Displaying items by tag: Upgrade

Germany: Australia-based Calix says that its LEILAC-2 carbon capture retrofit of HeidelbergCement's Hanover cement plant has passed its financial investment decision. The company is accordingly proceeding with detailed design and long-lead item purchasing. It will launch construction in 2023. Calix added that, due to a number of project risk flag points given the 'market situation,' it will not buy major components until closer to that time.

When commissioned, the installation will capture 0.1Mt/yr of CO₂ and cost an estimated Euro20 - 25/t of CO₂ captured.

China: China Resources Cement’s profit was US$993m in 2021, down by 13% year-on-year from 2020 levels. Its cost of sales grew by 22% to US$3.81bn from US$3.12bn. The group noted that the average cost of coal increased by 54% in 2021. It also pointed out that infrastructure investment growth slowed down in 2021. The company increased its turnover for the year by 9.7% to US$5.62bn. Sales volumes of cement and clinker fell by 7% to 81.3Mt and 7% to 3.3Mt respectively. Concrete sales volumes grew by 11% to 14.8Mm³.

During 2021 the group started construction of a second clinker production line and two cement grinding lines at its plant in Wuxuan, Guangxi. Once the upgrades are completed the plant will have a total cement and clinker capacities of 2.4Mt/yr and 1.4Mt/yr respectively. The group also acquired a 51% stake in Hunan Liangtian Cement in January 2022 to enter into the market in Chenzhou, Hunan. This company has cement and clinker production capacities of 1.6Mt/yr and 2Mt/yr respectively. An ongoing upgrade will increase the cement production capacity of 2.1Mt/yr. In March 2022 it sold its 72% stake in Shanxi China Resources Fulong Cement to Tangshan Jidong Cement to enable it to leave the northern market.

China Resources Cement has also been growing its co-processing capabilities in 2021. At the end of the year it reported 10 co-processing projects with a total capacity of 1.7Mt/yr. The projects, mostly based in Guangxi and Yunnan provinces, process municipal solid waste, urban sludge and industrial waste.

France: Lafarge France has announced a total planned investment of Euro46m in upgrades to its 1.6Mt/yr Saint-Pierre-la-Cour, Mayenne, cement plant and its 1.2Mt/yr La Malle, Bouches-du-Rhone, cement plant. The Holcim subsidiary will invest Euro40m to convert the Saint-Pierre-la-Cour plant to low carbon cement production. Meanwhile, it will invest Euro6m in the La Malle plant’s conversion to ultra-low carbon cement production. The L’Usine Nouvelle newspaper has reported that the transitions will complement the company’s strategy of over 25% EcoPact reduced-CO₂ ready-mix concrete sales by 2025.

Cement producers in the north of Pakistan have started to increase their use of coal from Afghanistan in response to the ongoing volatility in energy markets. Research from a report by Darson Securities found that companies were already using up to 70% Afghan coal in their fuel mix with a further 20% being considered. Most of the northern producers are reported to have secured the cheaper Afghan coal for about two months of inventory, although Maple Leaf Cement was said to have four to five months of inventory. Meanwhile in the south of the country, producers were reported to be facing a tougher situation as Afghan coal costs more for them due to higher logistics charges and export orders were being reduced due to the low cost of clinker internationally. So they are focusing on the domestic market instead.

Graph 1: Cement despatches in Pakistan, 2015 – 2021. Source: All Pakistan Cement Manufacturers Association.

Data from the All Pakistan Cement Manufacturers Association (APCMA) shows that cement despatches have been steadily growing since the mid-2010s with a blip in 2020 caused by the start of the Covid-19 pandemic. The upward trend has been driven by local sales. Exports have generally grown at the same time, with more variance, but they are yet to regain the high of nearly 11Mt reported in 2009. On a rolling annual basis, local sales have remained steady since mid-2021 but exports have been slowly falling. In April 2021 they were 9.17Mt but by February 2022 they were 7.33Mt. For the February 2022 figures APCMA blamed this on the growing cost of production, rising international freight rates, mounting coal prices and a trade ban with India. On that last point for example, Pakistan-based producers exported 1.21Mt of cement to India in the 2017 – 2018 financial year before exports stopped after February 2019. Despite a brief respite in the spring of 2021 talks are still ongoing to resume trade with India.

On the corporate side the country’s largest cement producer by capacity, Lucky Cement, drew the same conclusion as the APCMA with its half-year results to 31 December 2021. Its local sales volumes were down a little but its exports were down a lot. It noted that the reason its local sales were falling but national industry local sales were up slightly was due to some competitor plants being non-operational in the previous year. However, the company managed to keep sales revenue and earnings increasing year-on-year by successfully combating growing input costs with price rises. Bestway Cement, the country’s other large producer, reported a tougher situation in the second half of 2021, with both local sales and export volumes down. This was attributed to a boom in construction activity in the second half of 2020 as Covid-19 lockdowns were eased. Demand for cement since then was said to be ‘sluggish’ due to inflation and high commodity prices. It also pinned its marked fall in exports on political and economic instability in Afghanistan. However, turnover and operating profit were both up due to higher selling prices.

