September 2024
Spain: Heidelberg Materials’ subsidiaries HeidelbergCement Hispania, Cementos Rezola and Hanson have rebranded as Heidelberg Materials. HeidelbergCement Hispania used the Hanson brand for the production and sale of concrete and aggregates. Cementos Rezola (also known as FYM) was used for the manufacture and sale of cement. The marketing exercise follows the change in name of parent company Germany-based Heildelberg Cement to Heidelberg Materials in September 2022.
Heidelberg Materials in Spain operates two integrated cement plants, six quarries and four ready-mixed concrete plants.
Beumer Group opens new head office in the UK 28 April 2023
UK: Germany-based Beumer Group has opened a new local head office at Ashby de la Zouch in Leicestershire. The previous head office in the country, near London, will continue to operate as a satellite office.
David McGarry, the chief executive officer of Beumer Group UK, said “The opening of the new UK head office reinforces our strong partnership and commitment to our customers in the UK and Ireland, this will enable us to provide an even more seamless service to support them in their continued growth investing in local expertise in the long term.”
Beumer Group sells products for conveying, loading, palletising, packaging, sortation and baggage handling.
Dalmia Bharat executes definitive agreements with Jaiprakash Associates to buy cement assets 27 April 2023
India: Dalmia Bharat says its has executed definitive agreements with Jaiprakash Associates to buy cement, clinker and power plants. The latest part of the acquisition process has cleared Dalmia Bharat to buy the JP Super Cement plant in Uttar Pradesh for US$183m, subject to various clearances and approvals. In addition, Dalmia Bharat has also agreed to buy a 74% share of Bhilai Jaypee Cement for an enterprise value of US$81m and is in the process of signing a seven-year lease agreement with Jaiprakash Power Ventures for its 2Mt/yr Nigrie Cement grinding plant in Madhya Pradesh. Dalmia Bharat will have the option to purchase the Nigrie unit anytime within the lease period for an enterprise value of around US$30m.
Dalmia Bharat agreed to buy selected assets from Jaiprakash Associates for US$684m in December 2022. Cement and grinding plants under the deal are situated in Chhattisgarh, Madhya Pradesh and Uttar Pradesh. The Competition Commission of India (CCI) approved the deal in February 2023.
Dalmia Bharat says commodity inflation peak ending as earnings fall in 2023 financial year 27 April 2023
India: Mahendra Singhi, the head of Dalmia Cement (Bharat), says that the company has past the peak of commodity price inflation. Its income from operations grew by 10% year-on-year to US$1.66bn in the 2023 financial year from US$1.38bn in the 2022 financial year. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 5% to US$283m from US$297m. Its sales volumes of cement increased by 16% to 26Mt from 22Mt.
Mahendra Singhi, the managing director and chief executive officer of Dalmia Cement (Bharat), said “Our persistent efforts, on enhancing sustainability of our operations and rationalisation of our operating costs, have enabled us to mitigate the adverse impact of inflation and deliver stable earnings performance.” He added “With robust demand outlook, steady cement prices and the peak of commodity price inflation behind us, we are expecting profitability to gradually improve from here on.”
Sustainability targets that the group promoted in its fourth quarter results statement included reaching a carbon footprint of 463kgCO2/t of cement. Its renewable energy capacity increased to 166MW in the 2023 financial year from 100MW.
AdBri’s Kwinana grinding plant cost continues to grow 27 April 2023
Australia: Adbri says that the cost of an upgrade at its Kwinana grinding plant is now estimated to be US$255 – 277m following an engineering design, schedule and budget review. The original estimate for the project in December 2020 was US$130m. The cement producer has blamed the increase in cost on mounting construction costs, a labour shortage and supply chain issues. Commissioning for the upgrade remains scheduled for the second quarter of 2024 with full operation forecast for the third quarter.
Adbri’s chief executive officer Mark Irwin said, “While we are disappointed the project cost is materially higher than initially forecasted, we remain confident the Kwinana Upgrade will support solid returns over the long term. The project continues to have a positive net present value. We have used this review period to also strengthen our project delivery team, adding experience and capability.” He added “The consolidation of Adbri’s two existing cement production sites in Western Australia into a single, world class facility at Kwinana positions Adbri to take advantage of continued growth in the local market. We also expect to deliver greater operational savings than originally forecasted.”
Votorantim Cimentos opens new terminal in Fortaleza 27 April 2023
Brazil: Votorantim Cimentos has opened a new terminal in Fortaleza. The 19,000m2 unit replaces a previous site in the city in Ceará state. The new terminal location is close to a railway line operated by Ferrovia Transnordestina Logística (FTL) to support logistics. It will supply the northeastern market with cement from the Poty brand and adhesive and mortars from the Votomassa product line. Sustainability features of the new terminal include a recycling system for the water used to wash forklift trucks.
Votorantim Cimentos operates two integrated cement plant in Ceará, at Sobral and Pecém respectively, as well as three terminals.
