Displaying items by tag: Federation of Egyptian Industries

Energy has been the theme for a couple of cement news stories of note from Egypt this week. The first concerns the government’s impending plan to centralise distribution of mazut (heavy fuel oil) to cement plants to help them cope with ongoing power shortages. Earlier in the week Cemex signed a deal with the Assiut Governorate to operate a second municipal solid refuse processing unit in the country. The company’s first Regenera facility, in Mahala, started operations in May 2024. Another story from mid-September 2024, along the same theme, covered the inauguration of an 18MW waste heat recovery (WHR) unit at Heidelberg Materials Egypt's Helwan Cement plant.

The wider story is that the country has faced so-called load shedding, or power rationing, since mid-2023 due to falling gas production, rising energy demand and negative currency exchange effects making it harder to buy fuel imports. The power cuts were extended in duration in July 2024 due to a heat wave. The government then said in late September 2024 that it is making investments to prevent domestic power cuts in 2025.

The cement stories mentioned above show some of the ways cement companies cut their energy costs. Two potential ways of doing this are to increase the use of alternative fuels (AF), such as municipal solid waste, or to install a WHR unit. Titan Cement, for example, reported AF thermal substitution rates of above 40% in Alexandria and above 30% in Beni Suef in the first half of 2024. The local press hasn’t reported power shortages amongst the country’s cement producers, but the plans to control the distribution of mazut suggest that either ‘something’ has happened or the government is trying to avoid ‘something.’ Readers may recall that producers have periodically faced step changes in power supplies over the years. In the mid-2010s, for example, lots of plants switched from heavy fuel oil and gas to coal. The energy price fluctuations following the start of the Russia - Ukraine war in 2022 then saw the price of coal rise.

However, what the foreign-owned producers have complained about in the first half of 2024 is the declining exchange rate of the Egyptian Pound. Cementir, Cemex and Titan Cement all noted this. However, Titan reckoned that International Monetary Fund and European Union investment had actually eased the economic situation in the first half of the year leading to an increase in the number of large construction projects.

One effect of the currency problems upon the cement market has been a focus on exports. At the start of September 2024 the Federation of Egyptian Industries said that national cement consumption in 2024 was expected to drop by 4% year-on-year to 45Mt. However, exports were projected to rise to 15Mt. The first and second most popular destinations so far in 2024 have been the Ivory Coast and Ghana. Yet, exports to Libya, the third biggest external market, may have had the biggest effect. These have been blamed for creating a shortage of trucks that was causing delays to the local construction sector. The round-journey from Egypt to Libya can take up to 12 days. This has left building sites bereft of raw material deliveries because all the trucks are elsewhere! Vicat acknowledged the growing importance of imports for its business in Egypt in its half-year report for 2024. It said that ‘sluggish’ domestic market conditions “were more than offset by growth in cement and clinker volumes for export to the Mediterranean and Africa regions.”

The wider picture of the cement sector in Egypt remains one of overcapacity with integrated capacity estimated above 70Mt/yr. The government introduced cement production quotas in mid-2021 and this stabilised prices (and profits). The recent state of the local economy may have strained this, but the latest round of external investment appears to have buoyed things for now. Although the effects of the Israeli military action in Lebanon may have unforeseen consequences upon neighbouring markets. In the meantime, cutting energy costs and growing exports offer two ways for producers to raise their profits.

Egypt: Egypt's cement consumption is expected to drop to 45Mt in 2024, a decrease of 4% from 47Mt in 2023, reports Arab Finance newspaper. According to Ahmed Shireen, head of the cement division at the Federation of Egyptian Industries, the country is also projected to export 15Mt of cement. Local production capacity stands at 92Mt/yr. Recent reductions in transport availability have reportedly been exacerbated by exports, particularly to Libya, causing a significant cement shortage. This has reportedly impacted local construction projects and contributed to a 20% price increase since 1 August 2024.

Egypt: Medhat Istafanos, the head of the Cement Division at the Federation of Egyptian Industries (FEI), says that the market is only supporting 40% of local production. He blamed this on a slowdown in building activity and a lack of government-backed infrastructure projects to make up the shortfall, according to the Al-Ahram newspaper. Noha Bakr, an executive director at the cement division of the FEI, also blamed a construction ban on agricultural land.

The country’s 24 cement plants have a production capacity of 85Mt/yr but only 48Mt were sold in 2018. Cement sales have fallen since 2017 and are expected to reach 49Mt in 2019.

Producers are exploring options to increase cement exports. Walid Gamaleddin, the president of the Export Council for Building Materials and the Metallurgical Industries, has called for the government to support industry exports. The minister of trade and industry discussed a programme for cement-export subsidies with officials from the sector in late July 2019 that would include encouraging agreements to export cement to the African countries. The Central Bank of Egypt (CBE) has also instructed the banking sector to support cement companies that needed to restructure their debts. The merger of smaller companies to form larger conglomerates has also been encouraged.

