Displaying items by tag: Fuel

Suez Cement and Italcementi's first waste treatment plant in Egypt was inaugurated this week. The project uses 45,000t of household waste to produce 35,000t of alternative fuel annually. Given Egypt's on-going fuel concerns the project will be watched closely.

Italcementi has much riding on the success of the project. It has five integrated cement plants in the country. As reported in early February 2014, the cement producer suffered reduced production capacity in Egypt despite 'potential' domestic demand due to limited energy availability. Cement sales volumes in Egypt for Italcementi have continually fallen since 2011, accelerating from a 5.4% year-on-year reduction in 2011 to a 17.6% year-on-year reduction in 2013. Yet, despite this, rebounding domestic demand was reported in 2012 and 2013.

It must be extremely frustrating for Italcementi. It has the production capacity, it has demand but it doesn't have the fuel to power its lines. Any additional fuel will be welcome. At a rough and conservative rate of 200kg of fuel per tonne of cement produced, Italcementi and Suez Cement's new alternative fuel stream could help to produce 175,000t of cement or about 1.5% of the cement producer's clinker production capacity of 12Mt/yr.

Lafarge, with its mega 10.6Mt/yr cement plant outside of Cairo, hadn't suffered (publicly) as much as Italcementi from fuel shortages until the publication of its financial results for 2013. Although sales had decreased year-on-year since 2009, this has been blamed on competition. Now it has been announced that cement volumes decreased by 30% in the first half of 2013 due to shortages of gas. This was mitigated through fuel substitution to a 19% drop in the third quarter and a 7% drop in the fourth quarter.

However, Lafarge's strategy for fuel security may be threatened as the Ministry of State for Environmental Affairs ordered the producer to stop preparations to build storage units for petcoke in February 2014 citing environmental and economic reasons. What happening here is unclear given that the Egyptian government has been encouraging cement producers to move away from using natural gas.

The examples above show the reactions two multinational cement producers, Italcementi and Lafarge, have made to secure their fuel supplies. The outcomes remain uncertain.

In other news, Shijiazhuang in Hebei province in China has started the demolition of 17 (!) more cement plants. This follows 18 plants that were demolished in December 2013. In total, 18.5Mt/yr of cement production capacity has been torn down.

This is more than the cement production output of most European countries or any single US state! Where was this cement going previously? What were the effects on the price of cement in China? Who is taking the loss for the destruction of this industrial production capacity? BBC News Business Editor Robert Peston has some ideas.

The 8th Global CemFuels Conference & Exhibition on alternative fuels for cement and lime takes place in Vienna, Austria on 24 - 25 February 2014

Egypt: Lafarge has been ordered by the Ministry of State for Environmental Affairs (MSEA) to halt its preparations to build storage units for petcoke, according to a statement by the ministry. The MSEA expects the French cement manufacturer in Egypt to wait for a final decision on the use of petcoke as fuel in industrial operations.

France-based multinational cement producer Lafarge submitted a study to MSEA on the environmental impact of petcoke in May 2013 and awaits a government decision on its use. The MSEA does not allow cement factories to import coal, citing hazards to the environment and the economy. The cement industry consumes 9% of the total amount of natural gas produced in Egypt, after the electricity and fertiliser sectors. The switch to coal was first suggested as an alternative to gas when the government announced plans to gradually remove gas subsidies.

Egypt: The managing director of Suez Cement has announced that the company intends to invest US$145m by 2016 energy security measures. US$72.5m will be spent on converting two of its five cement plants for the use of coal instead of gas and diesel. The remaining US$72.5m will be spent on environmental upgrades.

Egypt: Jose Maria Magrina, chief executive officer of Arabian Cement Company (ACC), has asked the Egyptian government to help cement producers move to using coal and alternative fuels. In an announcement Magrina explained that ACC is ready to substitute all the natural gas used at its 5Mt/yr cement plant in Ain Sokhna to coal and refuse derived fuel (RDF) and had applied for the necessary government permits to do so on 14 March 2013. However until late May 2013 no answer had been received from the government.

"The investment needed to substitute natural gas or mazot (heavy duty fuel oil) with coal ranges from US$6-8m/Mt, while converting to RDF costs around US$8-12m/Mt. However for private companies to be encouraged to commit to such a huge investment, the government should look into incentivising this initiative by putting together a solid policy that includes governmental support," commented Magrina.

