Global Cement Newsletter

Issue: GCW614 / 28 June 2023

Headlines


Cemex highlighted its Clyngas project at its Alicante cement plant in Spain this week. The project will produce synthesis gas (syngas) from different types of waste for direct injection into the burner at the plant during the combustion process. It is being run in conjunction with Waste to Energy Advanced Solutions (WTEnergy), a company that Cemex invested in at the end of 2022. It is also receiving Euro4.4m in funding from the European Commission (EC) as part of its innovation fund for small scale projects. The initiative estimates that it will save over 400,000t of equivalent CO2 during the first 10 years of the project's life by replacing petroleum coke with syngas.

Clyngas is another example of Cemex’s innovation with alternative fuels for cement and lime. It follows on from the group’s work with hydrogen injection into cement kilns. As presented at the 15th Global CemFuels Conference 2022 it has been using hydrogen in low volumes as a combustion enhancer in more than 20 plants worldwide. However, it was also looking into using hydrogen more directly as a fuel and as a feedstock for other alternative fuels. WTEnergy’s gasification process could potentially link up to this as it converts waste streams such as wood chips, agricultural waste, refuse derived fuel (RDF), solid recovered fuel (SRF), dry sewage sludge, meat and bone meal, poultry litter and plastics into syngas. WTEnergy then proposes that its gasification process and/or the syngas can be used for power generation and thermal applications. In the case of the Clyngas project it will be the latter, as the gasification process will be used to boost the burnability characteristics of RDF with a high biomass content. One part of this to note is that the syngas can potentially be used to manufacture hydrogen. This would be a useful capability for a cement company, for example, that was already using alternative fuels and was now considering further decarbonisation by switching to using hydrogen.

A few other cement companies have been looking at synthetic fuels too, but this has generally been as a by-product of carbon capture and utilisation. This week Lafarge France, for example, said it had signed a memorandum of understanding with Axens, EDF and IFP Energies Nouvelles for a synthetic fuel production trial. Its plan is to build a unit that will produce synthetic kerosene using captured CO2 from a carbon capture installation at Lafarge France's Saint-Pierre-La-Cour cement plant. The kerosene will then be sold to airlines. Other examples of cement companies looking at using captured CO2 to manufacture synthetic fuels include Finnsementti’s pre-engineering study with Aker Carbon Capture to consider producing methanol as a fuel for transport, Holcim’s and TotalEnergies’ various plans of what to do with the CO2 captured from the-to-be upgraded Obourg cement plant and Cemex Deutschland’s ambitions for its Rüdersdorf plant.

As can be seen above there are different types of synthetic fuels and cement companies are at the research and pilot stages. Although there isn’t a commonly accepted definition of what a synthetic fuel is, the general meaning is that of a fuel made from feedstock using a chemical reaction as opposed to, say, a refining process. The wide variety of potential synthetic fuels puts the confusion over the different types of hydrogen into perspective. However, this may be a problem for a later date if usage by cement companies becomes more serious.

What is a problem, though, has been the EC’s planned legislation to phase out the use of industrial CO2 in synthetic fuels by 2041. Cembureau, the European cement industry association, warned in late 2022 of the issues this would pose for industries trying to find a way to utilise their CO2 emissions where storage was too difficult or expensive. Its view was that while synthetic fuels using industrial CO2 are not fully net-zero, as the captured CO2 is later released into the atmosphere, it is a necessary short to medium term step for sectors trying to make the transition. Companies trying to build industrial-scale chemical plants for synthetic fuels need running periods of 20 to 30 years to achieve payback. As of March 2023 Cembureau was still concerned about the implication of proposed regulations, specifically with regards to the proposed criteria for which synthetic fuels could be used, based on their greenhouse gas emissions savings (at least 70% compared to the regular fuels being replaced). It directly linked this to synthetic fuels projects being launched by the cement sector that might be adversely affected by the new rules. The EC published the legislation in late June 2023 and it is set to become legal in mid-July 2023.

Using synthetic fuels either as a fuel or a by-product from cement production is an area of interest currently with the projects detailed above and others in progress. One vision for their use in Europe, at least, is that they might offer a route for carbon capture for cement plants without access to the logistic networks necessary for sequestration. Whether they find a place in cement manufacture either on a transitional basis or over a longer term should become clearer over the coming decade. Yet the EC’s new rules are likely to slow this process down as at least some of the planned pilots may become unviable in Europe. Other jurisdictions around the world take note.


