Global Cement Newsletter

Issue: GCW627 / 27 September 2023

Headlines


Taiwan Cement has just commissioned a 107MWh energy storage project at its Yingde plant in Guangdong province, China. Subsidiary NHOA Energy worked on the installation and has been promoting it this week. The battery storage works in conjunction with a 42MW waste heat recovery (WHR) unit, a 8MWp solar photovoltaic unit and a proprietary energy management system. It is expected to store about 46,000MWh/yr of electricity and save just under US$3m/yr in electricity costs.

NHOA Energy, formerly known as Engie EPS before Taiwan Cement bought a majority stake in it, claims it is one of the largest industrial microgrids in the world. We can’t verify this for sure, but it is definitely large. For comparison, the 750MW Vistra Moss Landing Energy Storage Facility in California often gets cited as the largest such facility in the world. This is run by a power company, as are many other large battery energy storage systems. In its annual report for 2022 Taiwan Cement said it was planning to using NHOA’s technology to build seven other large-scale energy storage projects at sites in Taiwan including its integrated Suao, Ho-Ping and Hualien cement plants.

The aim here appears to be supplying renewable electricity to the national grid in Taiwan. Taiwan Cement is diversifying away from cement production, with an aim to derive over 50% of its revenues from other activities besides cement by 2025. In 2022 cement and concrete represented 68% of its sales, while its electricity and energy division, including power supply and rechargeable lithium-ion batteries, represented 29%. The company is also not using its own batteries at the Yingde plant. Instead it is using lithium iron phosphate batteries supplied by Ningde Times. This is worth noting, as the cement producer’s batteries are used in vehicles.

Global Cement regularly reports news stories on cement plants that are building photovoltaic solar power arrays. However, so far at least, energy storage projects at scale have been rarer. One earlier example of an energy storage system loosely associated with a cement plant includes the now decommissioned Tehachapi Energy Storage Project that was situated next to the Tehachapi cement plant in California. That project tested using lithium ion batteries to improve grid performance and integrate intermittent generation from nearby wind farms. It is also worth noting that Sumitomo Osaka Cement’s sister company Sumitomo Electric is one of the world’s larger manufacturers of flow batteries, although no installation at a cement plant appears to have happened yet. In simple terms, flow batteries are an alternative to lithium ion batteries that don’t store as much energy but last longer.

More recently, Lucky Cement in Pakistan started commercial operation of a 34MW solar power plant with a 5.59MWh energy storage unit at its Pezu plant in Khyber Pakhtunkhwa in late 2022. Reon Energy provided the equipment including a lithium-ion based battery approach to the storage. Then, in March 2023, Holcim US said that it was working with TotalEnergies to build solar power capacity and a battery energy storage unit at the Florence cement plant in Colorado. TotalEnergies will install, maintain and operate a 33MW DC ground-mounted solar array and a 38.5MWh battery energy storage system at the site. Operation of the renewable energy system is expected to start in 2025.

Away from electrical batteries, the other approach to energy storage at cement plants that has received attention recently from several quite different companies has been thermal batteries. The two prominent groups using them at different scales are Rondo Energy and Synhelion. The former company has developed its Heat Battery technology, which uses refractory bricks to absorb intermittent renewable energy and then supply the energy back as a steady stream of hot gas for use in a cement plant mill, dryer, calciner or kiln. Both Siam Cement Group (SCG) and Titan Cement have invested in Rondo Energy. In July 2023 SCG and Rondo Energy said that they were planning to expand the production capacity of a heat battery storage unit at a SCG plant to 90GWh/yr. Synhelion, meanwhile, has been working with Cemex on using concentrated solar power to manufacture clinker. It achieved this on an ‘industrially viable scale’ in August 2023. It has since been reported that the companies are working on building a small scale industrial plant at Móstoles near Madrid by 2026. Crucially for this discussion though, the process also uses a thermal energy storage unit filled with ceramic refractory material to allow thermal energy to be released at night, and thus ensure continuous operation.

