Global Cement Newsletter

Issue: GCW663 / 12 June 2024

Headlines


The National Development and Reform Commission and other government bodies in China released plans this week to cap clinker production capacity at 1.8Bnt/yr by the end of 2025. Energy efficiency of existing capacity will be used as the driver to determine which production lines can remain open. 30% of capacity will be required to be above the benchmark energy efficiency level. Plants below this line will be obliged to upgrade or face elimination.

Points of interest from the longer release include detail on how the authorities intend to promote energy efficiency. Installing improved production line equipment is as might be expected. However, there is also a drive towards low-carbon fuel substitution such as an increased thermal substitution rate (TSR) through the use of alternative fuels (AF), promotion of renewable energy sources and, interestingly, no new cement plants will be able to add captive coal power plants. The government is targeting a TSR of 10% by the end of 2025 with 30% of lines using AF in some form or another. A plan to reduce the clinker factor in cement is also being pushed through for the increased use of blast furnace slag, fly ash, carbide slag, manganese slag and other supplementary cementitious materials. This last point might have big implications for the ferrous slag export market but that’s a story for another day.

Working out how much these new measures will affect the cement sector in China in the short term is not straightforward since it’s unclear what the country’s actual production capacity is and how much of it is actually active. Data from the National Bureau of Statistics of China showed that cement output was 2.02Bnt in 2023. The China Cement Association (CCA) estimated that the capacity utilisation rate was 59% in 2023. So, if the sector were using all of its integrated cement plants flat out, then one might crudely suppose that the national production capacity might be around 3.5Bnt/yr. This guess does not take into account the prevalence of blended cements and a whole host of other factors so should be treated with caution. Given that cement output fell by 5% year-on-year in 2023, output could be just over 1.8Bnt in 2025 if the rate of decline holds. Research by Reuters in April 2024, suggested that the capacity utilisation rate hit 50% in that month, suggesting that the sector could meet the target in 2024 if it’s a particularly bad year. So, provided the production cap is enacted along the same lines of peak-shifting, where plants are temporarily shut for periods, then the target looks well within reach.

As reported in April 2024, the Chinese cement sector has faced rationalisation in recent years as the real estate market collapsed. Output peaked in 2020 and then fell subsequently. Most of the big producers endured falling sales volumes, revenue and profit in 2022, although some managed to resist the continuing decline in 2023. One coping mechanism has been to focus on overseas markets as proposed by the government’s Belt and Road initiative. Huaxin Cement has been a particular proponent of this strategy. The CCA says that China-based companies have invested in and built 43 clinker production lines in 21 countries with a cement production capacity of 81Mt/yr. Another 43Mt/yr of capacity is currently being built outside of China with yet another 25Mt/yr of capacity proposed for construction.

It is interesting, then, to note that the CCA issued an official warning this week to its members to invest ‘cautiously’ in Uzbekistan. The association said in a statement that at the end of April 2024 the country had 46 integrated production lines with a cement production capacity of 38Mt/yr. This is double the country’s demand for cement. Half of this production capacity is managed by China-based companies. It added that the utilisation rate was currently 50%, that the price had dropped by about 40% since 2020 and that competition was ‘fierce.’ Incredibly, another 7Mt/yr of capacity is expected to be added in 2024. The CCA has advised Chinese companies to consider the state of the Uzbek cement market before making any more investments.

The two news stories we have explored this week cover two sides of the same issue: Chinese cement overcapacity. The local market is finally slowing down after a period of phenomenal growth and the big question is what is the actual market demand now that all the big stuff has already been built. The government gives every impression it is using the decline to meet its sustainability goals. Like institutions in many other places it has set itself targets that it seems likely to meet. The flipside of overcapacity at home is investment overseas. China-based plant equipment manufacturers have certainly done well out of this situation. Yet in Uzbekistan, at least, it looks like the cement sector in China has also managed to export its overcapacity. This has created the absurd situation where the CCA has implored its members and others to exercise the same self-discipline abroad that the government extols at home. Another way to put this might be that Chinese cement companies are increasingly unable to make money at home… or in Uzbekistan. This then leaves a query over where else enthusiastic Chinese cement investors may be causing market imbalances. One solution might be for the Chinese government to impose a cap on clinker production by its companies outside the mainland. Whatever happens next though, the introduction of a capacity cap in mainland China marks a decisive change to the local cement sector.


