Displaying items by tag: Lafarge
Lafarge UK: sustainable to profitable?
24 October 2012Lafarge UK's release of its 2011 Sustainability Report for its cement business this week presented some bold headline figures. Key statistics for the period covering 2009 - 2011 included a 17% reduction in CO2 emissions through the use of solid recovered fuels (SRF), a 17% reduction in the use of electricity and a 26% cut in emissions to air.
For a European producer this is some positive news in a time of gloom. Looking a little deeper into the report reveals the usual ambiguities that can arise with interpreting statistics. Lafarge UK's fossil fuel consumption actually rose by 9% from 285,000t in 2009 to 311,000t in 2011. CO2 emissions to air rose by 15% from 2.31Mt to 2.65Mt. In terms of emissions per tonne of Portland Cement Equivalent (tPCE), the figures are more encouraging with fossil fuel use decreasing from 87kg/tPCE to 82kg/tPCE (6%) and CO2 emissions remaining stable at 704kg/tPCE. These figures are good considering that Lafarge's production increased from 2009 to 2011 due to construction for the London 2012 Olympics.
As mentioned in Edwin A R Trout's article 'The British cement industry in 2011 and 2012' the move to refuse-derived fuels (RDF) has consistently made the news with projects at several Lafarge plants. RDF use at Lafarge UK plants rose by 48%, from 92,758t in 2009 to 137,143t in 2011. Each of the alternate fuels – tyres, waste-derived liquid fuel, processed sewage pellets (PSP), meat and bone meal, SRF – roughly increased its unit share per tonne of cement produced by 2%.
Lafarge UK is clearly reacting to uncertain input costs and preparing for any further future green taxes. It failed to meet its 2011 target rate for RDF substitution of 31% (it reached 29%) but it has raised the target to 35% for 2012. It is also continuing to secure permits for PSP use at its Dunbar plant and SRF use at its Hope plant, although by the time this is approved Hope may be someone else's facility. However, the key question is, how can Lafarge push alternate fuels? It will be interesting to see how much Lafarge UK's fuel mix can be reduced in cost over the next five years.
UK: Lafarge has marked its 10th year of sustainability reporting in the UK with the release of its 2011/2012 Sustainability Reports.
Lafarge says that it has made significant investment in developing its sustainable credentials. Waste and water consumption have been cut by 92% and 88% respectively in the cement business since reporting began in 2001. The latest reports also show major advances in the reduction of emissions to air, an increase in the amount of material being moved by rail, greater bio-diversity in its landholdings and improvements in health and safety performance.
"Despite the economic downturn and challenging conditions in the construction market in recent years we have continued to invest in, and demonstrate our commitment to sustainability across, our UK businesses," said, the president of Lafarge UK, Dyfrig James.
Key highlights of the 2011 Sustainability Report for Lafarge Cement, which covers the period 2009 - 2011 inclusive in the UK include:
1. A 17% reduction in CO2 emissions through increased usage of sustainable, waste-derived fuels such as waste tyres and solid recovered fuel (SRF) in manufacturing processes.
2. A 17% reduction in the use of electricity driven by the implementation of Lafarge Cement's 'Golden Rules of Energy Management.'
3. A 26% cut in emissions to air in 2011.
4. Major reductions in waste production, with 76% of all non-hazardous waste sent off site now being recycled.
5. Progression in the regeneration of landholdings including granted approval for the creation of a mixed-use community including 500 new homes at the former Northfleet Works.
6. Significant improvements in health and safety performance, including a 31% decline in first aid instances in 2011 and Cookstown Works achieving a global record of 10 years with no Lost-Time Incidents (LTIs).
7. Piloting of independent water footprint assessments at a number of plants to identify ways to increase efficiency of water use.
8. Winning the Environment Agency Water Save Award for the Cauldon Shale Lake Project – the creation of a closed loop water system to recirculate water for gas conditioning and industrial cooling at Cauldon Works.
9. Growth in sales of lower CO2 packed cements from 51% in 2009 to 54% in 2011.
Lafarge also made improvements in its extensive UK ready-mix concrete operations, which saw a 30% reduction in the CO2 emissions resulting from concrete production compared to figures recorded in 1990 and a 16% reduction in CO2/t between 2010 and 2011.
