September 2024
Has MACT been sent for review? 12 December 2012
US: The US Environmental Protection Agency (EPA) has sent final revisions to its Portland cement sector air toxics and criteria pollutant emissions rulemaking for White House Office of Management and Budget (OMB) pre-publication review, according to industry sources. This could indicate that the agency might meet a looming 20 December 2012 consent decree deadline for issuing the proposal.
Industry sources say that the rule, which will revise EPA's 2010 maximum achievable control technology (MACT) standards for air toxics emissions and a related new source performance standard to cut criteria pollutants, was received at OMB either on 4 or 5 December 2012, although an EPA spokeswoman declined to say whether the rule has been sent for OMB review. She only said that the agency was, "Working on the rule and (plans) to finalise by 20 December 2012."
The 20 December 2012 deadline stems from a settlement with the Portland Cement Association (PCA) and others in the industry to propose a revision to the rules, a response in part to industry petitions for reconsideration. Cement manufacturers claimed that the 2010 rules' particulate matter (PM) limits were not achievable, among other concerns.
In addition to addressing the reconsideration petitions and other aspects of the settlement, the rule will also respond to the US Court of Appeals for the District of Columbia Circuit's December 2011 ruling in PCA v EPA remanding the rule to the agency. The court found that EPA had failed to reconsider how a related incinerator air rule may potentially alter the cement rule's emission limits and that the agency failed to give 'sufficient notice' of its final standards for open clinker storage piles.
In the 22 June 2012 proposed revisions to the rule, the EPA proposed to weaken the particulate matter (PM) limit for existing kilns from 18.14g/t (0.04lb/t) of clinker to 31.75g/t (0.07lb/t) of clinker and the limit for new kilns from 4.5g/t (0.01lb/t) of clinker to 9.0g/t (0.02lb/t) of clinker. The EPA also proposed to extend the MACT's compliance deadline to 9 September 2015, saying, "We believe that this date would require compliance 'as expeditiously as practicable'" as required by the Clean Air Act.
Several environmental groups have argued that the revisions are unlawful, both exceeding the changes required by the DC Circuit's narrow ruling and watering down the cement standards for 'unknown reasons.' In comments made on 17 August 2012 regarding the proposed reconsideration the Natural Resources Defense Council, Earthjustice and other environmental groups said that the compliance delay is arbitrary and capricious given that EPA failed to adequately justify it. They added that the delay, "Will greatly exacerbate the harm that EPA already has caused and the suffering that ordinary Americans have had to endure," given that the EPA was supposed to update the cement MACT in 1997.
Update: The White House Office of Management and Budget (OMB) website shows that the OMB received the revised EPA MACT standards on 6 December 2012.
Misr Beni Suef writes to President over fuel 12 December 2012
Egypt: Production at Misr Beni Suef's cement plants was stopped for the second time in two months on 6 December 2012 due to shortage in natural gas supply. The company has reported that the lack of fuel has led to a loss of approximately US$16.5m and that it may lead to the dismissal of some of its workforce if continued.
Misr Beni Suef's managing director Farouk Moustafa said that the company had sent a letter to the Egyptian President Mohamed Mursi seeking a solution to the gas supply cut but that no response had yet been received.
Siam City to fire up closed kiln 12 December 2012
Thailand/Cambodia: Owing to strong demand for cement in the country and the wider Far East region, Siam City Cement (SCCC) has announced plans to re-open one of the two clinker lines that it shut down in 2008, according to local press.
With the re-opening of the clinker factory in October 2013, SCCC's production capacity will rise by at least 1.4Mt/yr, or 10% of its current capacity, according to the company's managing director Philippe Arto.
SCCC shut down the two plants, which had total capacity of 2.25Mt/yr in 2008 because of an increase in production costs and a decline in demand for cement. However, the company has recently seen strong growth in demand. In 2013 it targets year-on-year growth of at least 5%, following an increase in both public and private sector projects.
