September 2024
Carolinas Cement clears hurdle for new plant 13 March 2012
US: Officials from Carolinas Cement Company have announced that the Division of Air Quality of the North Carolina Department of Environment and Natural Resources (DENR) has issued an air quality permit to parent company Titan America LLC to construct a cement plant in Castle Hayne. The issuance comes after four years of technical review of the proposed facility to ensure it will comply with North Carolina's air quality regulations and standards.
The permit was issued after extensive evaluation by DENR, including using air models that incorporate government-approved local meteorological, topographic and site-specific information. The models calculate the concentrations of regulated emissions at the boundaries of the plant property and ambient concentrations throughout the local region and other designated locations to assure they are below legal limits.
"These laws and regulations governing industrial emissions are among the strictest in the world," said Dan Crowley, Titan America's VP of Corporate Engineering. "The issuance of our air quality permit is only a first step. After the plant begins operating we will be subject to unannounced audits by State and Federal regulators as well as internal compliance audits to ensure our emissions are consistently within permitted limits." Carolinas Cement will meet all the new Environmental Protection Agency federal regulations for Portland cement plants that were finalised in 2010, and these regulations are fully represented in the Department of Air Quality permit.
Now that the air quality permit has been issued, Carolinas Cement plans to proceed with completing the federal Environmental Impact Statement (EIS) needed to obtain necessary wetlands permits. The EIS is an 18-24 month process led by the US Army Corps of Engineers (COE) and it requires Carolinas Cement to hire an independent third party to conduct studies of potential impact to numerous ecological and social factors, such as water, aquifers, traffic and flora and fauna.
Parallel to the COE permitting process, Titan America will begin a two-year process to design and engineer the new plant. The design process could not begin prior to the issuance of the air permit, as the design must correspond to the exact standards outlined by the air permit. The new plant will pioneer the industry's most advanced emission control technologies to ensure that public health, the aquifers, Cape Fear River and Island Creek are protected throughout every step of this process.
When it clears all of the regulatory hurdles, Carolinas Cement will create 161 permanent, full-time jobs. During construction it will create 1000 temporary jobs over two-years.
Lafarge fined over South African cartel 12 March 2012
South Africa: Lafarge Industries SA has admitted taking part in a cement cartel and agreed to pay a US$19.6m penalty. The company reached the settlement with the South African Competition Commission after admitting to having taken part in price fixing and market division in the cement industry. As part of the deal Lafarge agreed to pay the penalty, 6% of its 2010 annual turnover in the Southern African Customs Union (SACU) region, which covers South Africa, Botswana, Lesotho, Swaziland and Namibia.
The case, which has been running since 2008, has investigated dealings at Lafarge, Pretoria Portland Cement (PPC), AfriSam and Natal Portland Cement-Cimpor (NPC-Cimpor). Following a 2009 raid at the offices of the accused parties, PPC applied for leniency and confirmed the existence of a cartel among the four cement producers. In December 2011, an agreement was reached with Afrisam, in which it confirmed the information provided by PPC and agreed to pay a US$16.5m penalty, representing 3% of its 2010 annual turnover in the SACU region.
The commission said that it will continue to investigate NPC-Cimpor.
Lafarge plans blocked by French High Court 12 March 2012
France: The French High Court has decided to block Lafarge's project to close its plant in Frangey, northern France, until 25 November 2012. The Frangey facility employs 74 workers and had previously been slated for closure in 2012.
The planned closure is part of a much larger restructuring plan at the building materials' giant, which was also annulled by the High Court. However, the court said that the fundamental economic case behind closing the Frangey plant was valid. The group had explained that its decision to shut down the plant was due to overcapacity and high production costs.
The management of Lafarge will now propose a new restructuring plan to the staff representatives starting from November 2012.
Ministry removes cement import restrictions 09 March 2012
Saudi Arabia: Saudi Arabia's Ministry of Commerce and Industry has removed restrictions that had been in place on imports of cement, saying that it "has adopted several decisions to ensure the stability of the price of cement and its provision in the local market." The decisions include halting exports, making it obligatory for cement factories to work at full capacity and making producers bear the freight costs to the areas of increased demand. It expects that these measures will mean that cement reaches consumers at a 'reasonable' price.
This is not the first step taken to ensure that the cement supply keeps pace with the huge demand for cement that the construction boom has created. Earlier in 2012 Saudi cement factories were ordered to open up new production lines. These are estimated to have added an extra six million bags to the Kingdom's production every month, taking its total monthly production to about 80 million bags.
