Patricia Quintero Valderrama as its director general. She succeeds Juan Martínez in the post, according to Valora Analitik. The company is a joint venture between Spain-based Cementos Molins and Corona. It operates the Alión brand.

Quintero has worked for Alión as its commercial director since 2018. Prior to this she worked for Polpaico in Chile and spent over 20 years with LafargeHolcim and its associated companies in Colombia. She is a trained civil engineer from the University of Cartagena. She also holds postgraduate qualifications from the EAN University and Tecnológica del Caribe.


US: Sabia has appointed Hal Grodzins as its chair and chief executive officer (CEO). He succeeds Clinton Lingren in the post. Grodzins previously held the post of president and chief operating officer at Sabia. Prior to this he worked as the chair and CEO of Heuresis Corporation and also worked for Thermo Fisher Scientific.

Sabia produces analytical hardware and software for the bulk materials sector including applications for cement, coal, mineral ores and other markets.


Finland: Tana Oy has appointed Kalle Saarimaa as its chief executive officer with effect from 1 June 2023.

Saarimaa is currently working as the Senior Vice President for Circular Solutions at Fortum Oyj. However, he has been a member of the board of Tana Oy since 2021. Prior to working for Fortum Oyj he held posts with Ekokem and Walki Oy. He is also active in Finnish and European waste management organisations and as a board member of circular economy companies.

Tana sells products to the recycling and landfill sectors such as shredders, compactors, screeners, sifters and more.


India: Sagar Cements says that its subsidiary Andhra Cements will relaunch the clinker line at its Durga cement plant in Andhra Pradesh before July 2023. The Hindu BusinessLine newspaper has reported that the producer previously relaunched grinding operations at the plant in April 2023.

Sagar Cements plans to invest a further US$56.8m in Andhra Cements’ Durga cement plant to increase its installed cement capacity by 67% to 3Mt/yr and its clinker capacity by 39% to 2.3Mt/yr before 2025.


Philippines: San Miguel Corporation’s cement sales more than tripled year-on-year to US$183m during the first quarter of 2023, from US$57.1m during the first quarter of 2022. The group’s cement business contributed 3% of consolidated sales, compared to 1% in the first quarter of 2022. Overall, group sales rose by 9% to US$6.17bn, the Philippine Daily Inquirer newspaper has reported.

San Miguel Corporation completed its acquisition of Eagle Cement in December 2022.


Vietnam: The Vietnam National Cement Association (VNCA) expects members to record a 13% drop in their gross profit in 2023 due to a 3% rise in electricity prices. At the same time, it expects cement demand to fall due to the slowing of residential construction activity. During the first quarter of 2023, Vietnamese cement exports to China fell by 90% in value terms.

Việt Nam News has reported that electricity costs constitute 15% of operating expenses for the Vietnamese cement sector.


France: Cemex France and Ecocem have signed a deal to collaborate on the development of reduced-CO2 concrete development at 10 Cemex France ready-mix concrete batching plants. The partnership will explore methods that include the use of supplementary cementitious materials in place of clinker. Cemex hopes that the collaboration will help to realise its goal of a 55% CO2 emissions reduction across its European operations by 2030.

Cemex Western Europe vice president materials and Cemex France president Michel Andre said “Cemex continues to reinforce its commitment to advancing the sustainability agenda with the announcement of this extended partnership with Ecocem. We know that if we are to achieve our global ambition of operating as a net-zero business by 2050 we must prioritise exploring innovation and new technologies with like-minded companies who share our dedication to leading the industry’s transition to a lower carbon and circular economy.”


Germany: Flender has officially completed construction work on an expansion at its site in Voerde with the opening of its new logistics and storage hall for the assembly of large gear units. The hall has been built on an open area on the company's premises covering almost 8000m2. The new building is part of the drive manufacturer’s investments to be able to handle the expected growth in the global wind energy business and to drive the energy transition in Europe. In addition to large components for wind power gearboxes, the logistics hall will also serve its industrial business. The company has also leased another 10,000m2 hall, directly next door to its Voerde unit, to further support its logistics.