Meanwhile, the company's board of directors has said that it will consider a plan to invest in Cambodia early in 2013. The company has been working on the plan since 2010. "Our board of directors will make a decision on this plan in 2013. This would be our first investment outside Thailand," said Arto.
If the plan is approved, SCCC will set up a cement plant in Cambodia via a joint venture with a local partner. "We are interested in investing in Cambodia because we have a more-than 40% share in the cement market in the country," said Arto.
SCCC's sales in the first nine months of 2012 climbed by 10.8% to US$653.8m from US$590.5m in the same period of 2011 due to growing demand. However, its net profit dropped by 5.3% to US$94.1m from US$99.3m due to rising energy costs.
APCMA: Coal delivery strike to hit cement production 12 December 2012
Pakistan: The cement industry has faced a shortage of raw material since Friday 7 December 2012 because truck owners have stopped picking up coal consignments for factories from Port Qasim, according to the All Pakistan Cement Manufacturers Association (APCMA). They are observing a strike against increased incidences of theft, extortion and the charges from the motorway police. The Pakistan cement industry consumes around 4.5Mt/yr of coal.
Coal and various other raw materials are not currently being transported to any cement producer from Port Qasim, which is likely to hurt production in the coming days.
Aside from the thefts and extortion by criminals, the truck owners and drivers say that motorway police have imposed impractical restrictions on truck loading. Truck owners said that the load restriction of 58.5t including 28t from the trucks themselves, is too low. This requirement severely limits the coal-carrying capacity of many trucks, making the transportation cost per tonne unrealistically high.
The APCMA has demanded the government to resolve the issues of goods carrier at the earliest hence the supplies are made regular in order to continue uninterrupted cement production.
Jaypee nears end of Gujarat asset sale 12 December 2012
India: The talks between Jaypee Group and Aditya Birla Group regarding the sale of the former's Gujarat based cement units have finally moved to the final stages, according to local media. It was reported that valuations of the deal, which had already resulted in failed acquisition attempts by others, have continued to cause delays.
Birla has been negotiating the cost of Jaypee's Gujarat cement units with the aim of paying a total of US$800m. The reports say that Birla had offered to purchase the units at US$160/t of installed capacity. This is significantly lower than the US$200/t paid during deals between Holcim and ACC.
Minister visits Lafarge Cookstown following re-fit 12 December 2012
UK: A Lafarge cement plant in Cookstown, County Tyrone, Northern Ireland has invested Euro6m in new equipment and an apprenticeship scheme.
Northern Ireland Enterprise Minister Arlene Foster visited the plant, where she met employees and saw a refurbished electrostatic precipitator that will reduce overall dust emissions. She was also told about the Cement Kiln Dust (CKD) project, which has reduced some 8000t/yr of landfilled waste to almost zero.
Further plans for the Cookstown Works were also showcased, including a future upgrade of a central control room and the apprenticeship scheme, which saw two new apprentices join the works team in 2012. A further two apprentices will join the team in 2013.
The minister said that Lafarge's investment demonstrates its confidence in its workforce. "This is a difficult time for the construction industry and it is therefore particularly pleasing to see that the company is investing in its future by upgrading its current facilities and creating opportunities for apprenticeships," said Foster.
The investment in the Cookstown Works comes at a time when Lafarge is merging its UK building materials business interests with those of Tarmac Buxton. This has necessitated the sale of the French giant's Hope Works in Derbyshire, England.
Iranian cement production up again 10 December 2012
Iran: Iranian cement production surpassed 49.14Mt in the first eight months of the current Iranian calendar year which began on 20 March 2012. The figure is 6% higher than in the same period of 2011, according to the IRIB News Agency. Iran also exported over 9.38Mt of cement and clinker over the same period, a 30% increase compared to the same period of 2011.
Some 8.25Mt of cement and 1.14Mt of clinker were exported during the same period. Iraq, central Asian countries, the United Arab Emirates and Afghanistan were its main customers.
Iran's cement production capacity currently stands at 86Mt/yr, according to the Iranian president Mahmoud Ahmadinejad. He said that the country currently produces some 76Mt/yr.