UK: Aggregates Industries has appointed Pete Hollingworth as the managing director of its Concrete Products business. He has spent over 25 years working in the construction industry to date, holding various commercial and managerial positions across the flat roofing, structural waterproofing and flooring industries. Most recently, he was the head of business support in the Europe, the Middle East and Africa region for Sika.


Mozambique/South Africa: China-based Huaxin Cement has agreed to buy the Africa-based business of InterCement for US$265m. The deal includes the Brazil-based company’s assets in Mozambique and South Africa. It follows InterCement’s sale of its business in Egypt earlier in 2023 to an unnamed buyer. The company will use the latest proposed sale to reduce its debts. The transaction will be subject to approval from regulators in China, Mozambique and South Africa. InterCement appointed JP Morgan as its financial advisor to the sale of its operations in Egypt, Mozambique and South Africa.

InterCement operates two integrated cement plants and three grinding plants in Mozambique under its Cimentos de Moçambique subsidiary and one integrated plant and two grinding plants in South Africa under its Natal Portland Cement subsidiary. Huaxin Cement’s operations in Africa include subsidiaries in Malawi, Tanzania and Zambia.


Malaysia: Cahya Mata Sarawak subsidiary CMS Cement has secured board approval to build a new 1.9Mt/yr clinker line at its Kuching cement plant at Jalan Mambong. This will more than triple its clinker capacity to 2.8Mt/yr. The Star newspaper has reported that construction will continue for 36 months from the date of groundbreaking. CMS Cement expects to invest US$161m in the project.

The Kuching cement plant is reportedly operating at 55% utilisation of its 2.75Mt/yr cement capacity. It currently relies on 40% of its own clinker to produce cement, with 60% of clinker imported. It aims to achieve clinker self-sufficiency to better serve growing markets in Sarawak and elsewhere, including Malaysia’s upcoming new capital city, Nusantara, on the opposite side of Borneo.


Canada: Heidelberg Materials North America has appointed engineering firm WSP to carry out design, engineering and implementation of a planned 1Mt/yr carbon capture installation at its Edmonton cement plant in Alberta. Construction will begin in late 2024 and reach completion in late 2027. Through the project, Heidelberg Materials North America aims to realise net zero CO2 cement production at the 1.4Mt/yr Edmonton plant.

Heidelberg Materials’ vice president of cement Joerg Nixdorf said "WSP’s proven track record of delivering high-quality and sustainable engineering solutions aligns perfectly with our vision of driving decarbonisation in the cement industry. Together, we will push the boundaries of what's possible and create a truly transformative project."


China: China National Building Material (CNBM) subsidiary New Tianshan Cement plans to increase its stake in Ningxia Building Materials to 51% from 49% for US$373m. Reuters has reported that New Tianshan Cement will raise funds through the issuance of US$971m-worth of commercial papers.

Further to the restructuring, CNBM will enlarge its stake in Ningxia Building Materials subsidiary Ningxia Saima by 12%.


Bangladesh: Premier Cement Mills has installed an 11,000t/day vertical roller mill (VRM) at its West Mukterpur grinding plant in Munshiganj. The producer said that the expansion will more than double the grinding plant’s capacity to 7Mt/yr.

Energy & Power News has reported that Premier Cement Mills took a loan worth US$32.4m for the construction of the new mill.


France: Vicat says that it will commission its planned 100% carbon capture system at its Montalieu-Vercieu cement plant ‘before 2030,’ and possibly as soon as 2027. The Les Echos newspaper has reported that the system will have a capture capacity of 1Mt/yr of CO2, although the plant’s emissions are currently 800,000t/yr. Captured CO2 may then be transported by barge, train or pipeline to the port of Fos-sur-Mer.

When commissioned, the upcoming carbon capture system will reduce the CO2 emissions of cement produced at the Montalieu-Vercieu plant by 94% to 40kg/t.


Nigeria: Lafarge Africa has launched the Eco Label brand, as part of its wider UniCem brand, to promote its sustainable products. Products within the new branding have a lower 30% carbon footprint compared to the local industry standard. The formal unveiling of the new branding took place at the Mfamosing cement plant in Calabar.