The examples above demonstrate that some cement companies are actively testing out storing energy at scale. Whilst this will not solve the cement sector’s process emissions, it does potentially start to make using renewable energy sources more reliable and reduce the variable costs of renewable power. Whether it catches on remains to be seen. Most of these kinds of projects have been run by power companies and that is where it may stay. It is instructive to note that Reon Energy was the only company to state that its battery-based energy storage system has a life-span of 8 - 12 years. Our current vision of a net-zero future points to high electrical usage but it may be shaped by how good the batteries are… from our phones to our cars to our cement plants.

For more information on Rondo Energy read the January 2023 issue of Global Cement Magazine


Bangladesh: Md Alamgir Kabir, vice chair of Crown Cement, has been re-elected as president of the Bangladesh Cement Manufacturers Association (BCMA) for a two-year period until September 2025. Imran Karim, vice chair of Confidence Cement, and Abdul Khaleque Pervez, managing director of Diamond Cement, have also been re-elected as the first and second vice-presidents of the BCMA respectively. All three were re-appointed at the BCMA’s annual general meeting in Dhaka, held on 26 September 2023.

Speaking upon his reappointment as BCMA president, Kabir expressed his heartfelt thanks to all BCMA members for re-electing him as the president of BCMA. He said that the cement industry of Bangladesh was in a ‘deep crisis’ and that it must work with policy makers in order to flourish, as well as respond more effectively to the needs of consumers.


India: Anjani Portland Cement has appointed Rajesh Kumar Dhoot as its chief financial officer. He succeeds RS Ramanjaneyulu following his resignation. Dhoot is a chartered accountant with over 25 years of professional experience in the cement, sugar, pipe and textile sectors. He has worked in the cement industry for over 15 years, most recently with Chettinad Cement since 2014. Prior to this he held positions with UltraTech Cement from 2006 to 2014.


Pakistan: Pioneer Cement has appointed Talha Saif as its company secretary. He succeeds Abdul Wehab in the role. The company also appointed Jan Mohammad as Head of Internal Audit. He replaces Jamal Uddin.


Türkiye: Cimpor Global Holdings has appointed Erol Tosun as Operational Technologies Unit Manager. He worked as Operational Technologies Chief for OYAK Çimento since 2019 and was the Information Technology Chief for OYAK Modern Beton from 2005 to 2019.

Other appointments at Cimpor Global Holdings include the move by Burak Demir to Industrial Digitalisation Unit Manager. He previously worked for OYAK Çimento since 2017 in a number of process roles. Prior to this he worked for Cementir in Türkiye.

Pınar Özmen Söylemez has been appointed as Data Analytics & Planning Unit Manager. She has worked for OYAK Çimento since 2017 first as a Performance Controller and then Industrial Program and Analysis Chief. Before this she worked for Votorantim Cimentos for two years.


Greece/Germany: Greece-based cement producer Titan Group and Germany-based Orcan Energy have entered a partnership to explore the development and deployment of Orcan’s innovative modular waste heat recovery (WHR) solutions across Titan’s international cement production base. Orcan’s solution converts cement process waste heat into electricity that it says can accelerate decarbonisation while reducing operational costs. As a first step, the partners will undertake an assessment of where Orcan Energy's WHR systems can be applied across Titan's facilities. The study will encompass a thorough pilot site evaluation, starting at several plants within the group. The initial focus will be on recovering waste heat from pre-heaters and clinker coolers.

Samir Cairae, Chief Technology Officer at Titan said “The collaboration with our waste heat recovery partner Orcan Energy has the potential to transform waste heat into zero-carbon clean energy, with a novel but well-proven modular approach."

Andreas Sichert, chief executive officer at Orcan Energy, said “We are thrilled to partner with Titan to use its vast and valuable waste heat resources. Our technology will help not only to reach the group’s extraordinary decarbonisation ambitions but also to significantly save electricity expenses. Our modular approach will allow Titan to flexibly respond to outside changes in uncertain times.”

Look out for an interview with Orcan Energy in the forthcoming November 2023 issue of Global Cement Magazine


Uzbekistan: Hengyuan Cement has held a ground-breaking ceremony at the site of its up-coming cement plant in the Kattakurgan district of Samarkand. The plant, a joint-venture between Chinese and Uzbek partners, will have a capacity of 3Mt/yr and cost US$350m to construct. Cement will be sold in the local market and, according to developers, exported to as far afield as the European Union.