Flender’s chief executive officer Andreas Evertz said "With the new storage areas, we are making our logistics processes sustainable and thus reducing a considerable part of the previous transport routes and the associated CO2 emissions. Components that were previously stored elsewhere can now be stored centrally and made available for assembly more quickly with optimised transport routes.”

Flender’s Voerde plant is the company’s largest in Germany with an area of 276,000m2. It employs 1500 people.


Canada: Lafarge Canada signed a tri-partite agreement with Dimensional Energy and Svante Technologies for the construction of a synthetic hydrocarbons plant to use captured CO2 from its Richmond cement plant on 15 May 2023. The upcoming plant will convert the Richmond cement plant's 1t/day captured CO2 emissions into 1.5 barrels/day of synthetic hydrocarbons. The producer, a subsidiary of Holcim, selected this particular solution due to the lack of CO2 transport and sequestration infrastructure in the area of British Columbia where the Richmond plant is located. The project marks Phase 3 of the installation of Lafarge Canada and Svante's carbon capture project at the Richmond plant.

Holcim's Western Canada regional head of sustainability and environment, Stephanie Voysey, said "Carbon capture is an important lever in our net-zero roadmap. However, for a carbon capture project to succeed, it must be paired with permanent geologic sequestration or utilisation technology that will permanently isolate the CO2 in a specific media or product. If this pilot can be scaled to capture and use all facility emissions, it would be a first-of-its-kind project for Lafarge and advance export and global adoption of this technology.”


India: UltraTech Nathdwara Cement has commissioned its upgraded Neem Ka Thana grinding plant following an 800t/yr capacity expansion. The project expanded the plant's capacity by 57% to 2.2Mt/yr.

The Hindu Business Line newspaper has reported that parent company UltraTech Cement's 22 integrated cement plants, one clinker plant and 27 grinding plants give it an 80% market reach in India.


Australia: James Hardie's sales were US$3.77bn during the 2023 financial year, up by 4% year-on-year from 2022 financial year levels. Its flagship North America fibre cement segment increased its sales by 9% to US$2.79bn, its Asia Pacific fibre cement segment increased its sales by 1% to US$527m and its Europe Building Products segment increased its sales by 3% to US$470m.

James Hardie's CEO, Aaron Erter, said “We delivered full-year adjusted net income and operating cash flows of US$606m and US$608m respectively. I am pleased with how the team adjusted during the 2023 financial year to prepare the company to thrive through this cycle. This is reflected in our strong fourth quarter results, including all three regions delivering significant earnings before interest and taxation (EBIT) margin improvement sequentially in the fourth quarter.”

Looking forward to the first quarter of the 2024 financial year, James Hardie forecast adjusted net income growth of between -6% and +6.9%, to US$145 - 165m, throughout the quarter.


Kenya: A court has ruled in favour of Absa Bank Kenya and Kenya Commercial Bank's right to appoint an administrator for Savannah Cement. The banks are seeking to recover US$72.9m owed by the producer. The Star newspaper has reported that a previous court ruling in December 2022 prevented the lenders from appointing an administrator or seizing assets.


Mexico: Cemex's waste management subsidiary Regenera has signed a deal with the municipal council of Huajuapan de León to receive the latter's sorted non-recyclable municipal solid waste (MSW). Under the deal, Regenera will receive up to 6000t/yr of MSW, which it will supply to Cemex's Tepeaca cement plant in Puebla.


France: Germany-based Heidelberg Materials announced a planned Euro65m upgrade to its Bussac-Forêt cement plant in Charente-Maritime Department on 14 May 2023. The project will involve the installation of systems for the production of calcined clay cement. The producer says that this will enable the 0.8Mt/yr plant to reduce its CO2 emissions by 20%.

Chief sustainability officer Nicola Kimm said “In Bussac-Forêt, we are investing in a technology with great potential. It will allow us to significantly expand the range of low-carbon products. Using calcined clay as a clinker substitute is an important measure to reduce the carbon footprint of cement and concrete. In principle, a CO₂ reduction of up to 40% is possible when substituting cement clinker with calcined clay.”

Heidelberg Materials is already involved in the on-going pilot trial of a 400,000t/yr clay calcination plant in Ghana.