Egypt: Titan Egypt has appointed Amr Reda as its CEO. Reda has worked for Lafarge and related companies since 2008 starting as the Chief Financial Officer (CFO) for Lafarge Pakistan Cement. He then became the Country CEO for Lafarge Pakistan in 2012 and the Country CEO for Lafarge Jordan in 2015. Prior to holding positions with Lafarge, Reda held senior finance positions for subsidiaries of Heineken and 3M in Egypt. He is a business graduate from the American University in Cairo and holds a master of business administration (MBA) from the same institution.


Colombia: Holcim Colombia has appointed Martín Costanian as its CEO. He succeeds Marco Maccarelli in the position, who has been appointed as the CEO for Holcim Switzerland, Italy, South Germany and Haut Rhin.

Costanian, a Uruguayan national, has worked for Holcim since 2019 when he joined the group as the Chief Financial Officer for Holcim México. He later joined the group’s Strategy and Growth Directorate in early 2024. Earlier in his career he held finance roles for Keurig Dr Pepper and 3M, and has held roles with Kraft Foods Group. Costanian is a science and business graduate from the Universidad Católica del Uruguay and holds a master of business administration (MBA) from the Carlson School of Management, part of University of Minnesota.


Ireland: Ecocem has appointed Ghizlane Ruf as its Chief of Staff. The role will see her work with the company’s senior executives to prioritise strategic business decisions and enhance team efficiency. She has been in post since the start of 2024.

Ruf previously worked for LafargeHolcim from 2016 to 2022 in a variety of customer service roles eventually becoming the Head of Customer Services for Cements and Aggregates and Standards France. She has also worked for Salesforce and Teksial.


South Africa: PPC has appointed Roann Heunis as its National Technical Manager. Prior to this he worked as a manager and a technical consultant for the building materials producer. Earlier in his career, Heunis was a Technical Sales Representative for Chryso Southern Africa. He holds a qualification in civil engineering from the Cape Peninsula University of Technology.


US: Command Alkon has appointed Ron Carlson as Senior Vice President, Industry Liaison. The role will involve enhancing customer engagement, providing strategic industry insights, and fostering long-term relationships with key accounts.

Carlson previously worked as the Executive Vice President of Operations at Superior Materials, a Votorantim Cimentos North America company based in Detroit, and Wingra Ready-Mix and Stone Company based in Madison, Wisconsin. Prior to this he spent a decade with Ozinga Ready-Mix in Chicago. Carlson currently sits on the National Ready Mixed Concrete Association’s Operations Environment and Safety Committee, and he has also served as an elected board member of the Wisconsin Ready Mixed Concrete Association.


US: Saxum has appointed Jared Weston as General Manager for North American Operations & VP of Strategic Planning. He previously worked as Director of Sales and VP of Strategic Planning for the engineering and project management company. Earlier in his career he spent over 15 years working for FLSmidth, starting as a commissioning engineer in 2006 and becoming head of Capital Sales from 2020 to 2023. Weston is a graduate in Industrial and Manufacturing Engineering from Penn State University.


Kenya: The government has decided to sell its entire 25% stake in East African Portland Cement Company, as part of a strategic reform of its investments, guided by the International Monetary Fund. The Star newspaper has reported that the government expects to earn US$134m from the sale. It reportedly sold 30% of shares in the producer for US$117m in 2023.

Of East African Portland Cement Company’s multiple minority shareholders, the largest is Lafarge South Africa, with 42% of shares, followed by the Kenyan National Social Security Fund, with 27%.


Canada: Hyperion Global Energy has fired up its pilot Tandem Carbon Recycling System at Lafarge Canada’s Bath cement plant in Ontario. The system mineralises captured CO2 to produce mineral components for alternative building materials. It has a capture capacity of 1000t/yr. The partners will test the Tandem Carbon Recycling System in producing Lafarge Canada’s 30 – 90% reduced CO2 ECOPact concrete.

Lafarge Canada’s Eastern Canada regional president and CEO of David Redfern said "Our collaboration with Hyperion marks an exciting milestone in our decarbonisation journey and the advancement of our circular construction technologies. We look forward to advancing our net zero strategy by leveraging carbon utilisation technology like Hyperion's, enabling us to further reduce CO₂ emissions from our operations while at the same time producing innovative and sustainable building solutions."

Hyperion CEO Heather Ward said "Working together with an innovative partner like Lafarge on this exciting pilot project allows us to apply our proprietary carbon recycling technology to large-scale industries, and make an immediate, measurable reduction on carbon emissions. At the same time, we are advancing our vision to offer a scalable and affordable decarbonisation solution for industry, and a market-driven profit incentive on the cost of carbon removal."