Khaled El Dokani, the chief executive officer of Lafarge Africa, said “Lafarge Africa is proud to be the first local cement manufacturer of eco-friendly cement to the Nigerian market. With the rollout of this Eco brand, we are accelerating the transition to more sustainable building materials for greener construction.”


Russia: Cementum is preparing to upgrade the grinding capacity at its integrated Ferzikovo cement plant in Kaluga region. The US$40m project will add 0.3Mt/yr of grinding capacity to the plant. Other planned developments include building a dry building materials unit and a concrete plant. Maxim Goncharov, the general director of Cementum and Vitaly Bogachenko, the Director of Corporate Relations and Sustainable Development of Cementum, met with Vladislav Shapsha, the governor of the Kaluga Region, in mid-June 2023 at the St Petersburg International Economic Forum to discuss development in the region. Holcim’s divested Russian business rebranded as Cementum in early 2023.


Russia: Cemros’ integrated Serebryansky cement plant in Ryzan region has switched to using gas as a fuel. The project was conducted with Gazprom and the regional government, including linking the site up to the gas network with a 14km pipeline. CO2 emissions at the plant are expected to decrease by up to 17% and electricity consumption by 4%. The 1.8Mt/yr plant used around 200,000t/yr of coal before starting the switch to gas from March 2023.


Greece: Titan Group has successfully commissioned an upgrade to the pre-calciner system of its Kamari cement plant in Voiotia. Titan Group says that this will enable the 3.1Mt/yr plant to expand its range of lower carbon cements, reducing its CO2 emissions by 150,000t/yr. It also increases the plant's maximum possible alternative fuels (AF) substitution rate.

Titan Group’s Europe regional executive director Yanni Paniaras said "The completion of the Kamari plant upgrade represents a significant achievement for Titan Group. We are witnessing tangible results as our green innovation gains momentum and takes shape. This successful implementation of one of our major capital expenditure projects exemplifies our dedication to sustainable operations and strategic growth, while we continue to pursue more growth opportunities in all our active markets. We are committed to offering our customers and communities greener products and solutions, playing our part in building a sustainable future for all.”


Ethiopia: Derba MIDROC Cement is reportedly ready to sign a contract with China National Building Material (CNBM), for the latter to commence construction of Derba MIDROC Cement's 2.74Mt/yr Mughar Valley cement plant in Oromia. The producer said that it expects to invest US$500m in the project, 30% higher than its previous estimate of US$385m. Addis Fortune has reported that Derba MIDROC Cement now believes there to be adequate energy infrastructure to support the plant, following China-based Sinohydro's construction of a new US$12m power line from nearby Chanco.

When commissioned, the plant will double Derba MIDROC Cement's capacity and create 3000 new jobs in Oromia. The producer also hopes to ease the ongoing national cement shortage. The Ministry of Mines recorded domestic production of 7.6Mt in 2022, against demand of 36Mt.


Spain: Cemex España has secured Euro4.4m in EU funding for an upgrade to its Alicante cement plant in Valencia. The project will launch the use of Clyngas synthetic gas as alternative fuel (AF) at the plant. Thermochemical conversion specialist WtEnergy, a subsidiary of Cemex Ventures, will supply the syngas. The partners say that this upgrade will reduce CO2 emissions by 400,000t per decade.

Parent company Cemex said "This project is part of Cemex’s Future in Action programme, which seeks to achieve sustainable excellence through climate action, circularity and natural resource management, with the primary objective of becoming a net-zero CO2 company."


India/US: The US Attorney's Office has requested that large Adani Group shareholders submit correspondence from the group. Reuters has reported that the office is investigating representations made by India-based Adani to its US investors, following fraud allegations by US-based short-seller Hindenburg Research.

An Adani Group spokesperson said "We are not aware of any such subpoena to investors."


Saudi Arabia: Southern Province Cement has secured a loan worth US$373m from Saudi National Bank. The loan will cover its construction of a 5000t/day production line at its upcoming Jizan cement plant, as well as the construction of infrastructure for a second new line of the same capacity at the plant. The producer appointed China-based Sinoma International Engineering to build the plant in May 2023.

Reuters has reported that the loan has a duration of 10 years and a two-year grace period.