"Six year ago Iran was dependent on importing cement and nobody would believe that one day the country could become an exporter in the field. However, as we see today, Iran has become one of the world's greatest cement producers and exporters," said Ahmadinejad.
In August 2012 Iran's Industry, Mine and Trade Minister Mehdi Ghazanfari said that the country's cement production capacity would reach 110Mt/yr by 2015.
Dangote to shut Gboko plant 07 December 2012
Nigeria: The 4Mt/yr Dangote Cement plant in Gboko, Benue State, is due to shut because of glut of cement in the market, according to an announcement from the company.
The move was necessary because of the increase in local production of cement and also the continued import of subsidised cement into the country, according to the group's head of corporate communication Anthony Chiejina. He said in a statement that the production figures for the first 11 months of 2012 show that local supply now exceeds demand.
The total supply of cement to the Nigerian market at the end of November 2012 was a record 11.4% higher than by the same point in 2011. Chiejina said it was disheartening to note that despite the glut in the local cement market, cement imports, though reduced, have continued, thus calling to question the rigorous implementation of the backward integration policy, which was introduced to encourage local production.
Explaining why the Gboko plant should be shut, Chiejina said, "With the dumping of subsidised imported cement in the south-eastern market there is no way that our Gboko Cement plant can survive. The inventory of finished products is beginning to build up at our plants. Don't forget that projects from our investments of about US$1.8bn in additional capacity are already on stream, with lines three and four at Ibese and line four at Obajana, coming on stream early this year."
Chiejina said that other Nigerian manufacturers are also experiencing the same problem of low sales and high inventory. He advised that the government should vigorously implement the provisions of the cement backward integration policy, which he said is needed to protect local manufacturers from dumping. Chiejina said that he wants the government to consider the total ban on cement imports, in view of the fact that local production now surpasses demand for cement and in the interim also increase duty and levy on imported cement to the maximum permissible level.
Boral to shut kiln in favour of clinker imports 06 December 2012
Australia: Building products maker Boral is cutting 90 jobs as it reduces some manufacturing at a cement plant in Geelong, Victoria, in favour of imports. About 90 staff at the Waurn Ponds cement plant will be affected by the suspension of clinker production. Boral intends to import clinker due to the high Australian dollar and low shipping costs and use the plant as a cement milling facility only. It is thought that the kiln will be shut down by April 2013.
The Australian Workers' Union (AWU) said that it will work with the company to try and save as many jobs as possible. Talks will be held with the workers over coming weeks to explore all options, to avoid or mitigate job losses and to organise redundancies or redeployment within the company.
"A continued low level of demand associated with the downturn in Australian building and construction activity is also adversely impacting the profitability of Boral's cement business, where high fixed cost manufacturing assets continue to be under-utilised," said Boral's CEO Mike Kane said in a statement. "Across all of our businesses we need to ensure that we are aligning our domestic production with demand levels and that our cost structures are globally competitive and can be sustained through the cycle."
New continuous mercury gas emissions analyser from SICK 06 December 2012
UK/US: In anticipation of tighter regulations for mercury emissions, SICK has developed the new MERCEM300Z mercury measuring system, a high-accuracy continuous-flow gas analyser for emissions down to the 0–45µg/m3 range from a wide range of combustion sources.
According to SICK, the patented gas spectrum of the MERCEM300Z rapid monitoring system offers superior performance with better long term, drift-free accuracy and lower running costs. The system requires minimal maintenance, is self adjusting and uses no chemical consumables.
"Awareness of the pollution caused by mercury and its compounds in combustion emissions is increasing in the UK and Europe," explained John Exford, Process Automation Division Manager, SICK (UK). "From power generation, cement kilns and hospital waste to crematoriums, the need to tighten up on mercury will be very important in 2013, when the EU will be following the United Nations lead in a world-wide treaty."
Mercury emissions are a particularly pertinent issue in the US cement industry, which will experience tighter mercury level controls in 2013.