US: Representatives of the Portland Cement Association (PCA) and its members are meeting politicians at Congress to discuss cement sector decarbonisation on 12 and 13 June 2024. The PCA says that meetings will address permitting processes and new emission standards affecting the industry.

PCA president and CEO Mike Ireland said "There's a lot happening in Washington this year that directly impacts America's cement manufacturers, which is likely why we have a record turnout of cement company leadership in town for this fly-in. Our industry's top objective is to reach carbon neutrality. While our companies appreciate recent funding from the Department of Energy to assist in decarbonisation efforts, it's still challenging for them to make significant advancements due to a cumbersome permitting system and unrealistic Environmental Protection Agency regulations that could lead to eventual cuts in plant operations and staffing. As the infrastructure law is hitting its stride, the country needs more cement and concrete, not less. We're here to ask Congress to work with us to arrive at reasonable policies and standards that will allow manufacturers to continue to provide the resilient, sustainable building materials our country has come to expect."


Spain: Heidelberg Materials plans to stop clinker production at its Añorga plant near San Sebastián and run the site as a cement grinding plant instead. It says it intends to use the change to focus on low-carbon cement products in Spain and the South-West of France. The clinker required to supply the markets in Northern Spain and the South-West of France will be produced at Heidelberg Materials Spain’s Bilbao plant instead. The closure of the clinker production line at Añorga will start once staff negotiations at the plant are completed. The company said that, “socially acceptable solutions for all affected employees are being sought.”


Netherlands: Paebbl has successfully mineralised its first tonne of CO2 into raw materials for alternative building materials at its pilot facility in Rotterdam. The tonne of CO2 corresponds to 3t of material produced. In a post to LinkedIn, the company said that it is now seeking ‘more brilliant, planet-aligned, resilient people’ to join its team of 30 people.

Paebbl said “We're moving fast, but our journey is barely a humbling 0.0000001% complete.”


Canada: Votorantim Cimentos subsidiary St Marys Cement has entered redemption of all its outstanding 2027 senior notes, at a value of US$229m. The company notified the holders of the notes accordingly.


China: KHD’s management team met in Nanjing in May 2024 to strategise on advancing decarbonisation in the cement industry. The meeting focused on industry needs and sustainable practices.

CEO Jianlong Shen said "We were pleased to welcome members of KHD leadership from around the world to Nanjing. Everyone who attended had the opportunity to take part in the discussion and share their ideas and suggestions for our next steps. We look forward to sharing more about our direction in due course as we continue on our collective journey to cement beyond carbon."


Germany: Flender celebrated its 125th anniversary on 10 June 2024. The company reflected on the role of its forward-looking approach in making it market leader in industrial drive technology and a pioneer in industrial transformation and sustainable business practices.

CEO Andreas Evertz said "We have always been and will always be a large Flender family. Whether employees, customers, suppliers, partners or owners – today we all feel like Flenderans. I am incredibly proud to be part of this team and to advance the energy transition with you. Because without drive technology and Flender, nothing moves in this world."


Portugal: Sacopor has inaugurated a new bag production line at its paper bag plant near Lisbon. The new line will increase capacity to 160 million bags per year from 130 million at present. It had an investment of €11.5m. The subsidiary of Cimpor sells bags to the cement mortar industries.


Nigeria: The government of Bauchi State has signed a deal with Resident Cement and Sinoma Nigeria Company for the construction of their upcoming 10Mt/yr cement plant in the state. The deal stipulates total investments by the companies of US$500m to build the plant, situated in Gwana District.

Governor Bala Abdulkadir Mohammed said "We are reassured in our commitment to maximise the available resources to exploit the natural resources Bauchi State possesses for the economic development of the state.”


Germany: France-based Fives has won a contract to build a 50t/day clay calcination unit at Rohrdorfer’s Rohrdorf cement plant in Bavaria. The unit will integrate into the plant’s clinker line in order to allow it to test the production of limestone calcined clay cement with up to 40% reduced CO2 emissions. Fives’ clay calcination unit uses a flash calcination process, based on a three-stage preheater, flash calciner and decolourisation system.

