Displaying items by tag: Australia

Australia: Boral has posted a slump in its annual profit, which fell by a third year-on-year for the 12 months to 30 June 2022. It made a profit of US$73.7m, down from US$98m in the 12 months to 30 June 2021

The company said that the result had been impacted by rising energy and haulage costs, while severe rains in eastern Australia at the start of 2022 had forced temporary stoppages to numerous construction projects. The company withheld profit guidance in its announcement, saying only that it expected revenue to be higher in the 2023 fiscal year as a result of annual price increases and new freight charges for customers.

Australia: Adbri has reported that the ongoing upgrade at its Kwinana cement plant, previously estimated to cost US$137m, is now likely to cost closer to US$157m. It cited inflation and supply chain issues as the main reasons behind the 15% increase to the cost of the project, which seeks to combine its Western Australia operations at a single site, while raising its capacity by 36% to 1.5Mt/yr. The company said the upgrade was about 25% compete as at 30 June 2022, while procurement was about 75% committed. It is scheduled for commissioning in mid 2023.

Elsewhere, Adbri has also said that its definitive feasibility study for a Kalgoorlie lime kiln is on track for completion in the first half of 2023. The study includes mine planning and front-end engineering design.

Australia: James Hardie has informed investors that it has frozen all non-critical hiring. The Australian newspaper has reported that the move is designed to counteract the impacts of a rise in costs. The company also plans to announce a new round of price rises on its products.

Australia: James Hardie recorded sales of US$1bn in the first quarter of its 2023 financial year, up by 19% year-on-year from US$843m in the first quarter of its 2022 financial year. Its net profit was US$163m, up by 34% from US$121m. The group increased its North America fibre cement board sales by 28% to US$740m, its Asia Pacific fibre cement board sales by 9% to US$140m and its Europe building products sales by 7% to US$112. James Hardie launched its new European subsidiary James Hardie Fiber Cement Europe during the quarter.

James Hardie lowered its full-year adjusted net profit forecast to US$730 – 780m from US$740 – 820m. Interim chief executive officer Harold Wiens said "The current calendar year has seen the macro-economic environment change around us quite significantly, with unprecedented levels of inflation, global supply chain disruptions and a war in Europe. The current macro-economic environment is not only creating uncertainty for the housing markets in all three regions we do business in, but it is also putting pressure on our fiscal year 2023 financial results due to increased input and freight costs. That said, we are confident we will be able to deliver growth above market and strong returns in fiscal year 2023, and that is reflected in our updated guidance we provided today, which at its midpoint represents 22% growth in adjusted net income versus the prior year."

Australia: Boral announced the expiration of its tender offer for up to US$300m-worth of guaranteed senior notes on 21 July 2022. The producer recorded a total principal amount tendered of US$425.7m. The 3.75% notes are due in 2028.

A trio of slag cement stories have been in the sector news this week with reports from Australia, France and Sri Lanka. Of note from the first two reports is a focus on supplies of slag.

The first concerns Hallett Group’s US$80m supplementary cementitious materials (SCM) project in South Australia. This will see the company process slag and fly ash sourced from sites in the region to manufacture blended cement products and standalone SCMs. These will be principally milled, blended and distributed from a site at Port Augusta. However, an additional distribution site at Port Adelaide is also planned that can both import and export the company’s products in a bid to cut down on supply chain risk, particular for its mining customers. The company says it will replace up to 1.15Mt/yr of cement when fully operational, although initial production looks set to be about a third of this based on local media reports. Commissioning of the Port Adelaide distribution hub is scheduled for May 2023, following by the Whyalla Granulator in January 2024 and the Port Augusta processing plant in June 2024. Pointedly, Hallett Group is explicit about where is plans to source its SCMs from: Nyrstar Port Pirie and, potentially, Liberty GFG.

The second slag-themed story hails from France, where Hoffmann Green Cement has acquired ABC Broyage, which operates a slag grinding plant in North Dordogne. Like the project in Australia above, Hoffmann Green is focused on its supply chain. With this acquisition it will be able to grind its own blast furnace slag instead of buying it. Raw blast furnace slag will be imported via the port of La Rochelle where the company has storage silos. It will then be ground at the former ABC Broyage site and sent on to Hoffmann Green’s H1 and H2 production sites, located at Bournezeau in the Vendée region. Finally it will use it to manufacture its H-UKR and H-IONA cement products. There is no mention of how much the acquisition is costing Hoffman Green. Instead the emphasis, according to company founders Julien Blanchard and David Hoffmann, is very much to, “strengthen our control over our supply and secure our margins in the current highly inflationary context.”

Finally, the week’s third slag-themed cement story is from Sri Lanka, where local media reports that Insee Cement has started producing Portland Composite Cement, using SCMs such as slag, at its Ruhunu grinding plant. This story follows the trend of cement producers around the world switching to greater usage of blended cements, often for sustainability reasons. Unfortunately, political events in Sri Lanka are overshadowing everything else locally, with the president having fled amid social unrest provoked by the ongoing and severe economic crisis. To this end Insee Cement has astutely also donated medical supplies this week to the intensive care unit at the Colombo National Hospital.

These slag stories are important for the cement sector can be demonstrated by a recent update to the Center for International Climate and Environmental Research - Oslo’s (CICERO) research on global CO₂ emissions from cement production. When it published its estimate for 2021 it found that overall emissions were 2.6Bnt in 2021 or just over 7% of the world’s total CO₂ output. What is worse though, is that its data suggests that cement-based emissions have steadily grown year-on-year from 1.2Bnt in 2002. Apart from a dip in 2015 they have kept on rising! This can mostly be attributed to the growth of the Chinese cement industry in the early 2000s suggesting that a tipping point may be reached in the current decade as lowering cement production CO₂ intensity finally kicks in.

