Displaying items by tag: Cementir Holding

Italy: Cementir Holding recorded 'record' revenues of Euro1.72bn in 2022, up by 27% year-on-year from 2021 levels. Its earnings before interest, taxation, depreciation, amortisation (EBITDA) rose by 7.8% to Euro335m, also a record figure, according to the group. Throughout 2022, Cementir Holding sold 10.8Mt of cement and clinker, down by 2.8% from 11.2Mt. It attributed this to a 'general slowdown of the market,' mainly in Türkiye, Denmark, China and Belgium, especially during the second half of the year.

Chair and CEO Francesco Caltagirone noted the 'solidity and resilience' of Cementir's business model, even in spite of 'geopolitical uncertainty and more restrictive monetary conditions.' He said "We have already achieved significant results in terms of decarbonisation, innovation and transparency, evidenced by the improvement of all environmental, social and governance (ESG) ratings and we want to continue on this virtuous path, in the interest of all stakeholders."

Congratulations to Lafarge France for launching the first calcined clay cement unit in Europe. The subsidiary of Holcim says that the unit, based at the integrated Saint-Pierre-la-Cour cement plant, is the first of its kind on the continent. It is using the company’s proprietary proximA Tech technology and will produce up to 500,000t/yr of cement in its ECOPlanet range. The operation is also powered with biomass alternative fuels and uses a waste recovery system to further drive down overall CO₂ emissions. Once production ramps-up the producer expects that 30% of cement from the Saint-Pierre-la-Cour plant will be from the ECOPlanet range by 2024.

The investment at Saint-Pierre-la-Cour was Euro40m. Holcim is also producing calcined clay cement at its La Malle plant in France. It received an investment of Euro6m in 2022 to produce low-carbon cements. Together, both plants are aiming to produce over 2Mt/yr of calcined clay cement by 2024. As is usual for these kinds of projects, the French government partly funded the clay calcination unit at Saint-Pierre-la-Cour as part of the ‘France Relance’ scheme investing in large-scale decarbonisation and energy efficiency initiatives.

Calcined clay cements in Europe aren’t exactly new, but Holcim’s new unit in France does appear to be the first full-scale line located at a cement plant. Research by OneStone Consulting, for example, reckons that the first flash activated clay unit expressly set up to supply the cement sector was commissioned in 1995 in Toulouse, France. More recently, Hoffmann Green Cement inaugurated its 50,000t/yr pilot plant at Bournezeau in France in 2018. This site produces cements made from flash calcined clay and blast furnace slag, although it is unclear how demand for the different products varies. A new 0.25Mt/yr plant in the Vendée department was scheduled for commissioning in the second half of 2022. Another 0.25Mt/yr plant in Dunkirk is expected to be commissioned in the second half of 2024.

Cementir Group launched its calcined clay cement product FUTURECEM in Denmark in 2021 with production via a pilot plant. It then extended this to the Benelux and French cement markets in 2022. As part of its industrial plan for 2021 - 2023 it was planning to build a clay calcination unit to support the growth of FutureCem. FLSmidth revealed in June 2021 that it had won a contract to build a 400t/day clay calcination unit for Vicat’s Xeuilley integrated cement plant. The deal was worth around Euro27m and commissioning is scheduled for 2023.

Firstly, it is interesting to see a focus on France for some of the projects above. The presence of Lafarge’s technical centre in Lyon may explain the interest for that company. However, Hoffmann Green Cement and Vicat are also active in the field. It is worth noting that France also holds a busy secondary cementitious material market with standalone operators including Ecocem, Cem’In’Eu and Hoffmann Green Cement. Secondly, despite the early start, clay calcination for cement is currently more active outside of Europe. In Africa, for example, there is at least one live full production line and a number of other projects on the way. Various other pilots and projects are also happening elsewhere around the world, often in conjunction with the limestone calcined clay cement (LC3) initiative. Where calcined clay cement production in Europe goes from here is uncertain at present as it is one solution among many for lower carbon cement products in the future. Yet, the projects that have made it so far to the commercial scale will be watched closely by the companies that have invested in them - and their competitors.

Italy: Cementir Holding has appointed Roberto Marazza as its Group Chief Financial Officer with effect from 15 March 2023.

Marazza, graduated in business administration and accounting from Genoa University, started his career in IBM as accounting manager and then covered roles of increasing responsibility, including the position of CFO in fuel and energy and renewable energy companies such as Total ERG and Italiana Petroli (API Group).