India: Sinoma subsidiary LNV Technology has won an engineering, procurement and construction (EPC) contract in India. Reuters News has reported that the contract is in the area of 'cement production.' Its value is US$53.8m.

LNV Technology is headquartered in Chennai, Tamil Nadu. It previously supplied grinding systems and other equipment for JK Lakshmi Group, Jaiprakash Associates (now part of Dalmia Bharat) and Holcim India (now part of Adani Group).


India: Shree Cement has rejected findings by the government's Income Tax Department of tax fraud worth US$2.8bn. NDTV News has reported that the producer's alleged financial mismanagement resulted in losses of up to US$170m/yr for national and state governments. The mismanagement reportedly included the use of forged documents. Authorities conducted a second set of searches at company sites in Rajasthan during the week ending on 25 June 2023, following preliminary searches on 21 June 2023.

Shree Cement said "The company's management team is available and extending full cooperation to the officials. The information as required by the officials is being made available."


World: Menzel Elektromotoren says that it has successfully supplied a new MEBSSL-type three-phase slip ring mill motor to a cement plant. The supplier modeled the new motor on a preexisting machine at the site, with a 710mm-high shaft and 2000kW rated power capacity. It is also equipped with a short-circuiting and brush-loading device. It said that this will reduce costs and increase efficiency.

Menzel Elektromotoren is currently building a new motor plant at Henningsdorf in Brandenburg, Germany, which will also function as its new headquarters from 2024.


India: Tamil Nadu Cement Corporation plans to rehabilitate limestone mines which serve its 500,000t/yr Ariyalur cement plant in Tamil Nadu. The state's Minister for Industry Thalikottai Rasuthevar Baalu Rajaa said that the state-owned producer will plant saplings to start the restoration.

The Hindu newspaper has reported that Rajaa and other ministers of the Tamil Nadu government visited the Ariyalur cement plant on 25 June 2023.


France: Lafarge France has signed a memorandum of understanding with green hydrocarbons specialist Axens, utilities provider EDF and research firm IFP Energies Nouvelles for a synthetic fuel production trial. The partners will build a plant to produce kerosene using captured CO2 from a carbon capture installation at Lafarge France's Saint-Pierre-La-Cour cement plant. The project, called Take Kair, aims to produce fuel for use by aviation companies, including Air France-KLM Group.

Holcim France president François Petry said "The decarbonisation of our processes and products is at the heart of our strategic commitment to reach Net Zero by 2050. Beyond the modernisation of our production tools, we work on all industrial and technological levers to reduce our emissions, and thus decarbonise our industry. With the Take Kair project, we are taking a decisive step in the capture and management of our residual CO2 emissions and participate with our partners in the emergence of an innovative and sustainable sector serving the country's mobility needs."

Lafarge France, a subsidiary of Switzerland-based Holcim, announced a Euro40m investment in the 1.6Mt/yr Saint-Pierre-La-Cour cement plant to achieve carbon neutral cement production there in March 2022.


India: Nuvoco Vistas has commissioned feeding systems for alternative fuel (AF) in the pyro-process sections of its Nimbol and Risda cement plants. The systems will handle municipal solid waste, including unrecyclable plastic.

Managing director Jayakumar Krishnaswamy said "As part of our Protect Our Planet agenda, we view the AF projects as an important step towards fulfilling our commitment to sustainable cement manufacturing and reducing the environmental impacts. The successful completion of this project demonstrates our commitment to reducing carbon emissions, maximising waste consumption and demonstrating responsible resource management practices.” He added "This along with, other themes under Protect Our Planet agenda, is enabling Nuvoco to build robust partnerships with several stakeholders, and contribute to society at large.”


US: The Portland Cement Association (PCA) hosted a one-day session in mid-June 2023 aimed at establishing guidelines for the definition of 'low carbon' cement and concrete. The association called the session a 'Critical first step' towards ensuring clarity for stakeholders.

The PCA said "Low carbon is increasingly defined in the eye of the beholder, with little or no regard to either upstream and downstream impacts or short-term and long-term strength, durability and resilience concerns."


Kosovo: Alba Group has announced plans to build a lime plant in Kosovo, the first in the country. The company has appointed Switzerland-based Maerz Ofenbau to execute the project. The supplier said that it looks forward to many years of cooperation with Alba Group.