Diverging fortunes in Europe and the Americas
17 October 2012News from Mexico and the US over the past week confirms the contrasting fortunes of the cement industry in the 'Old World' and the 'New World,' of Europe and North America. First, Cemex reported a significantly reduced loss of US$203m in its third quarter, compared with a loss of US$730m in 2011. However, the firm's European units again faired worse than other regions.
The European problem is not limited to Cemex, but while much of the continent has seen a poor 2012 so far, North America appears to be in the midst of a construction renaissance. HeidelbergCement estimates US cement sales growth of 8-11% in 2012. In Mexico, a strong and growing industry, it has also been announced that the Mexican billionaire Carlos Slim had partly financed a new US$300m plant in Mexico, due to go into production early in 2013.
In light of this apparent upward trend in North America, it is surprising that France's Lafarge has agreed to sell two more of its US cement plants, this time to Eagle Materials. If the Eagle deal is approved, it will represent (along with the May 2011 sale of Lafarge's Roberta and Harleyville plants to Cementos Argos) a continued and substantial reduction in Lafarge's presence in the US. In under 18 months, Lafarge will have offloaded four plants, taking its total from 12 to eight.
Lafarge's decision to sell to Eagle seems like an attempt to meet its own debt-reduction schedule. Yet to do this it may be losing important territory in North America. This can't have been an easy decision.
Staying on track in Nigeria
10 October 2012"We believe that Nigeria has arrived as a cement manufacturing country," said Joseph Makoju, Chairman of the Cement Manufacturing Association of Nigeria (CMAN), to mark yet another 'moment' when Nigeria's ability to produce cement has overtaken its demand.
One of Makoju's reasons for Nigeria's 'arrival' was the fact that the Nigerian government hasn't issued any import licenses since the start of 2012.
As Global Cement Weekly #46 noted in April 2012 this is strange given that domestic consumption is up to 18Mt/yr: a figure 4Mt below modest estimates of national capacity which start at 22Mt/yr. According to Global Cement monthly price reviews the cost per bag has risen by 20% since 2010 despite presidential orders to keep it down. However much cement Nigeria seems to produce the price still keeps on rising.
The prices aren't the only figures that are rising year-on-year. Dangote, Nigeria's leading-producer, reported an increase in operating profit of 14% to US$745m in 2011 from US$654m in 2010. Lafarge WAPCO, the country's second largest producer, reported an increased operating profit of 41.7% to US$74.1m from US$52.3m.
Prices continue to rise but this could be due to cartel-like behaviour. President Goodluck Jonathan seemed to suggest as much in 2011 when he ordered prices down. Then again Nigeria's poor transport infrastructure and distribution chains could be to blame for rising prices instead. CMAN has announced plans to promote the use of concrete road construction with the government and Dangote announced plans in August 2012 to widen its distribution by opening more 'mega-depots' and signing on new distributors.
It's unclear exactly how much cement the Nigerian market actually wants. Its per capita consumption is 110kg, compared to 280kg in South Africa and over 600kg in Egypt. This is way down the consumption/GDP curve compared to Europe and North America. Its population has reportedly risen by 30m from 2006 to 2012. This implies massive total demand and demand potential.
So - past massive transport infrastructure projects, improved distribution and possible price inflation - how does Nigeria keep momentum? Ironically, given Nigeria's protectionist stance against imports, one of the measures CMAN is exploring is how to export cement to other countries. Recent news reports about local producers in Namibia and South Africa fighting foreign imports suggest that other African countries are starting to 'arrive' too. Even building the roads may not be enough to keep Nigeria's cement express-train on track.
How much is an American cement plant worth?
03 October 2012Eagle Materials has picked up two cement plants in the US from Lafarge with a combined capacity of 1.6Mt/yr for US$446m. The deal also included six distribution terminals, two aggregates quarries, eight ready-mix concrete plants and a fly ash business.
Following our column in August 2012 following an acquisition in India we decided to ask a similar question: how much are American cement plants worth?
Eagle's acquisition now increases its presence in the Midwest and South Central regions of the US, giving it a rough line of plants across the country nearly connecting Lake Michigan to the Gulf of Mexico. As shown in our industry report on the US between 2005 and 2011 cement consumption fell in both the states the plants are located in. Missouri's consumption fell by 45% from 2.82Mt to 1.56Mt, just above the US national average. By contrast Oklahoma's consumption only fell by 11%, from 1.6Mt to 1.43Mt, the fourth smallest decline in the country.
