Displaying items by tag: Plant

National Cement is preparing to open its new integrated West Pokot plant in September 2023. Readers may recall that the long-running project was taken over by Devki Group from Cemtech and Sanghi Industries after the Competition Authority of Kenya (CAK) gave it permission to do so in 2019. The original feasibility report by the Kerio Valley Development Authority dates back to 2010. The new plant will have a production capacity of 2.5Mt/yr.

However, this isn’t the only new clinker production capacity that Devki Group, which sells cement under the Simba Cement brand, is preparing to commission. Local media also reports that the company is also preparing to restart the former Athi River Mining Cement integrated plant at Bondora in Kaloleni, Kilifi County. After five months of trial runs the unit should be ready for full operation from April 2023. Devki Group also picked up this plant in 2019 following the long breakup of ARM Cement, after the latter producer entered financial administration back in mid-2018.

Devki Group started out in the steel sector but it has been steadily carving out a presence in the cement industry. The group opened its first cement grinding plant in 2013 and then built a 1.95Mt/yr integrated plant in Kajiado County, south of Nairobi, in 2018. Once the West Pokot plant is commissioned, the company will reportedly have a clinker production capacity of 7.5Mt/yr from three plants.

This kind of growth is making waves in the local cement sector. Since Global Cement Weekly covered the situation in September 2022 (GCW576), an argument has been brewing in Kenya over whether the country should import clinker or manufacture more of its own. This has moved to lobbying the government on whether the duty on imports of clinker should rise from 10% to 25%. Unsurprisingly, the country’s largest clinker producer, National Cement, even before the new plants are operational, has been a major advocate for putting up the import tariff. This carried over into 2023, when local press revealed the minutes of a meeting between the State Department of Industry and the Kenya Association of Manufacturers (KAM), with input from the cement producers. Rai Cement, Bamburi Cement, Savannah Cement, Ndovu Cement and Riftcot were all against raising the tariff, saying that it would enable the largest clinker producers, National Cement and Mombasa Cement, to dominate the market. However, unlike the last such meeting, Mombasa Cement was said to be non-committal on the proposal to increase the duty. Despite the disagreement over the tariff, all of the cement companies imported clinker in 2021.

Graph 1: Rolling annual cement production in Kenya, 2019 - October 2022. Source: Kenya National Bureau of Statistics (KNBS).

Rolling annual cement production in Kenya peaked at just over 10Mt in May and June 2022. Data from the Kenya National Bureau of Statistics (KNBS) shows that monthly production started to fall on a year-on-year basis from July 2022. This is likely to be connected to the elections that took place in August 2022, although wider economic trends such as inflation and high input material prices may not have helped either. Despite this, cement production rose by 5% year-on-year to 8.02Mt in the first 10 months of 2022 from 7.65Mt in the same period in 2021.

Other recent news of note in Kenya includes the restart of clinker production at East African Portland Cement’s (EAPC) Athi River Plant in mid-2022. The upgrade was conducted as part of a general five-year upgrade and expansion campaign by the company. The next steps were announced in January 2023 with a stated intention to consider entering markets in the Democratic Republic of Congo and Rwanda. The other story of note was in December 2022, when China-based Sinoma International Engineering announced that it had signed a deal with Savannah Cement to build a new 8000t/day clinker production line with a 2400t/day cement grinding unit, a 35MW captive power unit and a 13MW waste heat recovery unit. As is standard for Sinoma’s new contract releases, it said that the contract would become active once an “advance payment guarantee” had been received. Later in December 2022 the Kenya High Court intervened to stop two creditors from seizing assets from Savannah Cement and putting it into administration, although the court did acknowledge the company’s debts and a loan repayment default. In January 2023 Mauritius-based Barak Asset Recovery, another related creditor, was approved by the competition regulator to buy a majority stake in Savannah Cement. The current state of that new production line is unknown.

As the two stories above show, it is not just National Cement that is trying to move towards increased clinker production in Kenya. The whole situation is reminiscent of the time before Nigeria declared itself self-sufficient in cement in the early 2010s. Local producers became prominent and the market battle between producers and importers became public. Kenya’s range of different cement companies seem to be more diverse than Nigeria’s were, but a similar type of national interest argument may be rolled out by one side. The other parallel to note with Nigeria is that Dangote Cement is said to have attempted to buy National Cement previously and has also been trying to build its own plant in the country since the mid-2010s. Kenya’s demographics and location make it a prime place for this kind of producer-importer tussle. Let’s wait and see how much the situation has changed when the new plants open over the next six months.

Spain: Holcim Spain has appointed Lucas García and Raúl Lannegrand respectively as the managers of the Sagunto and Carboneras cement plants. García succeeds José Luis Coleto, who is moving to a human resources position.

García has worked for Holcim Spain for over 25 years. He has been the manager of the Jerez de la Frontera plant since 2014. Prior to this he held maintenance and production roles. He holds electrical engineering qualifications from the Technical University of Cartagena and the Polytechnic University of Cartagena,

Lannegrand was previously operations manager of Geocycle, Holcim's industrial waste management subsidiary. He has a degree in chemistry from the Autonomous University of Madrid and a Master's degree in Research in Inorganic Chemistry, Lannegrand has knowledge in the field of construction materials research from three years spent at the Institute of Construction Sciences Eduardo Torroja (CSIC).