The moves come following complaints by cement consumers in remote areas that the price of cement had skyrocketed in recent months, with some accusing dealers of fixing artificially high prices. Saudi Arabia currently has an estimated US$163.5bn-worth of construction projects in the concept phase. It is understandable that it wants to secure the best value cement possible.
FLSmidth taps into Chinese pollution-control sector 09 March 2012
China: The major Danish cement plant manufacturer FLSmidth has achieved authority approval of its first acquisition in China, which will help it to secure a lucrative share of the multibillion dollar Chinese market for environmental control technologies. The move comes less than a month after China announced new NOx emission regulations, providing an excellent market for FLSmidth's new capabilities.
Together with a minority shareholder, FLSmidth has started a company to market and sell air pollution control products to the cement industry in China. This local company is groundbreaking for FLSmidth as it combines local presence and relations with global technologies and resources. The founder company, Chinese Sino Environment Engineering Development Co. Ltd. (SEPEC), continues as a minority shareholder and brings a large reference base and contact network from the cement industry in China, both on a corporate and a plant level.
"FLSmidth and SEPEC are the perfect fit," said FLSmidth CEO Jørgen Huno Rasmussen. "FLSmidth's strong technological platform coupled with SEPEC's strong organisation, reputation and customer base in China will enable us to develop air pollution control products that are uniquely designed together with the Chinese customer and fit his specific requirements."
The local company will market FLSmidth's highly-efficient air pollution control products and thereby help Chinese cement manufacturers to fulfil the new and stricter emission standards imposed on the industry. As the majority shareholder, FLSmidth will retain the intellectual property rights to the technology. The Chinese market accounts for half of the total world market for air pollution control equipment. "With China's increased focus on environmental aspects as stated in the 12th five year plan, the timing of FLSmidth's local expansion is just right," said CEO of FLSmidth China, Anders Bech.
ACC to implement massive upgrade at Jamul 08 March 2012
India: ACC Limited has announced plans to set up a new clinker production facility at Jamul in Chhattisgarh, replacing its existing line at the plant. Currently the plant can produce 1.6Mt/yr of cement. The expansion will see this figure rise to 5Mt/yr by mid-2015. The existing line will be phased out as the new one is commissioned.
Along with the announcement, ACC also said that it is planning to set up decentralised grinding stations, which will use clinker produced at Jamul. These will be implemented in a phased manner and are scheduled for completion by March 2015.
At the same time, ACC will also increase its existing grinding capacity at its Sindri plant in Jharkhand. Another new grinding plant is currently being built at Kharagpur in West Bengal. Both installations will source clinker from the new Jamul plant.
The overall capacity of ACC will increase to 35Mt/yr when all these projects are completed, helping the company to meet the demand for cement in the east of India.
Safety First 07 March 2012
Lafarge UK has scored a notable success recently at its Cookstown Works reaching 10 years without a lost-time injury (LTI). It has emerged that this is the longest a Lafarge Group plant anywhere in the world has gone without a LTI. Cookstown also set the record the previous year in 2011, showing how far ahead it is of the rest of the group.
LTIs are generally defined as any work related injury or illness which prevents a worker from doing any work the day after the accident. Another similar measure is Lost Time Injury Frequency Rate (LTIFR), which takes into account hours worked by staff.
For example, in April 2011 Global Cement Magazine interviewed the safety manager at the Ste. Genevieve plant in Missouri, USA. He revealed a rate of zero lost-time incidents rate over the last 1.2 million-man hours and no LTIs over the last 700 days. Through construction the plant employed 2300 personnel and then 200 operational employees when it went live. By comparison Cookstown employs only 80 workers. Its LTIFR will be much lower.
The Mineral Products Association recorded a 81% reduction in LTIs between 2004 and 2009 for the UK cement industry. It has since set itself the further target to halve the LTIFR between 2009 and 2014. As of 2009 the UK LTIFR for direct employees was 3.59 per million hours worked. The MPAs target LTIFR for 2014 is 1.79 or lower.
Regardless of how you present the figures the Cookstown Plant LTI achievement is impressive. The challenge, as ever, lies in bettering it.
People in the cement industry 07 March 2012
TÇMB: Board members of the Turkish Cement Manufacturer's Association (TÇMB) were selected at its 54th General Assembly in Ankara on 28 February 2012. The board re-elected Mustafa Güçlü as the Chairman of Board of the TÇMB by acclamation.