Slag and other SCM-based blended cements fit in here as they are one of the ‘easiest’ ways to reduce the clinker factor of cement and concrete and thereby reduce the sector’s CO₂ levels. Hence they keep popping up on the various roadmaps and reports for the cement industry to reach net zero. The flipside of this however is that slag is becoming harder to source as the demand for granulated blast furnace slag increases and less new steel plants get built, especially in North America and Europe. Hence the focus on the supply of slag in the first two news stories above. Blended cements may be the future but getting there will be far from simple.

Australia: Hallett Group plans to establish a slag cement grinding plant in Port Augusta, South Australia. Magnet News has reported the cost of the project as US$83.9m, towards which the producer has received US$13.4m in government funding. The plant will produce cement using South Australian ground granulated blast furnace slag (GGBFS) from Nyrstar’s Port Pirie and Liberty Primary Steel’s Whyalla steel refineries and fly ash from the site of the former Port Augusta power plant. Its operations will be 100% renewably powered. An accompanying new distribution facility at Port Adelaide will ship the cement to markets. The project will create 50 new jobs.

When the Port Augusta grinding plant becomes operational in 2023, its products will reduce regional CO₂ emissions by 300,000t/yr, subsequently rising to 1Mt/yr, according to the company’s expansion plans.

Hallett Group chief executive officer Kane Salisbury said "We're talking about 1% of the entire country's 2030 [CO₂ reduction] commitment, delivered through this project." Salisbury added "We're looking at turning South Australia into a global leader in manufacturing green cement."

Australia: Boral Finance has announced the early results of a tender offer to purchase cash up to US$300m. The principal amount tendered is US$405m. The tender offer will expire on 20 July 2022.

India: UltraTech Cement has imported a 157,000t shipment of coal from Russia for US$25.8m, which it paid in Chinese Yuan. ET NOW News has reported that this is the first instance of an Indian entity using the currency in international trade. The deal has a value of US$164/t, 50% below average South African coal prices and 20% below average Australian cement prices in India. The deal reportedly signals the possible end of Indian coal prince inflation in the medium – long term.

Boral admitted this week that high energy costs in Australia had forced it to reduce production levels. Chief executive officer Zlatko Todorcevski revealed to Reuters that the company was temporarily cutting back some unspecified areas of its operations. He also said that it was going to have to pass on growing energy prices directly on its customers.

This has followed mounting alarm at fuel prices in successive financial reports by the building materials company leading to revised earnings guidance being issued in May 2022. Bad weather was responsible for the larger share of the expected additional adverse impact to underlying earnings in its 2022 financial year but around US$10m was anticipated from rising fuel prices. Growing coal and electricity prices were said to be impacting its production and logistics costs, with price rises in January and February 2022 having proved insufficient to keep up with inflation. In a trading update in March 2022 the company said that its exposure to coal prices was unhedged for the second half of its 2022 financial year, to June 2022.

An energy crisis in Australia may seem hard to understand given that the country is one of the world’s biggest exporters of coal and gas. Yet, the country has faced a number of problems with its electricity generation sector in 2022 with disruptions to coal supplies to power stations, outages, ongoing maintenance and a cold winter that adversely affected the market. This led the Australian Energy Market Operator to suspend the country’s main wholesale market on 15 June 2022 in an attempt to stabilise the supply of electricity. New South Wales has also reportedly forced coal mines to prioritise the local market over exports. Energy minister Chris Bowen even asked the residents of New South Wales to try and reduce electricity use in the evenings in an attempt to prevent blackouts. However, with the consumer electricity market now looking more stable, attention has turned to industrial users such as Boral.

Global Cement Weekly has covered energy costs for cement producers a couple of times in the last year. There has been plenty of angst about growing energy costs on cement company balance sheets since mid-2021 as the logistics problems following the lifting of the coronavirus-lockdowns became clear. The biggest story at this time was an energy crisis in China that caused supplies to be rationed to industrial users. This then intensified with the start of the war in Ukraine in February 2022 and energy prices went up everywhere as economic sanctions were imposed upon Russia. One standout was Turkey where cement producers publicly raised the alarm about jumps in coal prices.

Recently, some North American lime producers such as Lhoist North America and the Mississippi Lime Company have been notably bold in announcing price rises due to energy costs and other factors. This week, for example, Lhoist North America said it had raised the price of its lime products by up to 45%. It cited the ‘challenging circumstance’ for all parties at an ‘unprecedented’ time. One alternative to the direct approach of simply putting up prices has been the use of energy surcharges. Japan-based Taiheiyo Cement announced earlier in June 2022 that it was going to introduce a coal surcharge for its cementitious products in September 2022 due to rising energy prices. Its system is based on the coal price with revisions planned every two months. The scheme will run for one year in the first instance. How customers will react to this remains to be seen.

We have looked above at a few disparate examples of the problems that energy costs have been causing cement and lime producers over the last month. These issues look set to continue in an acute phase while the war in Ukraine rages on, but the longer term trends from the economic recovery from coronavirus will undoubtedly last for longer. As examples in Australia and China have shown, local energy crises can easily spill over into the industrial sector as domestic users are prioritised. So, even if cement companies source their supplies carefully, they may face issues if the wider market struggles. Meanwhile, cement producers face the dilemma of justifying price rises to customers adapting to mounting inflation. Taiheiyo Cement has shown one way of doing this. The problems caused by surging energy prices to other cement companies look set to become more apparent in the next few months as reporting of the first half of the year emerges.