At the opening ceremony, the Hokim of Samarkand region Erkinjon Turdimov and Chinese partners noted that cooperation between Uzbekistan and China has been developing steadily in recent years. The project will lead to 600 new direct jobs. The long-awaited cement plant was first announced in 2018, but has repeatedly been delayed, particularly by the Covid-19 pandemic.


Colombia: Data from DANE, the Colombian national statistics authority, shows that the country produced 1.22Mt of grey cement in July 2023, a 1.7% increase compared to July 2022. Of this, 1.05Mt was consumed domestically, a 6.5% fall year-on-year, with exports increasing to compensate. The July 2023 production figure is 9.2% higher than for the July 2019, the year before the onset of the Covid-19 pandemic. DANE also recorded that Colombia produced 557,900m3 of ready-mix concrete in July 2023, a 3.1% decline compared to July 2022, when 575,800m3 was produced.


Spain: Cement consumption in Catalonia fell by 11% in August 2023, while production fell by 2.7%, and exports by 32.7%, according to regional cement association Ciment Català. During the 12 months, to 31 August 2023 consumption decreased by 2.9% to 2.24Mt, while production fell by 4.4% to 3.15Mt and exports fell by 3.7% to 1.74Mt. Ciment Català’s president, Salvador Fernández, attributed these declines to the poor economic situation in the autonomous region, a lack of investment and ‘the challenges of the decarbonisation process,’ according to Europa Press.


Ireland/US: CRH has completed the move of its primary listing to the New York Stock Exchange. The group will retain a standard listing on the London Stock Exchange.

It said it had made the transition because “We believe a US primary listing will bring increased commercial, operational and acquisition opportunities for our business, further accelerating our successful integrated solutions strategy and delivering even higher levels of profitability, returns and cash for our shareholders.” It added that the North America market represents around 75% of the group’s earnings before interest, taxation, depreciation and amortisation (EBITDA) and that the US is expected to “be a key driver of future growth for CRH due to continued economic expansion, a growing population and significant construction needs.”

Albert Manifold, the chief executive officer of CRH, commented, “Today marks an important milestone in CRH’s development which will enable us to fully participate in the significant growth opportunities that lie ahead for our business”.


China: Taiwan Cement (TCC) commissioned a 107MWh energy storage project at its Yingde plant in Guangdong province in August 2023. Subsidiary NHOA Energy worked on the project that linked the battery storage capacity to a 42MW waste heat recovery (WHR) system and a 8MWp solar photovoltaic unit. It uses lithium iron phosphate batteries supplied by Ningde Times.

The company’s say that the project is one of the largest industrial microgrids in the world. It is intended to provide energy flexibility to the cement plant by using NHOA Energy’s proprietary energy management system to manage peaks in energy demand and acting as a backup for critical equipment to avoid damage caused by sudden blackouts.

The NHOA Energy storage project is expected to store about 46000MWh/yr of electricity and save just under US$3m/yr in electricity costs. The system will also support the Guangdong Provincial Government’s energy storage development policy and be eligible to associated subsidies of over US$350,000/yr.

Giuseppe Artizzu, the chief executive officer of NHOA Energy, said “NHOA Energy’s proprietary energy management system will optimise the generation and consumption profile of the industrial microgrid, while also supporting the regional grid towards its 100% green energy objective, taking the energy transition in the area one step forward in total accordance with NHOA Group’s and TCC’s shared mission of fostering a positive change for the future of our planet.”


France: Hoffmann Green Cement Technologies (HGCT) has signed a partnership deal with Point.P. Under the terms of the agreement, HGCT’s clinker-free cement products will be distributed to Point.P’s ready-mixed concrete (RMC) and batching plants. Point.P is aiming to reduce its CO2 emissions linked to the use of cement it uses in ready-mix concrete, concrete blocks and precast elements, by 35% by 2030.

