September 2024
Algeria: Germany's Gebr. Pfeiffer SE has won a contract through the Chinese General Contractor CBMI to supply a MVR 6700 C-6 type cement mill and a MVR 6000 R-6 raw mill, both of which will be installed at the Lafarge cement works situated near the Algerian town of Biskra. The cement mill is the second-largest in the world after a mill supplied by Gebr. Pfeiifer to Holcim's Barosso plant in Brazil.
The cement mill, featuring Gebr. Pfeiffer's MultiDrive® concept with an installed total drive power of 9125kW, will produce 231-342t/hr of OPC ground to a product fineness of 3700-4800cm²/g according to Blaine.
The raw mill, which will come equipped with a conventional drive with an installed power of 6120kW, is designed to grind 680t/hr of cement raw material to a finished product fineness of ≤12% R 90 µm and 460t/hr of limestone to a product fineness of ≤1% R 150µm.
The delivery of the mills is expected in the summer of 2015.
Mexico: Cemex has announced its financial results for the second quarter of 2014, which show that consolidated net sales reached US$4.2bn during the second quarter of 2014, an increase of 4% compared to the comparable period in 2013. Operating earnings before interest, tax, depreciation and amortisation (EBITDA) increased by 1% during the quarter to US$737m compared to the same period in 2013. On a like-for-like basis and adjusting for business days in its operations during the quarter, consolidated net sales increased by 5% and operating EBITDA increased by 3% versus the second quarter of 2013.
Cemex said that the increase in consolidated net sales was due to higher prices of its products in local currency terms in most of its operations, as well as higher volumes in the US and the Mediterranean, South & Central America and the Caribbean and Asia regions.
Fernando A González, Chief Executive Officer, said, "We are pleased with the year-to-date trends we have seen in volumes for our three core products and the continued success of our value-before-volume strategy. We expect improved performance from our Mexican operations during the second half of the year which should lead to stronger overall EBITDA generation for the full year 2014."
Breakdown by geographical area
Net sales in Cemex's operations in Mexico decreased by 4% in the second quarter of 2014 to US$816m, compared with US$847m in the second quarter of 2013. Operating EBITDA decreased by 1% to US$247m versus the same period of 2013.
Operations in the United States reported net sales of US$957m in the second quarter of 2014, up by 10% compared to the same period in 2013. Operating EBITDA increased to US$119m for the quarter, compared to US$80m in the same quarter of 2013.
In northern Europe, net sales for the second quarter of 2014 reached US$1.1bn, a 5% increase compared with the second quarter of 2013. Operating EBITDA was US$121m for the quarter, 12% higher than a year earlier.
Second-quarter net sales in the Mediterranean region were US$449m, 12% higher than sales of US$400m during the second quarter of 2013. Operating EBITDA increased by 6% to US$100m for the quarter versus the comparable period in 2013.
Cemex's operations in South & Central America and the Caribbean reported net sales of US$562m during the second quarter of 2014, remaining flat compared to the same period of 2013. Operating EBITDA was down by 16% to US$178m in the second quarter of 2014, from US$211m in the second quarter of 2013.
Operations in Asia reported a 2% decrease in net sales for the second quarter of 2014 to US$160m, versus the second quarter of 2013. Operating EBITDA for the quarter was US$34m, down by 11% compared to the same period of 2013.
Venezuela: Cemento Andino's Trujillo plant in Venezuela is set to undergo a US$240m capacity expansion. The plant currently produces around 600,000t/yr of cement. The construction of a new production line is expected to triple Cemento Andino's capacity. The project will take around two years to complete, generating around 500 direct and 1000 indirect jobs.
Croatia: Holcim Croatia is looking to post flat revenues in 2014, while hoping to raise them by 15% in 2015, according to the company's chairman Alan Sisinacki. Holcim Croatia currently operates one cement plant, two cement terminals, two concrete plants and three aggregates quarries.
In 2014 Holcim Croatia is hoping to cut its loss to Euro2.49m under its on-going '2015 Plus' programme, which should return the company to profitability in 2015. The turnaround plan is already yielding results, with Holcim Croatia posting an operating profit in the first half of 2014, the highest result over the last five years.