Rohrdorfer’s Net Zero Emissions Labs team is responsible for the project to decarbonise the Rohrdorf cement plant by 2038. Its managing director Helmut Leibinger said “After a detailed technical review, we decided that the flash calciner with an integrated clay calcination unit from Fives FCB was the best solution in terms of reliability, efficiency and colour control. We are confident that the unit will be essential in moving forward on our pathway to net zero.”


UAE: The board of RAK White Cement has recommended that its shareholders accept a cash offer from UltraTech Cement for the acquisition of a further stake in the company. Global Cement News reported in May 2024 that UltraTech Cement had offered to acquire 32% of shares in the company. It previously acquired 29% in April 2024.


North America: The Wildlife Habitat Council (WHC) has recognised Cemex’s conservation efforts in Mexico and the US with awards for four of its projects. These included its restoration of desert habitats at Cerro Jardín, Xoyatla and Coayuca in Atotonilco, Mexico. Cemex said that all of the projects advance its Future in Action strategy of sustainable excellence through circularity, climate action and water and biodiversity management, in line with becoming a net zero company by 2050.


Comoros: Cimentos Comores is considering finding temporary sources of bagged cement after its regular bulk deliveries via the Port of Moroni, Grand Comore, became disrupted. Al-Watwan News has reported that a malfunctioning landing buoy has prevented cargo ships from landing at the port.

Cimentos Comores said “In the absence of a technical solution, we will be forced to cancel the operations.”


The Gambia: The Gambian government has released over 300 truckloads of imported cement held at the Senegal border at Farafenni. The Ministry of Trade, Industry, Regional Integration and Employment described the move as a one-time measure intended to alleviate the backlog caused by a rise in import duties, by a factor of six, to US$2.66/bag. The Cement Importers and Traders Association (CITA) welcomed the release of the cement, citing concerns over a possible shortage.


China: The National Development and Reform Commission, along with other government departments, has launched the Special Action Plan for Energy Conservation and CO2 Reduction in the Cement Industry. The plan aims to cap clinker capacity at 1.8Bnt/yr by 2026, with 30% of it above the national energy efficiency benchmark level. This will reduce energy consumption per tonne by 3.7% from 2020 levels. The plan will eliminate 13Mt of CO2 emissions and 5Mt of coal consumption in 2024 – 2025.


India: The National Company Law Appellate Tribunal (NCLAT) has declined to stay insolvency proceedings against Jaiprakash Associates, following a challenge by its board. The board has been suspended since the NCLAT admitted an insolvency plea against the company on 3 June 2024. Press Trust of India News has reported that ICICI Bank first initiated proceedings over outstanding debts in September 2018.

The board of Jaiprakash Associates submitted that it will remain ‘asset-rich,’ even after it sells cement plants to repay loans. It attributed its present ‘liquidity crunch’ to delayed government approvals, ‘prolonged’ litigation and policy changes. The NCLAT stated that it must admit insolvency pleas in cases of defaulted debt repayment, saying that a judicial resolution will prevent further depletion of Jaiprakash Associates’ assets.


North Korea: State-owned Sunchon Cement has completed an upgrade to its cement plant in Sunch'ŏn-shi, P’yŏngan-namdo Province, Korea News has reported. The upgrade included the installation of real-time monitoring equipment in the plant’s raw materials conveying system. The company says that this will help to increase the plant’s efficiency. It also fitted new crushers and vibrating feeders.


India: Residents of Kamrup, Assam, have petitioned the district government to block Taj Cement’s plans to build a new 1Mt/yr grinding plant at Chamata Pathar. The residents’ petition cites groundwater and ecological concerns over the plan. The Sentinel newspaper has reported that the plant will be the third cement facility in the immediate area. The area adjoins the Amchang and Pabitora Wildlife Sanctuaries.

The Greater Dimoria Citizens’ Protection Committee said “The current cement factories have already taken a toll on our environment and health. The proposed Taj Cement plant will only make matters worse, putting our lives and the nearby wildlife sanctuaries at risk.”


Russia: Belarusian Cement has concluded a deal with the Moscow regional government to build a logistics facility in the region at Naro-Fominsk. Prime Press News has reported that the facility will cost US$22.5m. It will be equipped with ready-mix concrete, precast concrete and dry mix plants, as well as a rail terminal, storage areas and loading zones for despatches by road.

Director General Alexander Dovgalo said "This investment will not only bolster our logistics capabilities but also enhance our service quality for Russian partners and extend our market reach within Russia and the CIS member states."


Global: Ministers from Canada and the UAE have established priority actions to decarbonise the global sector. The announcement follows the initiative's launch at the United Nations Climate Change Conference (COP28) in December 2023.