Elsewhere in the sector news since the start of 2021, Pakistan’s exports to South Africa remained stymied in early 2020 due to a review of ongoing tariffs and the government decision to restrict infrastructure projects to only using locally produced cement. On the sustainability front the APCMA started to set out its decarbonisation strategy in November 2021. It may have a long way to go given that a think tank reported earlier in the year that the cement sector was the largest emitter of coal-related CO₂ emissions in the country, even more than power generation. Alongside this plenty of capacity additions have been announced. Lucky Cement started commercial cement production at its 1.2Mt/yr integrated Samawah cement plant in March 2021. Various new cement plants and upgrades to existing plants have been proposed by Bestway Cement, Cherat Cement, Fauji Cement, Kohat Cement Company, Lucky Cement and Maple Leaf Cement. Finally of note to a sector troubled by energy prices, in September 2021 the Pakistan International Bulk Terminal said it was going to upgrade its coal handling capacity to around 17Mt/yr by 2024.

Last week’s Global Cement Weekly covered Turkey. The contrasts are interesting because both of these countries have high cement exports and have raised energy concerns recently. This leads to the question of whether other cement exporters may be vulnerable to the current situation. Pakistan isn’t the only country where the cement industry is facing the negative effects of growing energy costs. This week in the sector news, Spain-based Tudela Veguín has shut down the kiln at its La Robla plant down for 10 days due to high electricity prices, Thailand-based Siam Cement Group (SCG) announced it was reviewing its investment plans and the UK-based Mineral Products Association lobbied the government on the issue.

The shift to Afghan coal by Pakistan’s cement producers is rational given the current situation. No doubt fuel buyers all over the world are doing similar things. In January 2022 the International Monetary Fund (IMF) forecast that Pakistan’s gross domestic product would grow by around 4% for 2021, 2022 and 2023 but current geopolitical events may test these estimates. Over the last year domestic cement demand has remained strong but inflation, growing input costs and the impetus to further rise prices may change this. Meanwhile, lots of new production capacity is in the pipeline and, if or when it is built, it may add additional competition pressure. This may present a problem in Pakistan if capacity utilisation levels drop but input costs keep on going up.

India: ISGEC Heavy Engineering has received an order from Shree Cement to supply a waste heat recovery (WHR) unit for the integrated 3.8Mt/yr Nawalgarh plant in Rajasthan. The scope of work includes design, manufacture and supply of the system. The supplier says that this will be one of the world’s largest steam-based WHR units by capacity. ISGEC previously supplied two WHR units for Shree Cement’s Raipur plant.

Mexico: Cemex has successfully commissioned its new Line 2 at its Tapeaca, Puebla, cement plant.

Cemex’s Mexico regional vice president operations and technology Ernesto Felix said that the work ‘brought together a great team’ of Cemex colleagues.

Germany: Australia-based FCT Combustion has successfully delivered a new Turbu-Flex burner to replace the existing burner at HeidelbergCement’s Hanover, Lower Saxony, cement plant. FCT Combustion will also supply burner accessories and add-ons, an igniter, a flame sensor, fans, blowers and spare parts. The project aims to improve combustion control and maximise alternative fuel (AF) use in the plant’s cement production.

China: Nanjing Kisen International Engineering has secured a collaboration agreement with Canada-based Delta CleanTech for the implementation of the latter’s carbon capture and storage (CCS) systems at two China National Building Material (CNBM) cement plants. SCMP News has reported that there is a one-time licencing fee - which is not paid by Nanjing Kisen International Engineering but is traditionally paid by the CO₂ capture plant customer - of 4.5 - 5% of capital costs. Installations cost upward of US$40m, depending on capacity.

There are currently 40 operational or upcoming CCS installations nationally with a total capture capacity of 3Mt/yr, chiefly in the oil, coal chemicals and energy sectors.The Chinese Academy of Environmental Planning has forecast that China’s cement industry CCS demand will reach 200Mt/yr by 2060. Delta CleanTech president Jeff Allison said that current challenges for Chinese cement producers seeking to reduce their CO₂ emissions include difficulties disposing of captured CO₂ and a lack of rewards and penalties around emissions control beyond the basic national efficiency requirements.

Nanjing Kisen International Engineering previously launched its first 155kg/day pilot CCS study in partnership with the Canada-based International CCS Knowledge Centre in July 2021.

Mexico: GCC has signed an engineering, procurement and construction (EPC) contract with ThyssenKrupp Polysius for an upgrade to its integrated Samalayuca plant to increase clinker production capacity, raise the usage of alternative fuels and reduce emissions. The project includes the engineering, supply and modification of the preheater, including cyclones, and an extension to the calciner, with the installation of a Prepol SC-S type system to increase the utilisation of alternative fuels. The work also includes fitting a Polytrack type clinker cooler and the installation of a bypass system. The project will begin in 2022 with operations scheduled to start in the second quarter of 2023.

Australia: Boral plans to install chlorine bypass technology at its Berrima cement plant in New South Wales. The Illawara Mercury newspaper has reported that the installation will help the plant to double its alternative fuel (AF) substitution rate to 100%. This is one of the ways in which the producer aims to reduce its Scope One and Two emissions by 46% between 2020 and 2030.

In mid-February 2022, Boral acquired new land at the site of its Dunmore quarry, also in New South Wales.