Sisinacki expects Holcim Croatia's cement sales to remain unchanged in terms of volume in 2014, with sales of aggregates also flat. The company's concrete sales are set to drop in terms of volume in 2014 due to the sale, closure or leasing out of a significant chunk of its unprofitable concrete-producing assets. Sisinacki said that his expectations for Holcim Croatia's 2014 performance are based on official statistical data showing a 4.0% year-on-year decline of building construction and 10% fall in other civil construction works in the first quarter of 2014 in Croatia.
During the first six months of 2014 cement demand dropped by 6.0%, according to data from the association of cement producers in Croatia. Market conditions in Slovenia and Italy, Holcim Croatia's biggest export markets, are not looking any better. Sisinacki said that Holcim Croatia is trying to offset this growth weakness by exporting to northern Africa, taking advantage of the cement plant conveniently located in the Koromacno port.
India: A new Inter-Ministerial Task Force (IMTF) has been constituted to undertake a comprehensive review of the existing coal resources and to consider feasibility for rationalisation of linkages.
The major recommendations of the IMTF include acceptance of the recommendations of Coal India Limited (CIL) to rationalise existing coal resources. CIL has received 31 applications for rationalisation, including eight from captive power plants, out of which it recommended rationalisation in seven cases. There were two applications from cement plants.
"The approved recommendations of the IMTF were sent to CIL," said Coal and Power Minister Piyush Goyal. "CIL and the coal companies have implemented the recommendations pertaining to rationalisation of coal resources to captive power plants, sponge iron and cement plants." With regard to the rationalisation of resources of power utilities, the IMTF's recommendations are all inter-linked and could be implemented only with the consent of all the consumers. However, the consumers concerned did not agree to the revised arrangement.
The government has also expedited environment and forest clearances and land acquisition processes to improve Indian coal production. According to Goyal, India does have adequate coal resources to meet demand. Steps have been taken by CIL and its subsidiaries to augment production, including capacity addition from new projects and the use of mass production technologies. As per official data, the total estimated quantum of coal resources in India is 301.56Bnt. Some 12.53Bnt of coal has been extracted between 1950 and 2013-2014, with 566Mt of that in 2013-2014 alone.
Turkey: Austria's A TEC Production & Services GmbH has been awarded a contract by Çimentaş Elaziğ for its plant in Elaziğ Province. The contract covers engineering for upgrades and efficiency optimisations of its preheater tower.
The scope of modifications comprises the redesign of all four cyclone stages, riser ducts and related equipment. The project target is to reduce the total preheater pressure drop by 25% and to increase production capacity by at least 8% on a sustainable basis.
The project will be executed in two phases. The first stage modifications were completed in May 2014, the second phase work is due to be completed shortly, while the third and fourth stages are due for completion in 2015. Phase one resulted in a sustainable production increase of 8% and a pressure drop reduction at the fan inlet by about 19%. Based on the phase one results, it is expected that the pressure drop before the fan will be reduced beyond the target figures after completion of phase two, which will allow higher production at less specific power consumption on the fan than initially targeted.
UK: Hope Construction Materials is bolstering its 300-strong concrete mixer fleet with 36 new Mercedes-Benz trucks. The new Arocs 3236 8x4 B11 4-axle mixer trucks, each equipped with a McPhee mixer system, are Euro 6 compliant, built to the latest diesel engine emission legislation from the European Commission.
The vehicles feature a string of active safety measures, including a vulnerable road user package, as well as a lane control system, collision-avoidance and smart system which warns the driver if pedestrians or cyclists are too close to the vehicle. The system, which was developed by Cycle Safety Shield using Mobileye technology, works to mitigate the risk of collisions and road departure. The Cycle Safety Solution warns drivers when a cyclist or pedestrian is within danger zones, such as the nearside blind spot area. All of the trucks are fitted with TomTom satnavs, allowing the driver to consistently take the most efficient route and for customers to be informed of the exact location of their order at any given point.