Julien Blanchard and David Hoffmann, co-founders of HGCT, said "We're delighted with this partnership with a major player like Point P. This is a major step forward for the marketing of our clinker-free low-carbon cements.”

France-based Saint-Gobain Building Distribution France, a subsidiary of the Saint-Gobain, is a distributor of building materials. Its main brands include Point.P, Cedeo, Asturienne, PUM, SFIC, La Plateforme du Bâtiment, Dispano, Panofrance, Clim+ and CDL Elec. It has a network of over 2000 sales outlets throughout France.


Bangladesh/India: The completion of an upgrade project to Chhatak Cement’s plant has been thrown into doubt due to uncertainty about securing limestone from India. The plant still needs to build a new 17km ropeway conveyor and this has been delayed due to failure to obtain permission on the Indian side of the border, according to the Daily Star newspaper. It is also facing problems procuring limestone in India due to on-going legal proceedings on environmental grounds between exporters in Meghalaya and the government. The Supreme Court of India granted permission for exports in 2022 but the case is still pending. In addition, plans to install a gas line from Sylhet to the plant has not started yet either.

The state-owned cement producer is run by the Bangladesh Chemical Industries Corporation (BCIC). It originally announced in 2016 that it was spending over US$100m to build a new 1500t/day dry production line at the plant to replace an old wet production line. Although the old line originally had a production capacity of 233,000t/yr, it had fallen to around half of this. However, despite the construction of new silos and other equipment at the site, the unit has not been operational since early 2020. The new line was originally planned to start operation in 2020 but this was delayed until 2023. The BCIC has now proposed that completion of the project be extended to mid-2025.


Togo: The Ministry of Commerce has denied that it has authorised a change in the price of cement. In a press release it confirmed that the ex-factory prices it set in late October 2021 remained in force, according to 24heureinfo. It reminded cement traders of this and provided a 24-hour telephone number for consumers to report any abnormal trading practices.

The ministry was responding to reports on social media channels about an increase to the price of cement. CimTogo said recently that it had adjusted its price structure in mid-September 2023 but not breached the price limits set by the government.


Zimbabwe: South Africa-based PPC says that it has completed a solar plant tendering process for its Colleen Bawn and Bulaweyo plants. Chief executive officer Roland van Wijnen said that a 30MW captive plant has been approved by the board, generation licenses have been approved and that the project site has been cleared ahead of construction.

Van Wijnen added that PPC continues to see Zimbabwe as a ‘strong market for the group’ despite some economic challenges, explaining “We took a relatively long operational stop to ensure our operations in the country are future-proof and improved from an environmental standpoint. The plant is now performing well from both an output and cost-per-tonne perspective. We knew our earnings before interest, tax, depreciation and amortisation (EBITDA) would be reduced due to this operational stoppage. We have since stepped up production and reclaimed market share and we anticipate EBITDA to meet or exceed full year 2022 levels in full year 2024.”


Liberia: Liberia Cement Corporation (CEMENCO) has introduced Superplast 22.5X, a new product that is specifically designed for use in plastering and laying blocks and tiles. Speaking at the launch on 25 September 2023, William Gaignard, CEMENCO’s General Manager, emphasised the historic importance of this product, highlighting its overall affordability, making it accessible for all Liberians to build their homes at a lower cost. Expressing his desire to witness a shift from mud houses to sustainable and economical homes made using concrete, Gaignard said that 50kg bags of Superplast 22.5X would cost 19% less than the average price of cement in Liberia.

"Today marks a significant moment in our journey here at CEMENCO,” said Gaignard. “When we do business, we have to assess our position in the market. Are we the leaders? If not, we must find solutions to become leaders. If we are the leaders, we must find solutions to maintain our position. This requires innovation, understanding the challenges faced by citizens and working towards solutions."

Vice President of the Republic of Liberia, Dr Jewel Howard-Taylor, who was present at the launch, praised CEMENCO for its forward-thinking approach in ensuring affordable cement for non-load-bearing applications in the local market. However, she urged the company to provide clear guidance to the public on the proper usage of the cement to avoid misuse, particularly in the production of load-bearing structures, for which it should not be used.


