Displaying items by tag: Grinding
Austria: Lafarge Zement has announced the successful commissioning of a new raw meal mill at its Mannersdorf cement plant in Lower Austria. CEO Berthold Kren congratulated process engineer Nina Wolf and the Mannersdorf plant team for carrying out the Euro23m project.
Buzzi Unicem launches CGreen reduced-CO2 cement in Germany and Italy
24 February 2022Germany/Italy: Italy-based Buzzi Unicem has launched its CGreen reduced-CO2 cement on the German and Italian cement markets. The product uses alternative raw materials to partially replace clinker and also optimises grinding and mixing conditions through the use of novel specialist additives. In Germany, the available range of CGreen cements will consist of Dyckerhoff Eco Comfort cement and Dyckerhoff Cedur cement.
Italy cemeny chief operating officer Antonio Buzzi said "The ecological transition calls for us to adapt our behaviors and actions in order to neutralise our carbon footprint. This transition implies the partial or total redesign of production processes, distribution systems and consumption patterns, heralding the start of a potential industrial revolution and a change in our habits."
Cementos Pacasmayo increases sales in 2021
21 February 2022Peru: Cementos Pacasmayo recorded full-year sales of US$519m in 2021, up by 49% year-on-year from US$348m in 2020. Sales exceeded pre-Covid levels of US$373m in 2019 by 39%. The company’s profit for the year was US$41m, more than double its profit of US$15.5m in 2020 and up by 16% from US$35.4m in 2019.
The Semana Económica newspaper has reported that Cementos Pacasmayo aims to maintain its 2021 full-year cement sales volumes in 2022. The company is in the process of a US$70m, 600,000t/yr clinker capacity expansion in order to increase its clinker capacity to 100% of its grinding capacity, from 61% currently. This will eliminate the producer’s reliance on clinker imports.
First Graphene starts deal with Fosroc to develop additives
24 January 2022Australia: First Graphene has started a five year collaboration research and development agreement with construction chemicals manufacturer Fosroc International to develop its PureGraph graphene-based cement additive product range. First Graphene will provide access to its formulation and dispersion process technologies and Fosroc will take responsibility for additive raw material supplies and formulations, mixing and dispersion and extensive laboratory trials. The objective of the deal is to jointly develop a range of PureGraph-enhanced cement additives that Fosroc will add to its portfolio of specialty products.
Michael Bell, the managing director and chief executive officer of First Graphene, said, “The agreement with Fosroc is a significant further step for First Graphene as we implement our go-to-market plan to become the world’s leading supplier of graphene-enhanced cement and concrete solutions. Fosroc has significant penetration into multiple global markets that will be highly beneficial in helping expand our reach and educating the market on the significant benefits, including emission reductions, that graphene-enhanced products provide.”
First Graphene says that the clinker factor of cement can be reduced by up to 20% through the use of its PureGraph additive products during the final grinding phase of cement production.
Spain: Cementos Cosmos plans to scale down the production of clinker at its Córdoba cement plant as a result as the high cost of electricity. The Cordoba Day newspaper has reported that parent company Votorantim Cimentos said that clinker grinding operations at the site will continue to ensure a sufficient cement supply in the region.
The Córdoba cement plant employs 48 people. The company is currently negotiating the situation and the scope of its impacts with the workforce.
Askari Cement orders three Gebr. Pfeiffer MVR vertical roller mills for Nizampur cement plant
23 September 2021Pakistan: Askari Cement has awarded a contract to Germany-based Gebr. Pfeiffer for the supply of three of its MVR vertical roller mills to replace the existing mills at its Nizampur cement plant. Two of the mills will be MVR 5000 C-4 cement mills with the capacity to grind 360t/hr of clinker to a fineness of 3250 blaine. The other mill, an MVR 5000 R-4 raw meal mill, will grind 520t/hr of clinker to a fineness of 12% R90µm. The Chinese contractor Hefei Cement Research & Design Institute will install an SLS V high-efficiency classifier on each of the mills. The upgraded plant is scheduled for commissioning in mid-late 2022.
Water recirculation initiative reuses 88 - 100% of cooling water in cement grinding in Panama in 2020
21 September 2021Panama: Panamanian cement producers reused cooling water used in cement grinding at a rate of 88 – 100% nationally in 2020. The development is part of a concerted water conservation effort first launched by Argos Panamá. The La Estrella newspaper has reported that Cementos Panamá’s Quebrancha grinding plant reduced its water consumption by 88% in five years, to 59,600m3 from 477,000m3 in 2015. The plant’s cement now has a water consumption of 100l/t, compared to 537l/t in 2015.
