Global Cement Newsletter

Issue: GCW654 / 10 April 2024

Headlines


Heidelberg Materials announced this week that it is preparing to close its integrated cement plants at Beffes and Villiers-au-Bouin in France by October 2025. It framed the restructuring as a response to ‘a significant decline in cement sales in France’ and a plan to focus on low-carbon products. Unfortunately, local media reported that around 170 jobs will be lost at the two sites. The company says it is looking at ‘socially acceptable solutions’ including redeployment to other locations in the country.

Investment has been forthcoming from Heidelberg Materials France in recent years. It reminded everyone that it initiated a Euro400m scheme at its France-based subsidiary Ciments Calcia in late 2020. Most of this was earmarked towards a new production line at the Airvault plant, which is currently being built. Other schemes at the Beaucaire, Bussac-Forêt and Couvrot integrated plants followed. More recently, Heidelberg Materials launched a carbon capture, utilisation and storage (CCUS) project at Airvault, part of the GOCO2 initiative, with the aim of starting initial capture in 2030 with full 1Mt/yr capture planned later. What the company didn’t mention though was at the time of that 2020 investment it was also preparing to convert the integrated Gargenville plant into a grinding unit, stop white cement production at its Cruas plant with the intention of turning the site into a terminal and it wanted to reduce its workforce by around 140. To be fair to Heidelberg Materials though, it did have the same goal of reducing its specific net CO2 emissions. The added detail this week was that the group aims to generate half of its revenue from sustainable products that are either low-carbon or circular by 2030.

Heidelberg Materials France is not alone with its ambitions for low-carbon products. Holcim notably opened in early 2023 what it said was the first calcined clay unit in Europe at its Saint-Pierre-la-Cour cement plant. Heidelberg Materials then followed in May 2023 with the announcement of a calcined clay project at its Bussac-Forêt cement plant. Other clay projects from Vicat, NeoCem and Neo-Eco have been reported since then. The other prominent France-based blended cement producer that has steadily been building its business in recent years is Hoffmann Green Cement. More general plant upgrade projects that are also worth mentioning include Eqiom’s (CRH) upgrade to its Lumbres plant in February 2024 and the ignition of a new kiln at Lafarge France’s Martres-Tolosane plant in October 2023. Both of these projects have been framed as driving sustainability.

Graph 1: Cement production in France, 2014 - 2022. Source: France Ciment. 

Graph 1: Cement production in France, 2014 - 2022. Source: France Ciment.

Heidelberg Materials’ assessment about the poor state of the cement market has been confirmed by local media. Sales reportedly started falling in 2022, were down by 6% year-on-year in 2023 and further downward pressure is expected in 2024. Production data shown in Graph 1 above released by France Ciment, the national cement association, doesn’t really show what has been happening with sales. Over the last 20 years production hit a high of around 22Mt in the mid-2000s before settling around 16 - 17Mt/yr from 2015 onwards. The more telling trend, perhaps, has been the increase in CEM II blended cements from 50% in 2012 to 64% in 2022. Cement production may have stayed roughly the same over the last decade but it is using less clinker than it used to. Hence the pressure on companies like Ciments Calcia to reduce clinker capacity.

A further cost pressure facing cement producers in France is the impending end to the price cap on electricity scheduled by the end of 2025. The government enacted the scheme in late 2021 at the end of the Covid-19 pandemic, but then carried on as energy prices spiked following the Russian invasion of Ukraine. France Ciment lobbied in August 2023 for further protection for the sector using the argument that decarbonisation was not possible without electricity available for a reasonable price. It added that decarbonising the cement sector in France with carbon capture would cost around Euro3.5bn. Electricity prices started rising in February 2024 as part of the government’s phase out of the scheme.