However, Eagle has demonstrated financial health in contrast to the US sector as a whole, reporting a 21% rise in total revenue in the quarter to 30 June 2012 and a 60% rise in operating earnings year-on-year in the quarter to 31 March 2012. The combined operations at the two plants generated about US$178m in revenue during the year ending in June 2012. By contrast Eagle Materials' revenue totalled US$529m during the same period. The plants' additional capacity will increase Eagle's total by about 60%.
Lafarge are still thinking big though, with the proviso that Eagle will supply certain Lafarge operations with cement for four to five years, as well as an agreement with a Lafarge affiliate to supply low-cost alternative fuels to the acquired operations. According to its 2011 annual report North America comprised 11% of Lafarge's cement sales. Lafarge's sales in the US remained flat in 2011. In that year the company's capacity was 12.8Mt with a 12% market share. This picture has started to change in 2012 with a reduced loss in earnings before interest, tax, depreciation and amortisation (EBITDA) in the first quarter followed by volume and sales increases of above 10% in the second quarter.
Back in June 2011 Cementos Argos picked up two plants from Lafarge in Roberta, Alabama and Harlyville, South Carolina for US$760m with a combined capacity of 2.7Mt/yr. As with the Eagle deal the sale included a number of peripheral assets including a clinker mill, cement mixer lorries and a marine port.
Cementos Argos recently put the world average at US$250m/t when publicising the expansion of its Rioclaro plant. The European Cement Association reports the figure at being above US$200m/t on its website. In August 2012, at the time of the potential CRH acquisition in India, the cost of Indian cement production capacity was placed at US$110/t-US$120/t.
Perhaps the question we should ask is how much is a US cement plant worth when it used to belong to Lafarge. Both the Cementos Argos sale and the Eagle deal worked out at US$280/t including all the ancillaries. The actual question we should ask is why has Lafarge chosen these specific plants to sell to a competitor in the US market?
France: Carlos Espina has been appointed as director of research and development for the Lafarge Group, with effect from 1 October 2012. Espina was previously the chief executive officer at ArcelorMittal Méditerranée, a position he had held since July 2009.
He began his career in the UK as a researcher at AEA Technology. In 1995 he joined the research and development (R&D) Centre of Aceralia Corporación Siderúrgica as manager of the product applications engineering department, before becoming vice president of intellectual property, knowledge management and artificial intelligence upon the merger with Arcelor in 2002. Within the Arcelor Mittal Group, he successively held the positions of vice-president in charge of R&D, Europe, and vice-president in charge of R&D, automotive.
Carlos Espina will be based at Lafarge's Research Centre near Lyons, with more than 250 researchers of 12 different nationalities. He holds a degree from Oviedo College of Mines in Spain.
Eagle Materials to acquire two Lafarge plants in US
27 September 2012US: Eagle Materials Inc. has issued a press release announcing that it has entered into a definitive agreement with Lafarge North America to purchase Lafarge's Sugar Creek plant in Missouri and Tulsa plant in Oklahoma, which have a combined cement capacity of 1.6Mt/yr. The deal also includes six distribution terminals, two aggregates quarries, eight ready-mix concrete plants and a fly ash business.
Eagle will also enter into a transition sales agreement to supply certain Lafarge operations with cement for four to five years and an agreement with a Lafarge affiliate to supply low-cost alternative fuels to the acquired operations.
The purchase price for the group of assets is US$446m, subject to customary post-closing adjustments. The acquisition will increase Eagle's cement capacity by 60% and it is expected to close in November or December 2012, pending regulatory approvals.
Steven Rowley, Eagle Materials' President and Chief Executive Officer, said that the agreement represents a major milestone event for the company. "Our stated strategy has been to grow the cement and aggregates side of our business. Our first priority has been to acquire cement plants that connect but do not overlap with the market reach of our existing plants."
"These two high-quality Lafarge cement plants are a compelling fit with our objectives and the transaction meets our stringent criteria for new investment," continued Rowley. "These assets will allow us to participate more fully in the US construction industry recovery. Additionally this transaction further positions the company near energy growth markets, where there is growing demand for our specialty oil well cement, along with our newly-offered high-quality northern white frac sand. These new cement, concrete and aggregates assets will immediately contribute earnings and cash flow for our stockholders. Moreover they will provide significant near-term opportunities for synergies and earnings growth."