Mozambique: Dugongo Cimentos plans to build a US$192m, 6000t/day cement plant at Nacala-Porto in Nampula Province. The Macao News has reported that the producer expects the plant to create 600 new jobs locally.

Dugongo Cimentos previously inaugurated its 2500t/day Matutuine cement and clinker plant in Maputo Province following a total investment of US$330m in 2021. The company is jointly owned by state-owned SPI Gestão e Investimentos and China-based West International Holding.

Cyprus: Vassiliko Cement has secured environmental clearance to build a new alternative fuel (AF) store at its Vassiliko cement plant in Nicosia. Philenews has reported that the facility will replace the site’s former AF store, which burned down in a fire started by a mobile shredder in June 2022.

India: Adani Group is planning to build two new cement plants in Andhra Pradesh with a combined production capacity of 10Mt/yr. Karan Adani, the son of the group’s founder Gautam Adani, made the announcement, among a slate of new investments being developed for the state, according to Business Today. At present the group does not have any cement production plants in Andhra Pradesh, although it does operate two ports at Krishnapatnam and Gangavaram respectively. The other projects include renewable power units with a capacity of 15,000MW and data centres.

Senegal: The International Finance Corporation (ICF) has arranged a Euro242m finance package for SOCOCIM Industries to build a new production line at its Rufisque cement plant in Dakar Region. Euro214m of the loans will be used to decarbonise cement production at the site, including a contribution towards a larger Euro260m upgrade project. The new planned production line will have an alternative fuels substitution rate of 70%, increased energy efficiency and will reduce the plant’s CO₂ emissions.

The finance package organised by the IFC comprises a Euro120m loan from the IFC's own account and Euro122m equivalent in local currency parallel loans from Société Générale Sénégal, CBAO Groupe Attijariwafa Bank, Banque Internationale Pour Le Commerce et l'Industrie du Sénégal, and Ecobank Sénégal. Société Générale Sénégal has been appointed as the administrative agent to manage the local currency financing with the other lenders.

SOCOCIM is a subsidiary of France-based Vicat. Fives revealed in early 2022 that it would supply a 6500t/day kiln line for the Rufisque plant.

US: Alamo Cement has completed a new solar power unit that supports its integrated cement plant in San Antonio, Texas. The unit has a capacity of 17,800MWhr and is situated on an 18 hectare site. It is expected to generate up to 15% of the plant’s annual power consumption and reduce electricity costs.

US: The Environmental Protection Agency (EPA) has announced that 10 cements plants have received its Energy Star certification in 2022 from a total of 86 manufacturing plants across all industries. The certification is awarded to the top 25% performers in energy efficiency in each sector. The EPA cited examples of how Titan America’s Troutville plant in Virginia and its Medley plant in Florida had converted production to Portland Limestone Cement (PLC), and achieved a 12% reduction in electricity use and an 18% reduction in CO2 emissions, respectively, thanks to improved energy management. It also mentioned Cemex’s Miami plant in Florida, which increased its energy performance in 2022 by modifying a finish mill, optimising the ball charge on the largest mill and identifying and correcting potential energy losses while also increasing the production of PLC.

Cement plants awarded the Energy Star certification in 2022 include: Drake Cement’s Paulden plant and Salt River Materials Group’ Clarkdale plant in Arizona; GCC’s Pueblo plant in Colorado, Cemex’s Miami plant and Titan America’s Medley plant in Florida; Argos USA’s Harleyville plant in South Carolina; GCC’s Rapid City plant in South Dakota; Buzzi Unicem USA’s Chattanooga plant in Tennessee; Titan America’s Troutville plant in Virginia; and Ash Grove Cement’s Seattle plant in Washington.

China/Uzbekistan: Anhui Conch has released an update on some of its major development projects. Its new plant at Tashkent in Uzbekistan has an investment of around US$260m. The company reports that 30,000m² of equipment and materials have arrived, the rotary kiln supporting wheels have been hoisted in place, the main body installation of the coal mill has been completed, the structure of the dormitory building has been capped and the main factory area has begun to take shape. It is also building a plant at Brakbash District in Andijan State. Civil engineering and main engineering construction are reportedly underway. The company also has a third cement plant in the country. So far the group has built over 10 cement plants outside of China.

In China, Anhui Conch is building a CO₂ energy storage demonstration project at its Baimashan cement plant in Wuhu, Anhui province. The group says that, once complete, the project will be the world's first commercial demonstration project of a CO₂ energy storage system. It says that during the low power consumption period, the excess power will be used to compress CO₂ at normal temperature and pressure into a liquid. The heat energy generated during the compression process will be stored. The stored heat energy will then be used to heat the liquid CO₂ back into a gas, driving the turbine to generate electricity, reducing the cost of electricity. The demonstration project has an area of 40,000m².

The cement producer says it is working towards a model of ‘one base and five industries’ where cement production links to other industries such as new energy, new materials, environmental protection, the digital economy and the promotion of international trade.

Kenya: National Cement Company expects to commission its upcoming West Pokot clinker plant in September 2023. The cement company says that the plant will produce clinker for export to neighbouring countries in Central and East Africa. A previous survey by the Kerio Valley Development Authority proved reliable reserves of 1.2Mt/yr of limestone in the area. When commissioned, National Cement Company expects the new plant to generate 2000 direct jobs.