Finally, 17 people were arrested on 5 April 2024 in connection with a demonstration at Lafarge France’s Val-de-Reuil ready-mixed concrete plant in Eure. Environmental activists reportedly trespassed on the site, according to local press, causing an estimated Euro450,000 in damages with acts such as spraying foam into machinery, ripping up bags of cement, breaking windows and more. The activists presented their actions as a response to both the environmental impact of cement and concrete production and the ongoing legal allegations about Lafarge’s actions in Syria in the early 2010s. Lafarge France’s La Malle integrated plant was also similarly targeted in December 2022 when around 200 activists stormed the site and caused damage to machinery and property. Lafarge’s response at the time was to remark that there was a feeling of misunderstanding given that the La Malle plant was piloting various decarbonisation methods.
All of this presents a febrile picture of the cement sector in France. Sales are down, electricity costs are set to go up and producers are switching to low-carbon cement products. Alongside this they are also closing clinker production plants but are also investing in new decarbonisation projects. At the same time environmental protestors have also been targeting cement and concrete plants and Lafarge’s association with its former actions in Syria appear to have made it more of a target than the other manufacturers. It is unsurprising then that Holcim, the parent company of Lafarge France, has raised the risk of damage to the group’s reputation, with both the general public and investors, should it fail to meet its targets. Reaching net zero was never going to be easy but setting unrealistic targets is increasingly not an option.


Pakistan: Fecto Cement has appointed Hanif Idress as its chief financial officer. He succeeds Abdul Samad in the post. The cement producer operates the integrated Taxila plant near Islamabad.


Pakistan: Fauji Cement has appointed Anwar Ali Hyder as its chair. He succeeds Waqar Ahmed Malik in the post. The company operates four integrated cement plants in the country. It inaugurated its Shadan Lund cement plant in Dera Ghazi Khan in November 2023 bringing its total cement production capacity to 10.6Mt/yr.


US: Eagle Materials and Heidelberg Materials North America, through their joint venture Texas Lehigh Cement Company, will start up a new slag cement facility. The facility will be located in Houston, Texas and will start production in the summer of 2024. When completed, it will have a production capacity of 500,000t/yr. This is in addition to Texas Lehigh’s cement plant in Buda, Texas.


US/Austria: RHI Magnesita (RHIM) plans to acquire Resco Group for US$430m. The acquisition of Resco will add fireclay and pyrophyllite-andalusite mining operations in the US to its existing magnesite and dolomite operations across Europe, the US, Brazil and China. Furthermore, RHIM aims to transfer ‘significant’ production volumes from non-US plants to Resco's US facilities. The completion of the acquisition is anticipated in the second half of 2024.


Philippines: Cemex Philippines has launched a new 1500m2 warehouse in Barangay Pangao West, Batangas, to improve its supply chain capabilities and meet the growing demand for construction materials in the region. This opening coincides with the Philippine national government's allocation of US$17.7bn for infrastructure development in 2024. The facility will support major development projects in Batangas, Quezon, and provide nearby provinces with cement. The Ibaan Warehouse operates 24 hours a day, providing staging areas for the loading and dispatch for cement products.

Luis Franco, president and CEO of Cemex Philippines, said "This warehouse is a great complement to our Luzon distribution network as it gives us a better position to address increasing cement demand in the market."


Global: The World Cement Association (WCA) has recently welcomed Refratechnik Asia as an Associate Corporate Member. Refratechnik Asia supplies refractory materials to the cement and lime industries in China, Southeast Asia, and Oceania. The firm produces 120,000t/yr of refractory materials.

Ian Riley, CEO of the World Cement Association, said "We are keen to see Refratechnik Asia promote its value-orientated culture within our organisation and its commitment to driving greener practices in the cement and wider construction industry.”


Kenya: President William Ruto has commissioned a Cemtech clinker plant in Sebit, West Pokot, valued at US$345m. Construction of the plant began in 2010 and it will produce 6000t/day of clinker with a cement capacity of 2Mt/yr. After production, the clinker will be transported to a grinding plant in Eldoret.

Mining Principal Secretary Elijah Mwangi said "The production is enough feed for all cement plants in the country. The demand for this critical material will now be met with the excess available for export." The opening of this plant is a ‘major relief’ for cement companies in Kenya, which have historically had to import 60% of their clinker. Currently, National Cement and Mombasa Cement manufacture clinker, while Bamburi Cement, Savannah Cement, Rai Cement, and Ndovu Cement import it.

Located at the Sebit limestone mines in Kipkomo subcounty, the plant has generated over 2000 job opportunities.


Vietnam: In the first quarter of 2024, Vietnam's cement and clinker exports maintained a volume of 7.9Mt but represented a 11.7% year-on-year decrease in value to US$298m, according to the General Statistics Office.