The plan outlines sector-specific actions across themes such as education, innovation and environmental coordination. These efforts aim to make ‘near-carbon neutral’ cement production the preferred option globally by 2030.

In addition, the government of Canada and the United Nations Industrial Development Organisation (UNIDO) have announced a new partnership aimed at accelerating decarbonisation in Thailand’s cement and concrete sectors. The collaboration was unveiled in conjunction with the CEO Gathering and Leaders Conference in Bangkok, hosted by the Global Cement and Concrete Association (GCCA). The partnership will provide technical assistance and investment support to develop policies, a regulatory framework and a national net-zero roadmap.


Taiwan: Taiwan Cement recorded a net income of US$60.8m in the first quarter of 2024, marking a 39% rise from the same period last year, despite a 2.9% decline in revenue to US$790m. The company's profit margin increased to 7.7% from 5.4% in the first quarter of 2023, attributed to reduced expenses.


India: UltraTech Cement has conserved 105m3 of water in the 2024 financial year, achieving a status of five times water positive. The company's water management strategy includes the installation of rainwater harvesting systems and zero liquid discharge plants at several manufacturing units to enable 100% reuse of treated water.


Saudi Arabia: Hoffmann Green Cement Technologies has initiated construction of H-KSA 1, its first production unit in Saudi Arabia, located at Rabigh. The foundation stone was laid following a licensing agreement with Shurfah Group, which includes building four Hoffmann units under an exclusive 22-year deal. These units will use Hoffmann's clinker-free cement, aligning with Saudi Arabia's Vision 2030 objectives. Completion is anticipated by end of 2025.

Co-founders Julien Blanchard and David Hoffmann said "We are delighted to participate in the decarbonisation of the Saudi construction sector by building several of our units on their territory and marketing our 0% cement clinker."


New Zealand: Golden Bay, New Zealand's sole cement producer and a division of Fletcher Building, is advancing its sustainability goals at its Portland plant near Whangārei. The plant has been incorporating old tyres and treated timber in its production process since 2021, with the Ministry for Environment helping fund US$10m of the US$15.5m to upgrade the plant for the project. The plant uses tyres to replace 55-60% of the coal required, and plans to eliminate coal use by 2030. The facility has increased its use of recycled tyres from 15,000t to 30,000t/yr and is aiming for 40,000t/yr. The government’s Tyrewise programme supports tyre recycling, with the plant also investing in an on-site shredder. Upcoming projects include substituting coal with non-recyclable materials like old carpets and plastics, targeting a 30% reduction in emissions. Construction has already started on the project and it is expected to be completed by the end of 2024, according to the New Zealand Herald.

Manufacturing manager Kelly Stevens said, "We’re diverting 100,000t/yr of waste that would’ve gone to landfill.”


France: Cem’in’log has surpassed 1Mt of clinker processed at the Sète site since its inception over four years ago, encouraging parent company Cem’in’EU to continue investments there. Since 2019, the Port of Sète has served as a key entry point for Cem’in’EU’s clinker imports, mainly from North Africa. The site's storage capacity was expanded to 300,000t/yr in 2023. A new warehouse set to increase capacity to 500,000t/yr will begin construction in summer 2024 with a €5m budget. Cem’in’log will also boost its equipment, expecting to operate six rail services weekly by the end of 2024, supporting future expansion.

General manager Jean-Yves Apard said "We are currently dispatching four to five trains per week from Sète, loaded with 1850t of clinker. By the end of 2024, with a second locomotive provided by Regiorail and handled at the port by Viia, we will increase to six trains per week."


Egypt: Beni Suef Cement Company has reported a 32% year-on-year decline in profit for the first quarter of 2024, with a net profit after tax of US$873,000 compared to US$1.3m in the same period in 2023. Despite the fall in profits, sales rose significantly to US$14m from US$5.8m in the first quarter of 2023.


China/Taiwan: Asia Cement (China) Holdings will be taken private in a US$647m deal by its majority owner, Taiwan-listed Asia Cement Corp. Asia Cement Corp offers US$0.41 per share for the remaining stakes in its Hong Kong-based unit, marking a 3% discount on the last closing price. Trading in Asia Cement China shares, suspended since 28 May 2024 after a surge, will resume on 6 June 2024. The firm is impacted by China’s struggling property sector and recorded a first-quarter loss of approximately US$18m in April 2024.