Italy: Cementir Holding sold 8.2Mt of cement and clinker during the first nine months of 2022, down by 1.7% year-on-year from nine-month 2021 levels. China, Denmark, Egypt and Türkiye all contributed to the decline. Group nine-month revenues were Euro1.26bn, up by 25% year-on-year. Third-quarter 2022 revenues rose most sharply, by 45%, in Türkiye, followed by the US (38%), the Nordic and Baltic region (20%) and Belgium (17%). During the third quarter of the year, operating costs increased by 36% to Euro365m from Euro268m. Raw materials, fuels and transport costs all contributed to the rise.

In the first nine months of 2022, the group recorded earnings before interest, taxation, depreciation and amortisation (EBITDA) of Euro238m, up by 11% from Euro215m during the first nine months of 2021.

Italy: Cementir Holding’s sales rose by 22% year-on-year to Euro811m in the first half of 2022 from Euro665m in the first half of 2021. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 7.7% to Euro144m from Euro134m. Its net profit grew by 39% to Euro66.6m from Euro47.9m. During the half year the group sold 5.41Mt of cement and clinker, down by 0.8% from 5.46Mt. The group attributed this to local sales declines in China, Denmark and Turkey.

Chair and chief executive officer Francesco Caltagirone said, “The first-half 2022 results are aligned with our forecasts. Despite the severe geopolitical tensions and the significant increase in raw materials, energy and logistic costs, the group is showing great resilience thanks to an increased geographical and product diversification and a focused cost management.”

Italy: Cementir’s revenue rose by 21% year-on-year to Euro362m in the first quarter of 2022 from Euro301m in the same period in 2021. It attributed this to higher prices linked to the increase in the costs of fuels, electricity, raw materials, transport and services. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 26% to Euro60.7m from Euro48.1m. Grey, white and clinker sales volumes increased by 1.8% to 2.4Mt and ready-mixed concrete sales volume remained stable at 1.13Mm³. Cement sales volumes grew in Belgium, Denmark and the US but fell in Turkey. Concrete sales volumes grew in Belgium and Norway but fell in Turkey, Sweden and Denmark.

From the Nordics to the Mediterranean, European countries lead the field in reduced-clinker cement production using supplementary cementitious materials (SCMs). While consumers, faced with ever-greater choice, continue to opt for sustainability, projects to improve existing SCMs and develop new ones have won government backing and have become a matter of serious investment for other heavy industries beside cement. European cement producers’ decisions are steering the course to a world beyond CEM I. Yet, even in Europe, great untapped potential remains.

Companies generated a good deal of marketing buzz around their latest reduced-CO₂ cement ranges in 2021 and the first quarter of 2022: Buzzi Unicem’s CGreen in Germany and Italy, Holcim’s EcoPlanet in six markets from Romania to Spain, Cementir Holding’s Futurecem in Denmark and Benelux, and Cemex’s Vertua in Spain and several other countries. All boast reduced clinker factors through the use of alternative raw materials. This, however, is really a rebranding of a long-established norm in Europe.

Since 2010, cements other than CEM I have constituted over 75% of average annual cement deliveries across Cembureau member countries (all cement-producing EU member states, plus Norway, Serbia, Switzerland, Turkey, the UK and Ukraine). This statistic breaks down differently from country to country. CEM II is the norm in Austria, Finland, Portugal and Switzerland, with deliveries in the region of 90%. Portland limestone cement (PLC) makes up a majority of deliveries in all four. It has been central to Switzerland’s transition to 89% (3.72Mt) of CEM II deliveries out of a total 4.18Mt of cement despatched in 2021. There, the main types of cement were CEM II/B-M (T-LL) Portland composite cement, with 1.38Mt (33%), and two different classifications of PLC: CEM II/A-LL PLC, with 1.28Mt (31%), and CEM II/B-LL PLC, with 888,000t (21%).

A second approach is that of the Netherlands, where CEM III blast furnace slag cement with a clinker factor below 65% predominates, favoured for its sulphate resistance and the protection it offers against chloride-initiated corrosion of steel reinforcement in marine settings. By contrast, the UK has traditionally maintained a higher reliance on CEM I cement. This can be partly explained by the preference of builders there for adding fly ash or ground granulated blast furnace slag (GGBFS) at the mixing stage. Nonetheless, CEM II Portland fly ash cement held a 14% (1.43Mt) market share in the UK’s 10.2Mt of cement consumption in 2021.