The value decrease is reportedly attributed to China's sluggish real estate market and anti-dumping duties imposed by the Philippines. Export prices also declined slightly, with the average price in 2023 dropping by 3% year-on-year. The Vietnam Cement Association anticipates further challenges for these exports in 2024, facing increased competition from the Philippines, Central America and South Africa. Domestic production is expected to exceed demand, with consumption estimated at 60-62Mt, prompting intensified export efforts to manage an excess production of around 30Mt.


India: Jahangirabad police have raided a cement warehouse, seizing 437 bags of counterfeit cement. The owner has been arrested under the Copyright Act of the Indian Penal Code.

The raid followed a complaint from Delhi resident Raunak Joshi, head of a company identifying fake and adulterated products. Joshi reported unauthorised sales of cement under the UltraTech brand in Jinsi Square, Jahangirabad. The police's operation at Mohammad Siddiqui's shop and warehouse uncovered the counterfeit cement, some falsely labelled as UltraTech and others with different brand labels.


Thailand: Biochar Life and Siam Cement Group (SCG) have signed a Memorandum of Understanding to jointly develop biochar-infused cement and sustainable building materials. This collaboration aims to utilise biochar in the construction industry and reduce carbon emissions.

The partnership will begin with a pilot project at Chiang Mai University, focusing on constructing biochar-infused cement roads. Biochar Life will evaluate the scalability of biochar production to meet SCG's material requirements. Both companies will engage in research and development to optimise the production and application of biochar in construction, considering environmental benefits and carbon removal credit opportunities.

SCG also plans to extend Biochar Life’s smallholder farmer program, incorporating mobile industrial units and other technologies. This joint effort is directed towards incorporating carbon-negative biochar into building materials. This will lower construction-related carbon emissions, aid in atmospheric carbon sequestration, and improve the durability and performance of these materials.


Ghana: A nine-member committee has been established to monitor and coordinate the local cement industry in Ghana, in line with the Manufacture of Cement Regulations (LI 2480).

The committee, inaugurated in Accra on 5 April 2024, is chaired by Professor Alex Dodoo of the Ghana Standards Authority (GSA). Other members include representatives from the GSA, Ministry of Trade and Industry, Ministry of Environment, Science, Technology and Innovation, Environmental Protection Agency, Ghana Institution of Engineering, Association of Ghana Industries, Chamber of Cement Manufacturers of Ghana, and an expert in cement production nominated by the Minister.

During the inauguration, Trade and Industry Minister Kobina Hammond said “The committee will appraise, evaluate and approve local content and local participation plans and reports of cement manufacturing entities. They will also promote the production, wholesale and retail of cement and cement components.”

According to LI 2480, there is a requirement for manufacturers of cement to register with the Committee. Regulation 11 in LI 2480 state that ‘A person shall not manufacture cement in the country unless the person registers with the Cement Manufacturing Development Committee in accordance with these Regulations.’ The regulations state that a person who did not register with the Cement Manufacturing Development Committee to manufacture cement shall not be granted a licence to manufacture cement under these regulations.


India: JK Cement has entered the East Indian market with the official launch of its grey cement business in Bihar. The company's initial phase targets nine districts in Southern Bihar, introducing its flagship JK Super Cement.

Deputy managing director and CEO Madhavkrishna Singhania said “Our initial focus will be on covering nine districts of Southern Bihar. With the upcoming Prayagraj plant coming online, we plan to swiftly expand our reach to encompass other districts in the near future. Additionally, we are actively exploring the possibility of setting up a plant in Bihar by 2025, further solidifying our commitment to the region."


Thailand: Saraburi, which houses Thailand’s key cement plants, is expected to start converting waste to energy in a project led by the Thai Cement Manufacturers Association (TCMA). TCMA has developed a pilot project to create ‘ignitable waste pallets’, which will replace imported coal in cement production, according to TCMA chair Dr Chana Poomee. The process involves using waste from mining, cement plants and local communities to produce fuel, focusing on waste that cannot be reused or recycled.

Seven cement plants are located in the Tan Diao subdistrict due to its proximity to limestone mountains essential for cement production. The province is facing a growing waste management problem, owing to urbanisation and the expansion of agribusiness in the area. ‘Saraburi Sandbox’ project, a public-private-people partnership (PPP), seeks to address these issues.

Kittipong Promwong, president of the National Higher Education, Science, Research and Innovation Office, believes the Saraburi Sandbox is crucial to the government's commitment to lowering CO₂ emissions.