Uganda: President Yoweri Kaguta Museveni has officially commissioned a new vertical roller mill at Tororo Cement’s plant in Tororo. The German-built mill cost US$25m and can produce 150t/hr of cement. The operator claims it to be the ‘most sophisticated’ in East and Central Africa. It is in the process of installing an additional 300t/hr mill, to bring its overall grinding capacity to 5Mt/yr. It is also planning the construction of a 5000t/yr integrated plant in Moroto, to eliminate the company’s need for imported clinker, which it claims will be launched within the next five years.

Speaking at the event, Museveni congratulated Tororo Cement’s chair Hasmukh Kanji Patel for the company’s ‘enormous contribution to Uganda’ and called for Ugandans to support foreign-owned companies, as they support national development, pay local taxes and contribute to gross domestic product. He said "I'm very glad that Mr Patel came here, that we privatised a government factory and now he has expanded it. This is why we had to go against people like Idi Amin who were ignorant. Ugandans should stop saying ‘Indian factory.’ This this is not an ‘Indian factory,’ it is a Ugandan factory regardless of who has built it.”


Nigeria: The Cement Producers Association of Nigeria (CPAN) has warned that the federal government’s plan to introduce concrete roads will nearly double the price of cement. It also called on the administration to ‘permanently address’ perennially high cement prices in the country by encouraging greater participation in the sector.

CPAN, in a statement jointly signed by its National Chair, Prince David Iweta and National Secretary Chief Reagan Ufomba, commended the government’s stance on converting the country to concrete-based roads, but suggested greater emphasis on road designs that allow both concrete and asphalt pavement to run concurrently and provide ample time for a smooth transition that allows contractors and producers time to adjust.

The statement read “While we commend the Honourable Minister’s position on concrete-made roads, we warn of the dire consequences if the supply end is not properly addressed. In fact, it would amount to dereliction of duty not to intervene. And the time is now. To do otherwise is to continue in a worsening pipe dream that prices would suddenly drop for this essential input that will continue to drain the purse of Nigerians, render them homeless, encourage chaos between demand and supply, and worsen the infrastructure deficit it sets out to cure, and lead to an unprecedented price hike.”


India: The India Cements expects to commission the upgraded grinding unit at its Sankar Nagar cement plant in Tamil Nadu later in September 2023. Hindu BusinessLine News has reported that the producer is undertaking the upgrade in order to increase efficiency and lower the plant’s operating costs. The producer has hired US-based Boston Consulting Group to ascertain other possible improvements to three of its plants in Andhra Pradesh and Telangana. At its Chilamkur cement plant in Andhra Pradesh, it is installing a waste heat recovery (WHR) system, scheduled for delivery in early 2024. FLSmidth and ThyssenKrupp Industrial Solutions are both reportedly conducting ‘detailed studies’ for possible future projects for The India Cements.


Mexico: Cemex says that it has entered negotiations with banks with a view to refinancing its US$3bn credit line. Bloomberg has reported that it previously financed the line in late 2021.

Cemex’s chief financial officer Maher Al-Haffar said that an anticipated 100% extension ‘will probably transform our maturity structure quite nicely.’


India: Ratings agency Crisil has forecast all-Indian cement consumption growth of 11% year-on-year to 440Mt during the current financial year, which ends on 31 March 2024. Crisil attributed this to a 51% year-on-year rise in infrastructure spending, to US$6.75bn throughout the year. Press Trust of India News has reported that infrastructure projects currently account for 30% of all cement consumption.


India: UltraTech Cement has bought a 29.8 hectare parcel of land in Andhra Pradesh’s Vizianagaram District from The India Cements. The Times of India newspaper has reported the value of the sale as US$8.44m. The India Cements’ vice chair and managing director Narayanaswami Srinivasan said that the company is looking for ways to monetise its assets amid on-going liquidity issues.

The India Cements’ sales of cement and clinker fell by 4.3% quarter-on-quarter to 2.66Mt in the three months to 30 June 2023 from 2.78Mt in the three months to 31 April 2023. It noted high fossil fuel prices and local overcapacity in the South Indian cement sector.