Gujarat Sidhee Cement suspends Sidheegram cement plant’s clinker production for maintenance work
07 September 2021India: Gujarat Sidhee Cement has shut down the kiln line of its Sidheegram, Gujarat, cement plant for 17 – 20 days. India InfoLine News Service has reported that the company will carry out routine maintenance on the plant during the shutdown. It says that grinding and dispatch of cement will continue as usual.
Cement news, abridged
07 April 2021Global Cement Weekly celebrates its 500th edition this week. This corresponds to nearly a decade’s worth of news and comment upon the cement industry, since the first edition went out in early June 2011. Time is brief, so the quick version of all of this is as follows: China; production growth; production overcapacity; grinding; corporate mergers; regionalisation; CO2; digitisation; and coronavirus.
Those looking for the longer version should read Peter Edwards’ review of the 2010s in the December 2019 issue of Global Cement Magazine. Although be warned, few were expecting a global pandemic to rock markets and possibly hasten future trends when that article was written. Those looking for the even longer version should read the last 10 years of the magazine and the website… and then let us know what we missed.
Looking back at the first few editions of Global Cement Weekly brings to mind the LP Hartley quote, “the past is a foreign country; they do things differently there.” It’s all very familiar until one comes across the little things that makes one realise how much has actually changed.
For example, countries were imposing import tariffs on cement, companies were buying each other, national cement associations were lobbying hard for their members and cement plants were investing in alternative fuels equipment. All that stuff has been happening continually over the last decade and right into this week, with Russian media announcing who has won the auction to buy Eurocement and LafargeHolcim closing its deal to buy Firestone Building Products. Yet, Lafarge and Holcim were still separate companies and Italcementi was independent in 2011. On the sustainability side, Norcem and its parent company HeidelbergCement Group, with the European Cement Research Academy (ECRA), had just started a partnership agreement with Aker Clean Carbon (ACC) to study post-combustion CO2 capture technology at Norcem’s plant in Brevik, Norway. Jump forward nine years and Norcem signed a deal with Aker Solutions in mid-2020 to order a full scale CO2 capture, liquification and intermediate storage plant at Brevik.
The big numbers from the United States Geological Survey (USGS) show that global cement production grew by 24% to 4.1Bnt in 2020 from 3.3Bnt in 2010. However, the big growth had stopped by around 2013 and production has hovered between 4.0Bnt/yr and 4.2Bnt/yr ever since. Alongside this, Getting the Number Right (GNR) data indicates that net CO2 emissions for cementitous products fell by 4% to 610kg/t in 2018 from 636kg/t in 2010. The former may show a levelling off of production as the Chinese market stabilised in the 2010s but the latter shows the progress that has been made in reducing cement-related CO2 emissions and the scale of the challenge that remains ahead.
Graph 1: Embodied energy versus embodied CO2 of building materials. Source: Hammond & Jones, University of Bath, UK.
Cement industry readers should not lose heart about the future of the industry though, while environmental pressure continues to mount. Graph 1 above shows the embodied CO2 and energy of common building materials. Cement has been rightly identified as a major emitter of CO2 but any society that desires to build strong structures cheaply and at scale requires concrete to do so whilst the data above remains unchallenged. The ratios may change, such as the perennial energy-cost influenced tug-of-war between asphalt and concrete roads, but concrete remains the only game in town. For now. At which point cement production becomes all about reducing the CO2 emissions or capturing them, and determining who exactly pays for this. This then brings us to the present with the European Union Emissions Trading Scheme carbon price of over Euro40/t and other schemes popping up all around the planet. One echo from one of the early editions of Global Cement Weekly was the furore over Australia’s attempt at a carbon tax in the early 2010s. It was repealed in 2014.
One prediction about how the 2020s might be summarised for the cement industry is this: how to get away with pumping out all that CO2? Let’s see what the next decade will bring.
Update on China: March 2021
31 March 2021Financial results for 2020 from the major Chinese cement companies are now out, making it time for a recap. Firstly, information from the China Cement Association (CCA) is worth looking at. The country had a cement production capacity of 1.83Bnt/yr in 2020. For an idea of the current pace of industry growth, 26 new integrated production lines were built in 2020 with a clinker production capacity of just under 40Mt/yr.