China: A new study from Hong Kong Polytechnic University showcases sustainable cement production methods, focusing on low-clinker cements and alternative solutions for incinerator fly ash (IFA). The research demonstrates that using carbonated-washed IFA mixed with slag, coal fly ash, or metakaolin can replace 60% of Portland cement, forming ternary blended cement. This approach reportedly reduces the carbon footprint of cement production.

The study found that slag was the most effective, improving pore structure and increasing ettringite and hemicarboaluminate formation with a blend of 40% slag and 20% IFA. It achieved 90% of the compressive strength of pure Portland cement after 90 days.

The researchers said "This study demonstrated the promising potential of the blended cements to simultaneously divert IFA from landfills and reduce the clinker content of cement."


Philippines: A recent study from Cebu, Philippines presents a method for reducing greenhouse emissions in the cement industry. The research, supported by the Department of Science & Technology (DOST) of the Philippines, focuses on partially substituting cement with coal fly ash (CFA). According to the University of San Carlos researchers, CFA's efficacy as a cement substitute depends on its source, with variations in quality, performance, and water requirements when used in paste and mortar formulations.

The study evaluated CFA from a Philippine power plant, examining its use as a partial cement substitute. Researchers designed paste and mortar mixtures with different CFA-to-binder ratios and water-to-binder ratios. The study revealed that increasing the amount of CFA in cement up to 20% by weight could enhance compressive strength, ‘outperforming’ pure cement mixtures.

The study concluded that substituting a portion of cement with CFA not only reduces greenhouse gas emissions but also improves the compressive strength of the resultant material.


Thailand: Chair of the Thai Cement Manufacturers Association (TCMA), Dr Chana Poomee, announced the company’s new strategy, called 'TCMA Synergising the Actions toward Net Zero 2050'. This strategy aims to drive the cement industry towards clean energy transition, connect with global green funds and address climate change.

The vision involves four key missions for 2024-2026, including developing low-carbon cement, enhancing resource-efficient mining practices, building an integrated waste-to-value ecosystem, and transitioning to clean energy.

The TCMA also aims to reduce its CO₂ emissions by 6.9Mt/yr by 2030. Collaborations with various partners, including the Thailand Fellowship Cement Manufacturers and the Thai Bankers Association, are planned to leverage innovation and government policy support.


Uzbekistan: Uzbekistan produced 1.35Mt of cement in January and February 2024. This production volume shows a year-on-year increase of 50%. In February 2024, the country produced 724,700t of cement.


France: Heidelberg Materials has announced plans to close two of its plants in France - Beffes and Villiers-au-Bouin - by October 2025. This move is part of the company's restructuring efforts aimed at accelerating its decarbonisation efforts and focusing more on low-carbon products.

The decision comes amid a decline in cement sales in France, attributed to weak demand in the construction sector. 170 employees are affected by the impending closures of these plants, according to the company.

These closures align with Heidelberg Materials' commitment to focus on lower carbon alternatives, enhance energy efficiency, increase the use of alternative fuels, and reduce the clinker content in its cement products in France.


China:  The UK-based Carbon Disclosure Project Carbon Majors database has released its Carbon Majors Database. The database quantifies the historical CO₂ emissions of 122 of the world's major emitters, among them the Chinese cement sector.

Notably, China's cement industry has been a significant contributor to global emissions. In the period up to the end of 2022, China's cement sector has produced 23,161Mt of CO₂, accounting for 1.3% of the global emissions recorded during this period. From 2016 to 2022, the cement industry in China emitted 8.16Bnt of CO₂, accounting for 3.2% of global emissions.

Figures for the cement sector include process emissions from the calcination of limestone, but exclude emissions from fuel and electricity used in production.


Poland: The Association of Polish Cement Producers has expressed increasing concern over quadrupled year-on-year growth in cement imports from Ukraine, to 330,000t in 2023.

Zbigniew Pilch, the head of the association, highlighted the contrasting rise in imports and 12% fall in domestic production, to 16.6Mt. He said “The scale of imports from Ukraine is growing almost every month, reaching nearly 50% of total imports in January 2024. These volumes are deeply concerning.”

A primary issue raised by the association is the difference in environmental regulations faced by Ukrainian and Polish cement producers. The association argues that Ukrainian producers are not subjected to as rigorous climate policies as Polish producers, leading to an uneven playing field. Additionally, the localised nature of the cement market means eastern Polish producers are particularly affected by the ‘influx’ of Ukrainian cement.


