September 2024
Adani Cement to close two plants in Himachal Pradesh 16 December 2022
India: Adani Cement has published its plans for the closure of two integrated cement plants in Himachal Pradesh. The Hindustan Times newspaper has reported the plants as ACC's 4.4Mt/yr Gagal cement plant in Bilaspur District and Ambuja Cements' 1.6Mt/yr Darlaghat cement plant in Solan District. The management of the Gagal cement plant said that losses ensuing from high operating costs, including transport costs, are the reason behind the decision to shut down that plant. ACC employs 1000 company staff and contractors at the site, and an additional 4000 truck drivers in its cement despatch operations. 3500 truck drivers also work in delivering cement from the Darlaghat cement plant. The Gagal cement plant alone reportedly despatches 5000t/day of cement for the Himachal Pradesh, Haryana and Punjab markets.
The Bilaspur District Truck Operators' Society said "The transport sector of Bilaspur is heavily dependent upon the Gagal cement plant. It's the source of livelihood for thousands of people, including operators, drivers and conductors. This decision should be reconsidered in the interest of the people." It added "Most roadside restaurants and mechanics' shops will also lose business. We never thought that this plant could ever stop functioning. It has been part of our landscape and economy for decades now."
Cemex Ventures enlarges investment in Synhelion 16 December 2022
Switzerland: Cemex's innovation investments subsidiary Cemex Ventures has made a further investment in solar-powered clinker production system developer Synhelion. Synhelion's technology enables cement plants to entirely replace fuels in their cement production with concentrated solar heat. Cemex Ventures said that its investment reflects the importance of sustainable fuel alternatives for Cemex's 2050 net zero CO2 emissions strategy.
Other investors include oil company Eni, engineering company SMS Group and airline Swiss.
India: The government of West Bengal plans to commence mining activity at the Deocha Pachami cement block in Birbhum District. The state hopes that the block will support further development of industries, including cement. Financial Express Online News has reported that Mangalam Cement, Purbanchal Cement and Shree Cement all plan to build new cement facilities in West Bengal. Shree Cement will invest US$102m in its planned Purulia grinding plant. Mangalam Cement's potential upcoming grinding plant will serve its planned new integrated cement plant in Chhattisgarh.
Israel: Cemex subsidiary ReadyMix Industries has placed a new order with transport safety technology supplier SaverOne 2014. The ready-mix concrete producer ordered a further 25 mobile phone control units for its truck fleet. The units are cloud-enabled and run off a mobile app which blocks drivers from using phones when their vehicle is in motion. The smart system can detect when a truck is stopped and differentiate between driver and passenger, enabling access when needed. Users can integrate their fleet's units with existing logistics management systems.
ReadyMix Industries completed a successful trial of SaverOne 2014's system earlier in 2022.
Hanson appoints MHI Engineering for Padeswood cement plant carbon capture installation 15 December 2022
UK: Heidelberg Materials subsidiary Hanson has awarded a contract to Mitsubishi Heavy Industries subsidiary MHI Engineering for installation of a planned 800,000t/yr carbon capture system at its Padeswood cement plant in Flintshire. The producer plans to store its captured CO2 in exhausted Irish Sea natural gas fields. MHI Engineering will carry out a pre-front-end engineering design study using its Advanced KM CDR solvent-based process. The supplier developed the process jointly with fellow Japan-based company Kansai Electric Power.
The project will be MHI Engineering's third of its kind at a cement plant, following similar commissions with Lehigh Cement in Canada and Tokuyama Cement in Canada.
EU concludes CBAM provisional deal 15 December 2022
Europe: The European Parliament (EP) of member states and the Council of the EU have concluded a provisional deal over plans for an EU carbon border adjustment mechanism (CBAM). Under the plans, importers of a range of emissions-intensive goods, including cement, will have to pay to obtain CBAM certificates for products entering the EU. Goods produced in countries with the same CO2 emissions reduction measures as the EU will be exempt from requiring a certificate. CNBC News has reported that the mechanism will enter force with a transition period beginning in October 2023. This is subject to ratification by the EP and member states independently.
EP member for the Netherlands Mohammed Chahim said “CBAM will be a crucial pillar of European climate policies. It is one of the only mechanisms we have to incentivise our trading partners to decarbonise their manufacturing industry.”
Vietnam National Cement Association lobbies against power price rise 15 December 2022
Vietnam: The Vietnam National Cement Association (VNCA) has spoken about the difficulties that would arise from a proposed power price rise by state-owned Electricity Vietnam (EVN). VNCA chair Nguyen Quang Cung said that cement producers foresee 'business havoc' ensuing from any further cost increase to their operations. The industry says that reduced demand has prevented them from raising cement prices amid already high costs. Coal price growth is a significant contributor, and now accounts for 60% of the industry's operating expenses.
Cung said "Many companies are suffering losses and have suspended the operations of many production lines." He continued "We understand that EVN is claiming force majeure because they face the same challenge relating to the input cost burden."