Magrina added that the government should remove the operating license fee imposed on new companies, as this was intended to cover the cost of subsidised natural gas, and that it should be granted an environmental permit. ACC is still waiting for the permit to use coal, which will replace 70% of its gas supply. Once the company is granted the permit, it will be ready to make the conversion by the fourth quarter of 2013.

Since February 2013, energy shortages have caused the cement industry in Egypt a loss of 20% (3.7Mt) in production capacity, while ACC has lost 25% (350,000t) of its cement production capacity in the same period. Losses of over 50% are expected during the summer of 2013. Until late 2010, the Egyptian government encouraged cement producers to switch to using natural gas. However, the current energy crisis has seen the government promote the use of coal and alternative fuels instead.

Egypt: Suez Cement, Egypt's biggest cement maker by market value, has said that a lack of fuel supplies had forced it to cut production by as much as 30% so far in 2013. Two years of political upheaval have brought chaos to Egypt's economy and a lack of state funds and foreign currency is now disrupting imports of vital energy supplies.

"A lack of fuel supplies has cut our annual production of 12Mt/yr by 20-30% since the start of the year," said Mohamed Shanan, director of business development at Suez Cement, a subsidiary of Italy's Italcementi. "Any increase in (fuel) prices must be matched by an increase in cement prices," he told local press. He highlighted that fuel costs had doubled in the past three year while cement prices have grown by just 30%.

Long queues at petrol stations, protests at cooking gas shortages and ever more frequent power cuts point to a gathering fuel crisis in the North African country. Energy accounts for around half the cost of producing cement in Egypt.

Egypt: Suez Cement has announced that it may have to halt production at two of its production lines due to an increase in the price of mazut, a heavy, low-quality fuel oil. The Egyptian government has raised the price of the fuel by 130% to US$372/t, effective 15 December 2012. Both of the threatened lines use mazut as their main energy source. The group has a domestic market share of around 20%.

Egypt: Production at Misr Beni Suef's cement plants was stopped for the second time in two months on 6 December 2012 due to shortage in natural gas supply. The company has reported that the lack of fuel has led to a loss of approximately US$16.5m and that it may lead to the dismissal of some of its workforce if continued.

Misr Beni Suef's managing director Farouk Moustafa said that the company had sent a letter to the Egyptian President Mohamed Mursi seeking a solution to the gas supply cut but that no response had yet been received.

India: Cement producers have suggested that the industry will be unable to 'absorb' increased freight charges caused by a rise in the price of diesel.

Following a US$0.10/l increase in the price of diesel, the All India Motor Transport Congress (AIMTC) increased freight charges across the country by 15%. The truck drivers' organisation claims to have around 8 million vehicles under its control.

"The increased freight charge is not going only to impact on the distribution of finished goods. Generally, it takes 2t of inputs to produce 1t of cement. So, the impact will be on a total of 3t freight. I don't think the industry is now in a position to absorb this," said, JK Lakshmi Cement whole-time director , Shailendra Chouksey.

Commenting on the impact of the rise in diesel prices, a major cement producer, which preferred not to be quoted, said the rise was high and that this would certainly push up the distribution cost for producers.

Currently, the Indian cement industry faces over-capacity with a utilisation of 76% of the total capacity of 330Mt/yr. According to UltraTech in its annual report the situation is unlikely to improve before 2015.

India: Pine needles, a major cause of forest fires in Himachal Pradesh, are now helping villagers earn money. The needles are being used as biofuel by a cement plant, with locals supplying production on a per-kilo basis. "Gujarat Ambuja Cements is using pine needles along with charcoal in its kiln," said the Divisional Forest Office, Pradeep Thakur. The substitution rate varies from 25-30%. "The needles have good calorific value and it's a good source of additional income for the villagers. In the Hamirpur forest division alone, more than 200 families are involved in the job. According to an official, an average a family can earn US$270/month through pine needles.

Manju Devi, a villager, said, "Since pine needles are not used in homes (due to the presence of various nitrogen oxides), they lie unused in the forests. The demand picked up after the company started procuring them and we are now earning up to US$750 in a season (from May to June)."

China: The Chinese Ministry of Information and Technology has announced that China's cement industry will source 65% of its electricity needs from waste materials by 2015, as part of the country's wide-ranging 12th Five-Year Plan period (2011-2015). It said that this would help China's building materials industry to see its energy consumption per unit of industrial value-added output reduced by 20% by 2015 compared to 2010.