Ethiopia: Berenta Cement has signed a strategic cooperation framework agreement with China-based Sinoma Cement to build a cement plant at Shebele Berenta in Amhara region. The two companies will form a joint venture to work on the unit, according to the Ethiopian News Agency. The regional government will support the initiative. The wider scope of the project also includes plans to supply products and services such as gypsum, gypsum wallboard, glass and glass fibre.
Syria: Abdul Qader Jokhadar, the Minister of Industry, has cited using Iran-based expertise in developing filtration system in cement plants to reduce emissions as an example of how the two countries can cooperate. Jokhadar met with Morteza Shahmirzaei, the director of the General Company for Petrochemical Industries and deputy to the Oil Minister of Iran, to discuss industrial development, according to the Syrian Arab News Agency. Other areas of collaboration include manufacturing electric batteries, agricultural machinery, tyres and optical cables.
UK: Aggregate Industries has launched the ECOPlanet product range. The products offer a reduction of at least 30% in the carbon footprint of cement, compared to CEM I ordinary Portland cement, by using second cementitious materials such as fly ash. The launch of the ECOPlanet range is part of the subsidiary of Holcim’s 2030 sustainability strategy, Building Progress for a Sustainable Future.
Dragan Maksimovic, the chief executive officer of Aggregate Industries, said “The launch of ECOPlanet expands on our existing low carbon products including ECOPact, the world’s broadest range of green concrete or Super-Low Carbon, the first asphalt using biogenic material within the bitumen. The product is driven by innovation and by our ambitions to build a net zero future, and we’re delighted once again to be pushing the boundaries of low carbon construction solutions.”
Update on fly ash in the US, April 2023 26 April 2023
Heidelberg Materials announced a US acquisition at the same time as the ongoing IEEE/IAS-PCA Cement Conference in Dallas, Texas this week. It has entered into a purchase agreement to acquire The SEFA Group, a fly ash recycling company based in Lexington, South Carolina. Its operations include five beneficiation plants, five utility partners, 20 locations and over 500 employees. It supplies fly ash to over 800 ready-mixed concrete plants in 13 states. It processes around 1Mt/yr of ash from storage ponds using its proprietary thermal beneficiation process. No value for the acquisition was disclosed.
The proposition for a heavy building materials manufacturer of securing a supply of fly ash is an attractive one. Fly ash can improve the performance of concrete, reduce its cost by lowering the amount of ordinary Portland cement (OPC) required and decrease the associated carbon footprint. It can also be use to make blended cement products. Heidelberg Materials and its US-subsidiary Lehigh Hanson could have various options here including using this new supply of fly ash internally, selling it on to other companies or licensing the beneficiation technology. Heidelberg Materials’ global sustainability report in 2021 reported that just under 9% of its cement-type portfolio comprised pozzolana or fly ash cements.
Graph 1: Coal combustion product production and use, 1991 – 2021. Source: ACAA.
Data from the American Coal Ash Association (ACAA) shows in Graph 1 that coal combustion products (CCP) production have declined in the last decade as the proportion used has steadily risen. In its annual production and use survey, the ACAA revealed that the use of harvested ash continued to grow in 2021 and that it constituted around 10% of the volume of ash recycled from current power plant operation. Thomas H Adams, the executive director of the ACAA, said “The rapidly increasing utilisation of harvested CCP shows that beneficial use markets are adapting to the decline in coal-fuelled electricity generation in the US. New logistics and technology strategies are being deployed to ensure these valuable resources remain available for safe and productive use.” Separately, the ACAA reported that coal-fuelled power stations represented about 50% of the country’s electricity demand in the mid-2010s compared to 20 – 25% in 2021 despite base-load remaining the same. It forecast that fly ash production was likely to remain fairly constant to around 2040 but that harvesting would help to cut the gap between supply and demand in some regional markets. It said that over 2Bnt of coal ash was in disposal. However, no indication of how recoverable this was given although it did note the higher cost of beneficiation. Work on updating specifications was ongoing to suit current circumstances.
As with the slag market, this presents a dilemma for cement and concrete producers that want to become more sustainable. They want to use more by-products from other carbon-intensive heavy industries – such as coal-fired power stations and steel plants – but these industries themselves are also trying to become more sustainable and are producing less secondary cementitious materials. Heidelberg Materials’ interest in a fly ash beneficiation company makes sense because it secures a bigger portion of a dwindling resource from the direct operations and opens up the possibility of selling the beneficiation technology to others. It is also worth mentioning that other fly ash thermal beneficiation processes are available. For example, Charah Solutions installed its MP618 technology at its Sulphur terminal in Louisiana in early 2019.
The general fly ash market in the US looks set to track the level of coal-fired power generation for the foreseeable future. Yet the proportion of CCPs being used continues to rise. In this context focusing on harvesting may be starting to make more financial sense. Charah Solutions’s new unit in 2019 and SEFA Group’s new units in 2020 and 2021 seem to support this view. Heidelberg Materials’ acquisition of SEFA Group may be further confirmation of this.