The UK Mineral Products Association (MPA) has identified limestone as an underutilised resource in the country’s cement production. Together with HeidelbergCement subsidiary Hanson Cement, it has applied for a change to National Application standards to allow the production of Portland composite cement from fly ash and limestone or GGBFS and limestone. The association has forecast that Portland composite cement could easily rise to 30 – 40% of UK cement consumption, and that this has the potential to eliminate 8% of the sector’s 7.8Mt/yr-worth of CO₂ emissions.

Metallurgical waste streams have long flowed into European cement production, primarily as GGBFS, but also as bauxite residue. In 2021, alumina production in the EU alone generated 7Mt of bauxite residue, of which the bloc recycled just 100,000t (1.4%) that year. Two projects – the Holcim Innovation Center-led ReActiv project and Titan Cement and others’ REDMUD project – aim to produce new alternative cementitious materials from bauxite residue.

By collaborating with other industries, cement producers’ investments can most effectively reduce the overall cost of using these materials in cement production. In Germany, HeidelbergCement and ThyssenKrupp’s Save CO₂ project aims to develop new improved latent hydraulic binders or alternative pozzolan from GGBFS by producing slag from directly reduced iron (DRI). The Save CO₂ team believes that GGBFS substitution for clinker has the capacity to eliminite 200Mt/yr of CO₂ emissions from global cement production.

Meanwhile in the world of mining, ThyssenKrupp and others’ NEMO project is investigating the recovery of a useable mineral fraction for cement production from the extractive waste of the Luikonlahti and Sotkamo mines in Finland and the Tara mine in Ireland, through bioleaching and cleaned mineral residue upcycling. This may give cement producers full access to Europe’s 28Bnt stockpiles of sulphidic mining waste, of which mines generate an additional 600Mt each year.

Denmark-based CemGreen, which produces the calcined clay supplementary cementitious material CemShale, is developing a shale granule heat-treating technology called CemTower. This consists of three pieces of equipment vertically integrated into cement plants’ preheaters, kilns and coolers, and brings the processing of waste materials – here oil shale – to the cement plant.

Lastly, cement producers are exploring the possible uses of waste made of cement itself. In Wallonia, HeidelbergCement subsidiary CBR’s CosmoCem project is investigating the production of alternative cement additives from large available flows of local demolition, soil remediation and industrial waste. Similarly, the Greece-based C2inCO₂ project seeks to mineralise fines from concrete recycling for HeidelbergCement to use in the production of novel cements in its Greek operations.

In Switzerland, ZND Portland composite cement (produced using fine mixed granulate from building demolitions) is the third largest cement type, with 178,000t (4.3%) of total deliveries – narrowly behind CEM I with 239,000t (5.7%).Holcim Schweiz developed its Susteno 4 ZND Portland composite cement with Switzerland’s lack of any ash or slag supply in mind, demonstrating the potential flexibility of a circular economic approach to cement production.

On 21 March 2022, the University of Trier reported that it is in the process of mapping mineral resources, waste deposits and usable residues ‘on a cross-border scale,’ in an effort to produce new materials for use in cement production. Industry participants include France-based Vicat, CBR, Buzzi Unicem subsidiary Cimalux and CRH subsidiary Eqiom. Vicat is preparing a kiln at its 1Mt/yr Xeuilley cement plant in Meurthe-et-Moselle to use in testing new alternative raw materials developed under the project.

For Cembureau and its members, work continues, with the goal of Net Zero by 2050 constantly in sight. This goal includes a reduction in members’ clinker-to-cement ratios to well below 65%. In this, the association and its members are working towards a world not just beyond CEM I, but beyond CEM II, too. What exactly this will mean remains to be seen.

Sources

CemSuisse, ‘Lieferstatistik,’ 11 January 2022, https://www.cemsuisse.ch/app/uploads/2022/01/Lieferstatistik-4.-Quartal-2021.pdf

WSA, ‘December 2021 crude steel production and 2021 global crude steel production totals,’ 25 January 2022, https://worldsteel.org/media-centre/press-releases/2022/december-2021-crude-steel-production-and-2021-global-totals/

MPA, ‘Low carbon multi-component cements for UK concrete applications,’ July 2018, https://prod-drupal-files.storage.googleapis.com/documents/resource/public/Low%20carbon%20multi-component%20cements%20for%20UK%20concrete%20applications%20PDF.pdf