US: Holcim US has announced an investment of US$20.5m in its Midwest operations. A key component of the investment is the new 35m-high cement storage dome in Fremont, Nebraska, which will increase its production capacity of ECOPlanet low-carbon cement. The dome has the capacity to store 50,000t of cement. Construction of the dome, which began in 2021, has contributed to local economic development and job creation at the terminal.

In line with the Nebraska Department of Transportation's blended cement requirement, the cement blended and distributed at the terminal incorporates natural pozzolan, a binding agent, to produce a lower carbon product compared to ordinary Portland cement.


Kazakhstan: Steppe Cement sold 175,383t of cement for US$8.5m in the first quarter of 2024, down from 214,832t for US$11m in the first quarter of 2023. This represents a year-on-year decline of 18% in volume and 23% in value. Despite the decrease in sales, its production of clinker grew by 25% year-on-year.

Cement sales in Kazakhstan declined by 12% to 1.69Mt in the first quarter of 2024. Exports fell by 6%, mainly due to reduced exports to Uzbekistan. Imports remained level at 4% of domestic demand, with the majority coming from Russia. Steppe Cement anticipates a total market demand of approximately 11Mt in Kazakhstan for 2024, a 5% year-on-year decrease. Rising transport costs and an increased proportion of shipments to southern Kazakhstan resulted in low margins, according to the company.


China: Tangshan Jidong Cement has reported its earnings for the full year ending 31 December 2023. The company's sales fell to US$3.9bn from US$4.8bn, an 18% year-on-year decrease. It recorded a net loss of US$207m, compared to a net income of US$194m a year earlier.

Although managing to grow its cement sales volumes, the company reported heightened competition in the north and north-east of China where most of its plants are located.


India: Ramco Cements has doubled the production capacity at its Jajpur plant in Odisha to 1.8Mt/yr. The company commissioned its Line II on Monday 1 April 2024 and started commercial production, adding 900,000t/yr to the plant's capacity. Additionally, an 18MW thermal power plant in Kolimigundla will be commissioned soon.


US: The Portland Cement Association (PCA) has commended the Connecticut Department of Transportation's approval of Portland limestone cement (PLC), marking its acceptance in all US states and the District of Columbia. PLC, with increased limestone content, maintains traditional Portland cement's efficacy but reduces CO₂ emissions by up to 10%. The US avoided more than 4Mt of CO₂ emissions in 2023 by using PLC and other blended cements. This achievement coincides with growing cement consumption by state transportation departments, fuelled by the Bipartisan Infrastructure Law.

Mike Ireland, president and CEO of PCA, said "This milestone is a huge step forward for sustainable American construction. Switching to PLC promises to save millions of tonnes of CO₂. Using a lower-emission product that meets all the performance requirements of traditional cement means the construction sector can build with durability, safety and sustainability in mind."


Poland: The Polish Cement Association reported a 12% fall in cement production in 2023, with output reaching 16.6Mt, according to data from the Central Statistical Office. The decline reflects challenges faced by the construction sector amidst a slowing economy, despite a slight GDP growth of over 0.2%.

Zbigniew Pilch, chief marketing officer of the association, said "2023 was a difficult year for the construction sector as the economy slowed down while GDP grew by a little over 0.2%." The initial data for 2024 suggests a potential rebound in the Polish cement industry, however, with Pilch adding "In February 2024, cement production totalled 1.2Mt, which represents a 33% year-on-year increase.”


Mexico: Members of the National Cement Chamber (Canacem) are set to reduce cement bag weights from 50kg to 25kg to comply with NOM-036, according to El Financiero, which aims to prevent and control musculoskeletal and ergonomic diseases in construction workers. The shift affects companies such as Cemex, Cementos Moctezuma, GCC, Cemento Cruz Azul, Cementos Fortaleza and Holcim.

The standard came into effect on 31 March 2024, but Cementos Moctezuma has already started transitioning to 25kg bags. José Barroso, CEO of Cementos Moctezuma, said "Since 2023, Cementos Moctezuma began the transition from 50kg to 25kg bags in all of its packaged product family.” He added "In Mexico, musculoskeletal disorders represent almost half of the occupational injuries, so we are already implementing changes in our plants to operate according to the new standard.”