An economics graduate from Ankara University, Güçlü has held positions in the Turkish Finance Ministry and Foreign Trade Inc, becoming the General Manager of General Directorate of State Monopolies in 1991. In May 2000, Güçlü started to work as the General Coordinator and the Chairman of Executive Committee in Çimentaş Group.
Hanson UK (HeidelbergCement): Chris Coton, Hanson UK's concrete technical services manager for the south west, died suddenly on 26 February 2012. Coton, aged 59, began his career at the Swansea plant of the now-defunct Pioneer, which was acquired by Hanson, part of the HeidelbergCement group, in 2000.
Coton became area technical manager for Hanson in 2000 and in 2004 he became technical services manager responsible for over 40 concrete plants. Hanson's national technical director Charlie Jones, said, "Chris was a great character and well respected throughout the industry. I will miss him greatly as I am sure many of his colleagues will. He was a good friend and an industry stalwart. Our condolences go to his wife Elaine."
'Soft landing' shouldn't damage Chinese cement demand 07 March 2012
China: On 5 March 2012 Premier Wen Jiabao lowered China's growth target for 2012 to 7.5% from 8%, signalling Beijing's determination to manage a 'soft landing' to moderate its runaway economic expansion. The slowdown will likely hit China's construction sector, which accounts for most of China's rampant cement consumption. China exported only 10.6Mt/yr of cement in 2011, just 1.1% of national output. The worries over China's plans are affecting certainty in all major materials markets.
Credit Suisse described China's more moderate growth target as 'acceptance of slower medium-term growth.' It also said that infrastructure spending was on a downward trend due to the completion of many large highway, railway and airport projects.
Despite this, Guo Wensan the chairman of China's largest cement producer Anhui Conch, has announced that demand for cement remains strong in China. He said that the government's drive to push the construction of subsidised affordable housing is successfully offsetting declining cement demand from the private housing market.
Guo said that cement demand from the 10 million affordable housing units started in 2011 will peak from the second quarter of 2012 onwards. "This year there will be another 7 million public housing starts, so we remain confident," he said. Guo added that the cement industry has benefited from consolidation since the start of 2011, which has seen the removal of older, inefficient kilns and the closure of some companies.
France: The board of directors of Ciments Français, part of the Italcementi Group, has examined and approved the audited annual and consolidated accounts as of 31 December 2011, which show a net consolidated profit of Euro274m, a 13.7% drop year-on-year.
Cement sales volumes for the entire year were down by 1.4% at 42.4Mt. Ciments Français Cement sales improved in France, North America, Morocco and India but decreased in Egypt due to the political crisis there. An overall fall in demand, strong inflation on fuel prices and negative translation effects resulted in deterioration in the company's operating results. These impacts were only partly mitigated by efficiency measures implemented throughout the year.
As of 31 December 2011, Group consolidated revenues were Euro3.89bn, down by 3.8% year-on-year. Its recurring earnings before interest, tax, depreciation and amortisation (EBITDA) amounted to Euro702m, down by over 20% year-on-year. Earnings before interest and tax dropped by 38% to Euro309m following recognition of Euro359m in depreciations and Euro53.4m in impairment losses, mainly in crisis-hit Spain and Greece.
Group investments in industrial and intangible assets amounted to Euro301m as of 31 December 2011, down by 25.6% compared to 31 December 2010. They mainly related to the strengthening of production in France, Belgium and Egypt and an increase of production capacity in India and Morocco.
A tight management of cash flows, the disposal of assets in Turkey and the sale of subsidiary Axim contributed to strengthen Ciments Français' net financial position. At the end of December 2011, its net financial debt was reduced by Euro390m to Euro1.02bn compared to Euro1.41bn as of 31 December 2010.
Regarding 2012 Ciments Français reported that the markets in which it operates should be more stable. Sales volumes are expected to stabilise at a level similar to that of 2011, increasing in North America and Morocco while declining in southern Europe. Egypt remains a source of uncertainty. Prices are likely to trend more positively and partially offset the rise in energy costs and the impact of inflation on fixed costs. Additionally, the efficiency programs launched in 2011 should increase operating results in 2012.
The group will initiate a new cycle of investments in 2012 related to its industrial facilities, mainly in Gulbarga, India and Bulgaria. In Morocco, the group expects a new expansion phase after the commissioning of the Ait Baha plant.