Mexico: Holcim Mexico says that its supply of cement to the government’s Tren Maya railway project is 170,000t/month. This corresponds to 50 – 60% of its total production volumes. Local press has reported that construction of the 1500km-long Tren Maya railway will consume 1Mm3 of concrete. Holcim supplied its cement for Sections 1 – 3 of the line between 2020 and 2022. It is currently supplying Section 5, which is 50% complete. The cement comes from the company’s Orizaba, Veracruz, plant; its Macuspana, Tabasco, plant and its Mérida, Yucatán, plant.

Holcim Mexico’s infrastructure development manager Fernando Roldan said "Our participation has been a challenge, but the relationship we have with the suppliers and with the construction companies in charge of the railway has allowed us to meet the requirements."


Zimbabwe: South Africa-based PPC has raised its stake in PPC Zimbabwe from 71% to 90%. In an operating update, PPC told investors that PPC Zimbabwe increased its sales by 19% year-on-year in the five months to 31 August 2023. Meanwhile, the group’s South African business raised its sales by 58% year-on-year over the same period. PPC attributed the growth to cost reductions and price increases across both markets, as well as ‘exceptionally strong’ growth in its cement volumes in Zimbabwe. Overall, cement volumes rose by 3% year-on-year.

PPC was previously reported to be considering selling its entire PPC Zimbabwe stake for US$200m in February 2023.


Honduras: Cementos Argos Honduras has commissioned a 1.6GWh/yr solar power plant at its Choloma grinding plant in Río Blanquito. Grupo Argos’ energy subsidiary Celsia built the plant, which consists of 2160 photovoltaic modules. The La República newspaper has reported that the installation cost US$1.2m. It will supply 25% of the Choloma grinding plant’s energy consumption, and reduce its total CO2 emissions by 23%.

Cementos Argos Honduras CEO Luis Eduardo Tovar said "This partnership marks a significant milestone in our efforts to address climate change and revitalise our ecosystems, while generating significant impact in communities with new employment and investment opportunities.”


South Korea/Egypt: The South Korean government plans to implement a 72% import duty on white cement from Egypt. Yonhap News has reported that the Korea Trade Commission (KTC) recommended the duty as an anti-dumping measure, following its investigation into the impacts of Egyptian imports on the South Korean white cement industry. This consists of Union Corporation’s 200,000t/yr Chongju white cement plant in North Chungcheong.

South Korea consumed 100,000t of white cement in 2022. Egyptian white cement commanded a 10% (10,000t) market share. The domestic cement industry complained to the KTC against Royal El Minya Cement and Albatros International Cement Trading in March 2023. An additional probe will now follow to assess the correct rate for the duty.


Mexico: Cemex said that it has successfully implemented labelling showing the environmental impacts of all of its main products across its ‘most important markets.’ Depending on prevailing practices in each market, products’ packaging either displays an Environmental Product Declaration (EPD) or Cemex’s own third-party validated CERO2 designation.

General director Fernando González Olivieri said “We are committed to being the leading partner in sustainable construction for our clients. In this way, our clients have environmental impact information that they can use to develop sustainable construction.” He added “We continue to expand our portfolio of sustainable products, allowing our clients to effectively design and manage the carbon footprint of their construction projects.”


Peru: The Central Reserve Bank of Peru expects national cement consumption to fall by 3.7% in 2023. The Gestión newspaper has reported that demand declined month-on-month over seven successive months up to August 2023. It fell by a double-digit figure year-on-year in the first half of 2023. In August 2023, imports of cement declined by 95% month-on-month, to 2000t from 38,000t.

Peruvian Chamber of Construction executive director Guido Valdivia said "The first factor to consider is El Niño. If it starts in November 2023, it will affect construction output in 2023; if it is postponed to 2024, we expect a drop of only 3.3% in 2023.″ The Peruvian Property Developers’ Association (ASEI) forecast a 4% drop in construction output in 2023, followed by growth of 3.2% in 2024.

Grupo Gloria’s vice president, cement, concrete and lime, Luis Díaz told investors that the gap between Peruvian cement production and consumption will close ‘substantially’ during the remaining months of 2023, due to raised demand from infrastructure projects.