India: NCL Industries has concluded a share purchase agreement with the owners of Vishwamber Cements. Under the deal, NCL Industries will acquire 100% ownership of Vishwamber Cements. The group says that it plans to merge the newly acquired subsidiary into its own cement business. It noted that Vishwamber Cements owns 130 hectares of active limestone quarries.


Italy: Buzzi Unicem reported first-quarter sales of Euro956m in 2023, up by 20% year-on-year from Euro800m in the first quarter of 2022. The producer's cement volumes dropped by 8.8% to 5.8Mt from 6.36Mt. It attributed this to a general slowdown of the construction sector across its markets. Local low demand from the residential market and adverse weather compounded the regional sales contraction in Central Europe. On the other hand, the group recorded volumes growth in Mexico and Russia and stability in Brazil. Both Mexico and Brazil produced revenues growth, while Buzzi Unicem's revenues fell in Russia due to the effect of the appreciation of the ruble against the comparison period in 2022, when the start of the on-going Russian invasion of Ukraine devalued it.

Overall, the group expects to 'easily' match its 2022 full-year earnings before interest, taxation, depreciation and amortisation (EBITDA) in 2023. It said that that it could not currently delineate a 'clearly different picture,' but added "The stabilisation of energy prices, albeit at higher levels than in 2022, if confirmed, will allow us to have better visibility on the unfolding of the production costs from spring onwards."


Italy: Caltagirone Group subsidiary Cementir Holding reported year-on-year growth in sales of 15% to Euro415m during the first quarter of 2023. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 34% to Euro81.2m. The group ended the period under review with a net debt of Euro32.1m, down by 64% year-on-year.

Cementir Holding said that its cement sales volumes rose in Türkiye, but failed to offset declines in its Nordic & Baltic, Belgium and US regions, resulting in an overall decline of 4%.


India: The municipal corporation of Kolkata, West Bengal, has enacted regulations requiring landowners to send construction waste from projects on their property to construction and demolition waste recycling facilities. The Telegraph newspaper has reported that the new regulations apply to all construction, demolition and repairs work on plots of land larger than 0.24 hectares. The city authorities have built a 183,000t/yr recycling plant in New Town, Greater Kolkata, to support the increased volumes.


France: Hoffmann Green Cement Technologies has commissioned its H2 plant, a 1000t/day clinker-free cement plant, adjacent to its existing H1 clinker-free cement plant in Bournezeau, Pays de la Loire. L'Usine Nouvelle News has reported that the new plant took 24 months to build and cost Euro22m. The main part of the plant consists of a 70m tower, where activated clay, ground granulated blast furnace slag (GGBFS) and gypsum are mixed to produce the cement. It is installed with solar panels capable of supplying 50% of its energy consumption. The producer says that its clinker-free cement has over 90% lower CO2 emissions than cement produced with ordinary Portland cement (OPC). It aims to sell 24,000t of the product throughout 2023.


India: Ambuja Cements has placed orders with equipment suppliers for an 8Mt/yr clinker capacity expansion across two of its cement plants. The plants in question are the 2.9Mt/yr Bhatapara cement plant in Chhattisgarh and the 4.5Mt/yr Maratha cement plant in Maharashtra. Ambuja Cements will also build 42MW-worth of waste heat recovery (WHR) power capacity. The new cement capacity will be able to operate on renewable energy and use 50% alternative fuel (AF). As such, upon completion of the project, the plants will together produce 14Mt/yr of Ambuja Cements' reduced-CO2 Blended Green Cement. The producer will fund the work through internal accruals, and expects to complete it in May 2025.

CEO Ajay Kapur said "These brownfield expansion projects are part of our strategy to double our production capacity over the next five years from the current capacity of 67.5Mt/yr. Our ongoing investments in capacity expansion and sustainability will enable us to achieve our long-term objectives, as we remain committed to delivering sustainable growth and value to our stakeholders."


Uzbekistan: United Cement Group subsidiary Qizilqumsement says that it has awarded contracts for the upgrade of Lines 1 and 2 at its Qizilqum cement plant in Navoiy Region. Uzbekistan Newsline has reported that the producer has completed testing to ascertain the lines' parameters of operation, fuel and energy consumption and output. This will inform its decisions, with a view to reducing the cost of clinker production.