This is as one might expect from the world’s biggest cement market. However, the CCA also revealed that the country has over 3400 domestic cement companies, of which two thirds are independent cement grinding companies. Most of these were reportedly created during the late 2000s as dry kilns started to predominate. The CCA is concerned with the quality of the cement some of these companies produce and the lack of order in this part of the market such as regional imbalances. This suggests that the government’s attempts to consolidate the cement industry as a whole had led to the independent companies heading down the supply chain. It also raises the possibility that the government-led consolidation drive may move to grinding next. One news story to remember here is that in February 2021 the CCA called for its industry to respect competition laws following a government investigation. Later in the month it emerged that eight cement companies in Shandong Province had been fined US$35m for price fixing in a sophisticated cartel whereby the perpetrators went as far arranging a formal price management committee to regulate the market.
The CCA described 2020 as a year of sudden decline, rapid recovery and stability. Coronavirus hit cement output in the first quarter of 2020 leading to unprecedented monthly year-on-year declines before it bounced right back in a classic ‘V’ shaped recovery pattern. Despite the pandemic and bad weather later in the year, annual output rose by 2% year-on-year to 2.37Bnt in 2020 from 2.32Bnt in 2019. This has carried on into 2021 with a 61% increase in January and February 2021 to 241Mt from 150Mt in the same period in 2020. That’s not surprising given that China was suffering from the pandemic in these months in 2020 but the growth also suggests that the industry may have gone past stability and is growing beyond simply compensating for lost ground.
Graph 1: Year-on-year change in cement output in China, January 2010 - February 2021. Source: National Bureau of Statistics of China. Note that accumulated data is issued for January and February each year so these months show a mean figure.
Chart 2: Annual cement production growth by Province in 2020. Source: China Cement Association.
Chart 2 above shows cement production in 2020 from a provincial perspective. Note the sharp decline, more than 10% year-on-year, in Hubei Province (shown in dark green). Its capital Wuhan is where the first documented outbreak of coronavirus took place followed by a severe lockdown. Zooming further out, China’s clinker imports grew by 47% year-on-year to 33.4Mt in 2020. This is the third consecutive year of import growth, according to the CCA. The leading sources were Vietnam (59%), Indonesia (10%), Thailand (10%) and Japan (8%). China has become the main export destination for South East Asian cement producers and Chinese imports are expected to continue growing in 2021.
Graph 2: Revenue of large Chinese cement producers in 2020 and 2019. Source: Company reports.
Moving to the financial figures from the larger Chinese cement producers, CNBM and Anhui Conch remain the world’s two largest cement producing companies by revenue, beating multinational peers such as CRH, LafargeHolcim and HeidelbergCement. Anhui Conch appeared to be one of the winners in 2020 and Huaxin Cement appeared to be one of the losers. This is misleading from a cement perspective because Anhui Conch’s increased revenue actually arose from its businesses selling materials other than clinker and cement products. Its cement sales and cement trading revenue remained stable. On the other hand, Huaxin Cement was based, as it describes, in the epicentre of the epidemic and it then had to contend with flooding along the Yangtze River later in the year. Under these conditions, it is unsurprising that its revenue fell.
CNBM’s cement sales revenue fell by 3% year-on-year to US$19.5bn in 2020 with sales from its new materials and engineering compensating. Anhui Conch noted falling product prices in 2020 to varying degrees in most of the different regions of China except for the south. CNBM broadly agreed with this assessment in its financial results. Anhui Conch also reported that its export sales volumes and revenue fell by 51% and 45% year-on-year respectively due to the effects of coronavirus in overseas markets. The last point is interesting given that China increasingly appears in lists of major cement and clinker exporters to different countries. This seems to be more through the sheer size of the domestic sector rather than any concerted efforts at targeting exports.
One major story on CNBM over the last 15 months has been its drive to further consolidate its subsidiaries. In early March 2021 it said it was intending to increase its stake in Tianshan Cement to 88% from 46% and other related transactions. This followed the announcement of restructuring plans in mid-2020 whereby subsidiary Tianshan Cement would take control of China United Cement, North Cement, Sinoma Cement, South Cement, Southwest Cement and CNBM Investment. The move was expected to significantly increase operational efficiency of its constituent cement companies as they would be able to start acting in a more coordinated manner and address ‘fundamental’ issues with production overcapacity nationally.
In summary, the Chinese cement market appears to have more than compensated for the shocks it faced in 2020 with growth in January and February 2021 surpassing the depression in early 2020. Market consolidation is continuing, notably with CNBM’s efforts to better control the world’s largest cement producing company. Alongside this the CCA may be starting to suggest that rationalisation efforts previously focused on integrated plants should perhaps be now looking at the more independent grinding sector. The government continues to tighten regulations on new production capacity and is in the process of introducing new rules increasing the ratio of old lines that have to be shut down before new ones can be built. Finally, China introduced its interim national emissions trading scheme in February 2021, which has large implications for the cement sector in the future, even if the current price lags well behind Europe at present.