Bahrain: Fives Services Gulf has held the inauguration ceremony for its Bahrain workshop. The facility includes offices, warehouses and machining, parts production and repair facilities. The site first entered operation amid Covid-19 restrictions in early 2021.

Fives Services Gulf chief executive Frederic Gicquel said "We are proud to be part of the industrial development of Bahrain and support the government's efforts to improve the foreign investor experience. This workshop will enable us to provide better quality services to our clients in the region and contribute to the sustainable growth of the industrial sector."

The subsidiary of France-based Fives employs 134 people.


Uruguay: The government has tendered for offers to acquire state-owned Administración Nacional de Combustibles, Alcohol y Portland (ANCAP). The Caras y Caretas newspaper has reported that the board of directors approved the tender on 18 May 2023. The tendering process will run until 11 July 2023, and any resulting privatisation will require ratification by parliament.

ANCAP operates two 300,000t/yr integrated cement plants.

The tender can be viewed here.


Türkiye: Italy-based Bedeschi says that it received an order for four pipe conveyers and an SHL 26/1000 ship loader from Medcem Cement. Medcem Cement will install the equipment as part of an expansion to its Yeşilovacık cement and clinker terminal in Mersin Province. The conveyors will form a 1km-long system with a conveying capacity of 1000t/hr of cement or 1350t/hr of clinker.

Bedeschi said that it previously supplied a ship loader of the same specifications for the Yeşilovacık terminal.


France: Ireland-based Ecocem has partnered with CB Green to launch a joint venture to scale up production of 70% reduced-CO2 cement based on Ecocem's ACT technology. The technology combines widely available alternative raw materials into a product with enhanced strength and durability compared with ordinary Portland cement (OPC). The new joint venture will build a grinding plant in Dunkirk, Nord Department. The plant will produce 600,000t/yr of limestone filler for use in alternative cement production with ACT technology. The partners expect to invest Euro60m in the plant's construction, with commissioning scheduled for mid-2025.

Ecocem managing director Donal O’Riain said “This long-term cooperation agreement with CB Green marks a major milestone in our work to scale ACT, our low carbon cement technology, and deliver on our commitment to help the cement industry cost-effectively decarbonise by 50% by 2030. It secures production of fillers and access to high quality limestone, and is an important next step to ensuring that our ACT technology can be distributed at scale and start delivering on its potential to reduce CO2 emissions by up to 70%. Technology is no longer the issue, scale and speed are what matters now."


UK: Mineral Products Association Lime (MPA Lime), the body representing the UK lime sector, has launched the Net Negative 2040 Roadmap. The association said that the roadmap sets out the strategy for its to 'go beyond net zero' by 2040. The industry will rely on the deployment of fuel switching, carbon capture, renewable energy sources and green transport technologies, among other approaches. It called on the government to support its aims through the implementation of carbon accounting, subsidisation of renewables and decarbonisation technologies, the development of green hydrogen infrastructure, ensuring that UK lime can remain competitive in the UK and overseas markets.

MPA Lime director Mike Haynes said “Each lever will contribute to decarbonisation – many initiatives are happening already or will come on stream this decade." He added "The combination of using biomass fuels with carbon capture and lime product carbonation will result in removal of 250,000t/yr of atmospheric CO2, making the sector net negative overall. Other levers, especially indirect emissions and transportation, require broader collaboration and enabling action by government and other industries.”

Through their actions to date, MPA Lime members reduced their absolute CO2 emissions by 25% between 2005 and 2022.


India: The government's income tax department has carried out raids at five locations belonging to Shree Cement. Reuters has reported that the authorities said they conducted 'survey action' on 21 June 2023.


World: Market Research Future has forecast a composite annual growth rate (CAGR) of 5.3% between 2022 and 2030. This would result in a market value of US$505bn in 2030, compared with US$335bn in 2022. The report added that the rate of new construction projects is increasing across all regions.


Taiwan: A 57-year-old worker died after falling into slag cement in the production line of CHC Resources Corporation's Kaohsiung slag cement plant at 16:00 on 22 June 2023. CNA English News has reported that the victim was submerged for a prolonged period. A second man, aged 51, also entered the cement, but escaped with 'minor injuries.' The workers had been carrying out cleaning work on the line. Local authorities reportedly said that CHC Resources Corporation had 'No proper safety protocols' in place for the activity.