Qizilqumsement is currently in the process of building the Qizilqum plant's new 767,000t/yr Line 4, which will also increase its clinker capacity by 657,000t/yr. The producer expects this to lower the cost of its clinker production by 30%.


Brazil: Votorantim Cimentos recorded consolidated sales of US$1.18bn during the first quarter of 2023, corresponding to year-on-year growth of 18%. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) also rose, by 85% to US$158m. Cement sales volumes fell in Brazil and Bolivia, but rose in Spain. The producer noted 'pressure' from high raw materials, freight and fuel costs in Brazil.

CEO Osvaldo Ayres Filho said "Price management implemented globally to face cost inflation contributed to the positive results in the quarter, despite the still volatile and uncertain scenario in the global economy. The company remains firm and aligned with its strategic plan, financially solid and prepared for the opportunities and challenges that lie ahead."


Colombia: Cementos Argos sold 3.9Mt of cement during the first quarter of 2023, down by 0.6% year-on-year. This contributed to a 12% rise in its consolidated revenues to US$721m. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 42% to US$127m.

President Juan Esteban Calle said "In the first quarter of the year we experienced a stable market dynamic in most of the territories in which we are present, sequential improvements in costs, especially in fuels, energy and, in some cases, raw materials and mixed macroeconomic signals that keep us optimistic about medium-term trends." He added "Beyond the constant challenging conditions, we continue to take forceful steps toward our goal of creating value for the company, our investors, customers and other stakeholders."


Canada: Lafarge Canada has renewed its partnership with fuel logistics company 4Refuel to launch renewable diesel use in its operations in Manitoba. The producer says that trucks will run on renewable diesel produced from waste oils and fats. This will eliminate 39% of the producer's Scope 3 CO2 emissions in the province.

Lafarge Canada's vice president Manitoba and Saskatchewan Tina Larson said "Switching to renewable diesel is a significant step forward in our sustainability journey. We recognise that climate change is one of the most significant challenges facing our planet, and we are committed to doing our part to reduce our impact on the environment. We believe that renewable diesel is an excellent solution to help us achieve our sustainability goals while maintaining the high level of performance that our customers expect.”

Lafarge Canada previously implemented renewable diesel in its operations in Greater Vancouver, British Columbia, in November 2022.


India: Dalmia Cement (Bharat) plans to invest US$560m following the signing of a memorandum of understanding (MoU) with the Assam government on the construction of a new cement plant in the state. The Economic Times newspaper has reported that the producer expects the project to generate a total of 2500 new jobs.

Managing director and chief executive officer Mahendra Singhi said “This year also marks the 10th anniversary of Dalmia Bharat’s manufacturing presence in Northeast India. We remain deeply committed to continuing to be a partner in the region’s economic progress." He continued "The Northeast region has showcased a very forward-leaning mindset, being one of the fastest adaptors of low-carbon blended cement. The penetration of Low Carbon Green Cement is in line with our vision of becoming carbon negative by 2040, and further intensifies our commitment towards the Grey to Green movement.”


Japan: Taiheiyo Cement's consolidated sales rose by 14% year-on-year to US$6.02bn for its 2023 financial year, which ended on 31 March 2023. Its cement volumes fell by 1.5% to 37.3Mt. It said that current high costs of labour and building materials generally reduced cement demand in its local market. It reported a net loss of US$247m, up by 15% from US$215m. Nikkei News has reported that the company has forecast a US$297m profit in the 2024 financial year.


Japan: Sumitomo Osaka Cement's consolidated sales rose by 11% year-on-year to US$1.52bn in the 2023 financial year from US$1.37bn in the previous financial year. Despite this growth, the group recorded a loss of US$42.5m, compared to a net profit of US$71.8m in the previous financial year.


South Korea: The Korea Trade Commission (KTC) has launched a probe into imported white cement from Egypt. The commission will investigate the possible necessity of anti-dumping duties on imports of the product. Yonhap English News has reported that the KTC is responding to a complaint from domestic white cement producer Union Corporation. The producer accuses International Cement Trading and Egypt-based Royal El Minya Cement of damaging its business through cement dumping. The KTC will complete its preliminary investigation before 1 September 2023.