However, growing exports of Egyptian cement is challenged by its relative high cost compared to other countries. Istafanos said that Egyptian cement is US$12/t higher than its competitors.

Tourah Cement in Egypt took the tough decision last week to temporarily stop production. It blamed this on an acute financial crisis rendering it unable to pay its running costs. The subsidiary of Germany’s HeidelbergCement was reported in the Global Cement Directory 2019 as already being partly closed. This latest news is regrettable but not surprising.

Graph 1: Cement consumption and production in Egypt. Sources: Industrial Development Agency, Global Cement Directory 2019, Cement division of the Building Materials Chamber of the Federation of Egyptian Industries.

As Graph 1 shows that the backdrop here is of a local cement sector rife with overcapacity. Capacity utilisation rates have hovered around 70% in recent years. The sector breaks down into about a quarter of production capacity under state control and the remainder owned by private companies. Overall, about half of the production capacity is run by multinational companies like Greece’s Titan, France’s Vicat and Germany’s HeidelbergCement.

The country hosts some of the largest cement plants in the world as well as several very big plants by European or North American standards anyway. The whopping 13Mt/yr government/army-run El-Arish Cement plant at Beni Suef opened fully in 2018. It seemed likely that there were going to be losers in the industry following that kind of disruption from a state-owned player. Indeed, Medhat Istvanos, head of the cement division of the Building Materials Chamber of the Federation of Egyptian Industries, explicitly blamed the El-Arish Cement plant for making the situation worse in September 2018. He said that the decision to build the plant was ‘not based on precise information’ and that it had harmed local production.

In the wider picture, the cement sector started to move away from subsidised natural gas and heavy fuel oil to coal instead in the mid-2010s. Tourah Cement mentioned this in its statement about halting production. The government has supported the cement industry through large-scale infrastructure projects and a state-sponsored compensation system under the Contractors Compensation Act that offset the loss prompted by the Egyptian pound’s floatation in 2017.

However, overcapacity has consistently been a problem and this was clear when the El-Arish Cement plant was approved. Exports of cement crept up to 1Mt/yr in 2017 from 0.1Mt/yr in 2015. Yet, as the Low-Carbon Roadmap for the Egyptian Cement Industry pointed out, Egyptian FOB exports of cement cost US$20/t higher than regional competitors such as Turkey. At this kind of disadvantage Egypt lacks the traditional escape route for an overproducing cement sector.

In these kinds of conditions, consolidation appears to be crucial while organic or government-backed demand plays catch-up with the production base. Certainly Egypt has the population and the development potential as its economy grows in the medium to long term. The government stabilising the economy after recent troubles is crucial for the construction industry. In the meantime all is not lost as the focus is on efficiency gains and cost cutting. The growth of alternative fuels as the sector’s fuel mix continues to adjust to the new normal following the abolition of subsidies on natural gas is one example of this.

Egypt: Noha Bakr has been appointed as the executive director of the Cement Division at the Federation of Egyptian Industries (FEI). Bakr, who holds a PhD in International Relations and International Organisations, was educated at the American University in Cairo and at Cairo University, according to Arab Finance. He has held several government posts, including working as the Assistant to the Minister of International Cooperation, in charge of International Economic Cooperation with Canada and the Americas.

The cement division of the FEI was established in 2013 to develop cement production in Egypt. The division is a subsidiary of the Chamber of Building Materials at the Federation of Egyptian Industries.

Egypt: Medhat Istvanos, head of the cement division of the Chamber of Building Materials, affiliated to the Federation of Egyptian Industries, says that exports from the country are being made uncompetitive due to the government’s decision to raise energy prices in June 2018. He said that the local exchange rate had aided exports but that “the government’s bureaucracy has eliminated export hopes,” according to the Daily News Egypt newspaper. The local industry exported cement worth US$57m during the first half of 2018.

Istvanos said that the industry has a production capacity utilization rate of 60% with a production capacity of 84Mt/yr but consumption of only 54Mt/yr. He added that the decision to build the new 12Mt/yr Beni Suef cement plant was “not based on precise information” and that it had harmed local production.

Egypt: Cement producers have decided to keep the prices of cement 'stable' for the fifth consecutive month, Minister of Supply Khaled Hanafy has announced. Medhat Stephanos, head of cement companies at the Federation of Egyptian Industries (FDI), said the supply surplus is behind the price stability, according to local media.

Hanafy stated that 854,000t had been produced for the current month and that the total amount of supplied cement was 1.86Mt. Around 818,000t of cement were distributed in the local market and around 500,000t were exported between 9 and 15 April. Staphanos added to Daily News Egypt that the country's cement production capacity has increased following the introduction of coal as a source of energy, which reduced the energy problem that faced producers.

"We expected more activity in the processes of construction but those expectations were not met," said Stephanos. "Some projects were expected to start but have not started yet."