Sheerness grinding plant secures planning permission 15 December 2022
UK: The planning applications committee of Kent County Council has approved Hercules Enterprises' Euro46.5m plan for a new 500,000t/yr grinding plant at Sheerness Docks on the Isle of Sheppey. The Sheerness Times Guardian newspaper has reported that the council assented subject to the producer's adherence to its particulate and dust management plan and continual noise monitoring. When commissioned, the new plant will create 52 new jobs, generate up to 144 truck movements per day and increase traffic on the A249 by 1%.
Hercules Enterprises' director Stuart Mason Elliot said that the new facility will help to move cement production away from its reliance on road transport. He said “This is not an open, dated, dusty old operation, but a fully-enclosed, clean, modern, environmentally responsible and sustainable plant designed to be a good neighbour to residents and other occupants of the port.”
Platinum Equity acquires HarbisonWalker International 15 December 2022
US: Investment firm Platinum Equity has concluded a deal to acquire refractories producer HarbisonWalker International (HWI).
HWI chair CEO Carol Jackson said “This is excellent news for our employees, customers, and communities. Platinum Equity supports our intent to continue driving HWI forward into an unprecedented new era of growth. Over the past several years in North America and throughout our global operations, we’ve built operational excellence, differentiated ourselves through our supply reliability, and delivered the deepest and widest offerings of refractory products and expertise. Our new owner is wholly aligned with our leadership team’s vision to aggressively accelerate investments in our business. We are poised to capitalise on the momentum that our team of employees has built together."
Dalmia Bharat goes central 14 December 2022
Further consolidation of the Indian cement sector looked closer this week with the news that Dalmia Bharat’s cement subsidiary has agreed to buy the remaining cement plants from Jaiprakash Associates. The US$685m deal covers cement and power plants in Madhya Pradesh, Uttar Pradesh and Chhattisgarh. It includes clinker production capacity of 6.7Mt/yr, cement capacity of 9.4Mt/yr and 280MW of captive power capacity.
Chart 1: Map of Dalmia Bharat’s cement plants in November 2022 with region of proposed new plants highlighted in orange. Source: Adapted from Dalmia Bharat investor presentation.
The acquisition gives Dalmia Bharat the opportunity to draw level with Shree Cement in terms of cement production capacity. If the deal completes, then both cement companies will hold a capacity of around 46Mt/yr. This puts them behind UltraTech Cement and Adani Group nationally. In terms of the cost, the proposed acquisition works out at around US$73/t of cement capacity, although this doesn’t take into account the additional captive power generation capacity. This compares to US$119/t for UltraTech Cement’s purchase of Jaiprakash Associates plants in 2017 and US$97/t for Adani Group’s purchase of Holcim’s Indian-based business in September 2022.
Dalmia Bharat’s rationale for its move this week was that it wants to grow in the Central Region of the country and work towards a capacity target of 75Mt/yr by the 2027 financial year and at least 110Mt/yr by the 2031 one. It backed this up in an investors’ presentation by saying that cement consumption was around 170kg/capita locally and that the region represented about 15% of national demand at 54Mt/yr. This roughly checks out with regional integrated/clinker production capacity distribution analysis that Global Cement Weekly carried out in June 2022. Only the East region was lower, but this didn’t take into account grinding plants or new projects.
Completion of the agreement is planned by December 2023 and is subject to the usual regulatory approvals. However, readers may recall the difficulties UltraTech Cement had in the mid-2010s when it attempted to buy two plants from the subsidiary of Jaypee Group. Problems stemming from an amendment to the Mines and Minerals (Development and Regulation) (MMDR) Act caused the original proposal to be rejected by the Bombay High Court in early 2016. UltraTech Cement bounced back though with a deal to buy far more plants instead. This deal completed successfully in mid-2017.
Jaypee Group’s debts have also caused problems along the way. Indeed, this is the reason why it has finally decided to leave the cement business altogether. In early December 2022 it reported its latest default on interest payments towards some of its loans. Overall its outstanding debt was US$3.39bn. Due in part to this, there have been plenty of stories in the local press over the last decade on whoever was reputedly buying the Jaypee Group’s cements assets. In October 2022, for example, Adani Group was reportedly in advanced talks to buy Jaypee Group’s remaining cement business until it denied it publicly. One deal that did reach fruition was Dalmia Bharat’s purchase of Bokaro Jaypee Cement back in 2014 from a joint-venture majority controlled by Jaypee Group. That agreement gave it full control of the 2.1Mt/yr Bokaro grinding plant in Jharkhand. Looking at the current proposed acquisition, one commentator from HDFC Securities in the local business press noted that detail on the transaction is lacking, such as what will happen to existing limestone reserves. Another pointed out that the deal was probably 30 – 40% below the replacement cost because the plants were old, lack of interest from potential buyers and due to the “likely need for additional CAPEX to run operations.”
If the Dalmia Bharat - Jaiprakash Associates deal completes then it marks the end of an era for the Indian cement industry as one of the big players bows out of the sector. It shows once more that, despite the mounting fuel and raw material costs in 2022, companies are still seeing big opportunities. In its December 2022 report, the ratings agency ICRA found that cement sales volumes grew by 11% year-on-year to 187Mt in the first half of the 2023 financial year. The acquisition might also, hopefully, put an end to the endless speculation about who Jaypee Group might be selling its cement plants to! Although, of course, the question then becomes who else might be considering divesting cement assets.