Ambuja, Grassim and Lafarge face coal block cancellations
26 September 2012India: An inter-ministerial panel has recommended the de-allocation of two coal blocks held by five companies, including Gujarat Ambuja Cement, Grasim Industries and Lafarge India, bringing the total number of such blocks to 13. The Inter-ministerial Group (IMG) has completed the review of 29 coal blocks held by private companies and recommended cancellation of licences for blocks holding an estimated 2.6Bnt of coal, affecting 28 private companies.
The affected blocks include the Bhaskarapara block in Chhattisgarh and Dahegaon Makardhokra IV in Maharashtra. The Dahegaon Makardhokra IV coal block, with 132Mt of reserves was allocated to IST Steel & Power, Gujarat Ambuja Cement and Lafarge India in 2009. The Bhaskarapara block with 48Mt of reserves was allotted to Electrotherm (India) Ltd and Grasim Industries Ltd in 2008. The coal ministry has not decided yet how it will re-allocate the 13 blocks.
A senior coal ministry official said the coal blocks would be auctioned to private firms or given to government companies at the reserve price if the ministry does not want to allocate them to Coal India. The ministry has already identified 54 coal blocks for three types of allotments: to government companies, to power companies and to private firms through auction.
"If we decide that Coal India has enough blocks, we may give it to other companies through the auction route. Whatever the route is, no block will be given free of cost and even Coal India will pay a reserve price," the official said.
The de-allocation recommendation follows a probe into the so-called 'coalgate' scam, concerning the allocation of coal mines to private firms since 1993. The practice of granting captive coal blocks to private power, steel and cement companies began in 1993, following an amendment to the Coal Mines (Nationalisation) Act. India's main opposition, the Bharatiya Janata Party, has accused the government of using the probe for alleged vested political interests.
Dubai Group looking to exit Lafarge Emirates Cement
19 September 2012UAE: Dubai Group plans to sell its 45% stake in a joint venture firm with French cement maker Lafarge to help to repay its debt, which currently stands at US$10bn. Lafarge Emirates Cement is restructuring and needs additional capital to help support the business.
Lafarge Emirates Cement was set up as a joint venture between Lafarge, the largest cement company in the world, Dubai Group, part of conglomerate Dubai Holding, and the Fujairah Emirate in 2005. The company runs a plant in Fujairah with a cement production capacity of 3.2Mt/yr.
Ash Wednesday: cement in the Philippines
05 September 2012Coal ash seems to be in short supply in the Philippines. Lafarge Republic has signed a deal with a local energy producer to buy coal ash from a new 600MW coal plant.
Although the cost of the deal was not announced, the agreement will run from when the plant starts operation until 2019. This move follows a similar arrangement by Cemex Philippines in June 2012. In that instance Cemex agreed to purchase coal ash from the 200MW Kepco SPC Power Corp plant in Naga, Cebu for US$0.95/t.
Distinctively both arrangements were set up in conjunction with local government. For the Lafarge deal part of the agreement involved donating at least 10,000 bags of cement per month for use in various infrastructure projects of the province. Bataan governor Enrique Garcia put the value of the deal at US$1.19m/yr. For the Cemex deal the Cebu Provincial Government signed the agreement. In November 2009 Cebu Province and Kepco entered into an Ash Disposal Agreement, where Cebu Province was granted exclusive rights to the ash produced by the power plant.
Adding to the suspicion that the Philippines lacks sufficient coal ash, back in the autumn of 2011, the Cement Manufacturers' Association of the Philippines (CeMAP) asked the Department of Trade and Industry (DTI) to impose mandatory quality standards on raw materials, such as coal ash. This followed accusations by CeMAP that poor quality coal ash might be behind complaints from contractors working on infrastructure projects. In 2009 a DTI profile on the cement industry placed the demand for Portland cement at 73% and the demand for pozzolan cement at 27% of the total.
Cement sales in the Philippines have been steadily growing over the last decade. Lafarge Republic announced in August 2012 that it was increasing its capacity to just below 9Mt/yr in 2013. Around the same time CeMAP released data showing that sales were up 20% year-on-year for the first half of 2012. The local industry reported combined sales of 15.6Mt in 2011. Previous to this, Holcim Philippines announced the US$9.46m upgrade to a previously closed mill in Batangas.