"The purchase represents a significant commitment by Hope to providing our drivers with the best possible vehicles," said Mike Cowell, COO at Hope Construction Materials. "They are the most advanced trucks on British roads and will benefit our drivers, customers and other road users."
"This is the first fleet of 8x4 Euro VI Arocs mixers to enter service in the UK and Hope has demonstrated how both safety and sustainability work hand in hand," said James Colbourne, Head of Strategic Accounts (Trucks) at Mercedes-Benz UK Ltd.
Turkey: Turkish cement producer Çimsa Çimento has agreed to take over Sançim Bilecik Çimento Madencilik Beton for Euro163m. Çimsa will purchase all 87.5 million shares of Sançim Bilecik Çimento from Turkish companies AUNDE Teknik Tekstil, E.N.A. Tekstil and six individual shareholders. Sançim Bilecik Çimento has 1.4Mt/yr of cement production capacity. The transaction is subject to regulatory approval.
Nigeria: The board of directors of Ashaka Cement plc, with the support of parent company Lafarge, has agreed to fast track the expansion of its US$617m cement plant in Ashaka, Gombe State. The move became imperative in order to guarantee the future of Ashaka Cement, to enhance job creation and to deliver economic and social welfare to the immediate communities. Chairman of the board of Ashaka Cement, Alhaji Umaru Kwairanga, confirmed the developments.
"Having secured sufficient limestone and coal reserves to support the existing plant as well as the new plant, the contracts have been signed with the main equipment and engineering suppliers," said Kwairanga. He added that credit facility lines of US$308m had been secured and signed in addition to internally generated cash flows to support the expansion project.
"Ashaka Cement has operated in harmony with all of its neighbouring communities to the mutual benefit of both parties," said Kwairanga. "In the last three years alone the company has spent US$2.47m on community-related projects and there is the opportunity for the company to do more as the partnership thrives."
An update on the algae bioreactor project at Votorantim's St Marys cement plant in Canada this week provides a good opportunity to review this particular aspect of carbon sequestration. The project, run with Pond Biofuels, went live in 2009. It has now reached its third generation bioreactor at the site.
Little or no performance data has been released generally so we have no way at present of knowing how viable the process is commercially. Cement backers, Brazilian firm Votorantim, are certainly excited by the project even if only for the sustainability kudos it gives them. Director Edvaldo Araújo Rabello presented the project as one of the company's highlights at a keynote presentation at the 6°CBC Congresso do Cimento held in São Paulo, Brazil in May 2014.
One hurdle for the St Marys pilot is the relative lack of light, a required input for algae photosynthesis, even in Canada's most southerly state. Pond Biofuels have reportedly dodged this by using continuously flashing LEDs to simulate artificially short days that encourage growth. On paper or powerpoint a process that could potentially cut even a proportion of CO2 emissions from a cement plant sounds enticing. Yet if it creates more CO2 than it saves, through electricity requirements for example, than it isn't worth using.
This is probably what shelved Lafarge's Carbon Capture and Transformation project. It ran a pilot project at its Val d'Azergues plant in France in 2009 with Salata GmbH. The pilot worked but the researchers decided that new advances in processes and biotechnology were required to make the economic and environmental results better. Other companies have also had problems. Holcim started its Aurantia – GreenFuel project in late 2007 at its Jerez cement plant in Spain, backing it with an investment US$92m. This project stalled when GreenFuel shut in 2009 citing lack of funding as the recession hit.
ACC in India also reportedly started its own algae project in 2007, mentioning it in its sustainability report, but nothing more has been reported since. Since this burst of interest InterCement has invested US$2.5m towards algae research in 2013 working with the Federal University of São Carlos, the Federal University of Santa Maria and Algae Biotecnologia.
Algae-based carbon projects for cement plants may remain stuck in the research stage but the market for biofuels continues to grow. For example, this week we report that Ohorongo Cement in Namibia plans to increase its use of blackthorn as a biofuel to use as an alternative fuel in co-processing. The prospects of turning waste CO2 into a valuable commodity remains uncertain, but the rewards are great. Let's wait and see what St Marys can do.