European Commission, ‘European Training Network for Zero-waste Valorisation of Bauxite Residue (Red Mud),’ 16 July 2020, https://cordis.europa.eu/project/id/636876

European Commission, ‘Industrial Residue Activation for sustainable cement production,’ 16 February 2022, https://cordis.europa.eu/project/id/958208

Recycling Portal, Zement der Zukunft – Forschungsprojekt „SAVE CO₂“ gestartet, 28 May 2021, https://recyclingportal.eu/Archive/65677

h2020-NEMO, ‘Project,’ https://h2020-nemo.eu/project-2/

European Commission, ‘Green cement of the future: CemShale + CemTower,’ 14 April 2021, https://cordis.europa.eu/project/id/101009382

CosmoCem, ‘Communiqué de Presse,’ https://cosmocem.org/

CO₂ Win, ‘C²inCO₂: Calcium Carbonation for industrial use of CO₂,’ https://co2-utilization.net/en/projects/co2-mineralization/c2inco2/

Les Echos, ‘Rendre le ciment moins gourmand en CO₂,’ 21 March 2022, https://www.lesechos.fr/pme-regions/innovateurs/des-substituts-au-clinker-rendent-le-ciment-moins-gourmand-en-co2-1395002

Benelux/France: Cementir Holding has introduced its Futurecem limestone calcined clay cement into the Benelux and French cement markets. Futurecem cement applies Cementir Holding’s patented processes to substitute over 35% of clinker in cement with limestone and calcined clay, preserving the cement’s strength and quality while reducing its carbon footprint by 30% compared to ordinary Portland cement (OPC).

Cementir Holding previously rolled out Futurecem cement in Denmark in 2021. In 2022, it plans to launch InBind high performance concrete (HPC) and ReCover ultra-high performance concrete (UHPC) to expand its range of HPC and UHPCs using Futurecem technology.

Eddy Fostier, managing director of Cementir Holding’s Belgian subsidiary CCB, said “Thanks to the joint efforts of the group and CCB teams, Futurecem technology is the main pillar for CCB’s low carbon transition within the Group roadmap. This product technology is matching customer needs, highlighted through a specific survey carried out across the most relevant market areas and applications.” Fostier concluded “I’m fully convinced that Futurecem will play a relevant role in the decarbonisation of the construction industry, where cement and concrete are essential building materials both in the present and in the future.”

Italy: Cementir’s revenue grew by 11% year-on-year to Euro1.36bn in 2021 from Euro1.22bn in 2020. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 17.9% to Euro311m from Euro264m. Sales volumes of cement and concrete increased by 4.1% to 11.2Mt and 14.8% to 5.01Mm3 respectively.

“2021 marked for Cementir the year of the historic record of revenues and EBITDA despite the uncertainties related to the pandemic crisis, the substantial increase in energy costs, materials and services and the devaluation of the Turkish lira,” said Francesco Caltagirone Jr, chair and chief executive officer of Cementir.

The group also reviewed and approved the three-year Group Industrial Plan update for the period 2022 - 2024 and the 2022 budget. It has a target of reduce CO₂ emissions (scope 1) by 30% in 2030 compared to 1990 levels. It is also planning to invest Euro116m in the 2022 – 2025 to meet this goal and others. Some of this will go towards building a new production line at its integrated Gaurain cement plant in Belgium, where the work is intended to raise the unit’s alternative fuels substitution rate to 80% from 40%. The group noted that this project has been delayed to 2022 due to the coronavirus pandemic. Changes at other cement plants include switching to natural gas and biogas as well as energy efficiency projects. It is also said it was planning to ‘significantly’ increase the production of its FUTURECEM calcined clay cement and related sustainable products.

Denmark: Aalborg Portland Cement says that the market ‘warmly welcomed’ its new FUTURECEM calcined clay cement in 2021. The product has reached its sales expectations for the year and is now nearly sold out for 2022. The company says that its plan to ramp up FUTURECEM production to replace 50% of grey cement production at its Rørdal cement plant is on track.

Parent company Cementir Holding says that the success of FUTURECEM rests on four pillars, namely its suitability for intended applications, targeted communication, close dialogue with concrete producers and the entire value chain and strategic partnerships with leading construction clients. It said “The lesson learned is that the market needs thorough information about new products and its industrialisation to rely on and implement them in place of conventional products.” The group added that its experience in Denmark paves the way for limestone calcined clay technology rollouts in other markets in line with its sustainable roadmap towards 2030.