Displaying items by tag: GCC
US: The Environmental Protection Agency (EPA) has awarded its Energy Star certification to cement plants belonging to two Titan America subsidiaries. Titan Florida’s Pennsuco, Florida, cement plant has secured its 14th consecutive Energy Star, while Roanoke Cement’s Troutville, Virginia, cement has secured its 15th consecutive Energy Star.
Other cement plants to receive Energy Stars in 2022 included two Argos USA plants (Calera, Alabama, and Harleyville, South Carolina), two GCC plants (Pueblo, Colorado, and Rapid City, South Dakota), Buzzi Unicem’s Chattanooga, Tennessee, plant and three plants in Arizona: CalPortland’s Rillito plant, Drake Cement’s Paulden plant and Salt River Materials Group’s Clarkdale plant.
GCC worker dies following explosion at Chihuahua cement plant
28 February 2022Mexico: GCC has reported that a worker at its Chihuahua cement has died in hospital following an explosion on 25 Feburary which injured five others. The company says that it activated all safety protocols in response to the disaster and coordinated its actions with the responding authorities. It continues to support the investigation into the cause of the blast.
The company said “Unfortunately, one of the six injured died in hospital. We are currently in contact with his family, to whom we have expressed our deepest condolences, and with the families of our other injured collaborators to make all our support and resources available to them at this difficult time.”
GCC orders upgrade for Samalayuca plant from ThyssenKrupp Polysius
23 February 2022Mexico: GCC has signed an engineering, procurement and construction (EPC) contract with ThyssenKrupp Polysius for an upgrade to its integrated Samalayuca plant to increase clinker production capacity, raise the usage of alternative fuels and reduce emissions. The project includes the engineering, supply and modification of the preheater, including cyclones, and an extension to the calciner, with the installation of a Prepol SC-S type system to increase the utilisation of alternative fuels. The work also includes fitting a Polytrack type clinker cooler and the installation of a bypass system. The project will begin in 2022 with operations scheduled to start in the second quarter of 2023.
Growing Portland limestone cement production in the US
16 February 2022Argos USA announced this week that its integrated Roberta plant in Alabama is set to produce 100% Portland limestone cement (PLC) by June 2022. As part of the transition three of its terminals in North Carolina will also switch over at the same time. The company also expects that all of its plants will convert to PLC in 2023. Cement sites including Newberry in Florida, Harleyville in South Carolina and Martinsburg in West Virginia are already producing PLC.
The change by Argos marks the latest example in an ongoing trend of US-based cement companies moving entire plants to PLC production. In September 2021 LafargeHolcim US said that its integrated Midlothian plant in Texas was preparing to convert to full PLC production and that it would be the first plant in the US to do so. It later confirmed that the plant had done so by the end of 2021. In October 2021 GCC said that its Trident Plant in Montana would fully move to PLC in early 2022. Then in November 2021 Titan America said that its Pennsuco cement plant in Florida would make the change possibly by 2023. Moving into 2022 brought the news that LafargeHolcim US’ Ste. Genevieve plant in Missouri and its Alpena plant in Michigan had each transitioned to PLC production. Lehigh Hanson then rounded up the bunch earlier this month, at the start of February 2022, when it announced that a PLC was the primary product now coming out of its Mason City plant in Iowa. It even invited a US Member of Congress to celebrate!
The current expansionist phase of PLC usage in the US dates back to late 2020 when the Portland Cement Association (PCA) launched a dedicated website to promote the use of the blended cement by discussing its applications and benefits. It then released a new environmental product declaration in March 2021 and PLC received a mention in the PCA’s Roadmap to Carbon Neutrality when it was released a year later in October 2021. Lots of work went into PLC prior to 2020 though, both by the PCA and others. The first commercial production of PLC in the US started in 2005 and PLC gained its own blended cement specification in 2012. Notably, the PCA has been tracking the state acceptance of PLC by the Department of Transportation and it grew markedly during the 2010s.
The US is playing catch-up with PLC. In Europe its usage dates back to the 1960s. Cembureau, the European Cement Association, reported usage of around 30% in 2004. More recently in 2020, the VDZ, the German Cement Association, reported a similar figure domestically with the proportion of blended cement shipments including limestone, shale and multiple additives at 31.6%. In the US it is hard to gauge the scale of the current move towards PLC by producers, due to limited publicly available data. A PCA survey reported PLC production of 0.89Mt in 2016. If all the plants mentioned above convert fully to PLC and maintain their rated production capacity that would be something like 14Mt/yr of PLC in 2023 or 11% of the US’s total cement capacity. For comparison, the United States Geological Survey (USGS) reported total shipments of all blended cements at 3.3Mt in 2020 and a total of 5.4Mt for the first 11 months of 2021. Plus, remember that PLC is just one blended cement among others, like those that use slag or fly ash.
Recent developments show that a large change is coming towards the US cement market in the update of blended cements. It’s been a long time coming but the last six months have seen brisk increases in PLC production at scale. The exact data is not available but one might expect something around triple the current number of production plants making PLC if the US market heads towards European levels. This rough estimate doesn’t take into account existing partial PLC production levels. At the same time the US cement sector should see a fall in its emissions due to PLC’s 10% reduction in CO2 emissions compared to ordinary Portland cement
GCC to invest US$500m in North America by 2024
27 January 2022Mexico/US: GCC plans to invest US$500m over the next three years to the end of 2024 on increasing its production capacity and strengthening its logistics and distribution network in North America. New projects in development include the expansion of a cement plant, debottlenecking at the integrated Samalayuca plant in Mexico, the construction of two new terminals and other projects to improve the company’s operational efficiency and its social and environmental strategy. The cement producer reported strong sales in 2021 and it expects even better results in 2022 and 2023, particularly in the US, due to the effect of the US infrastructure bill.
Notably GCC reported that both the kilns at its Odessa plant in Texas were running at full capacity in 2021 and an additional kiln at a plant in Chihuahua, Mexico was complimenting supply to the US state. High demand was also recorded in Montana.
GCC records strong 2021 performance
26 January 2022Mexico: The net sales of Grupo Cementos Chihuahua (GCC) increased by 10.8% year-on-year in 2021 compared to 2020, according to its fourth quarter financial report. Its net sales for the year came to US$1.04bn, while operating profit rose by 14.2% to US$214.3m from US$211.3m a year earlier.
GCC said that its stronger result was due to both volumes increases and higher selling prices in the US and Mexico. In the US market, the company’s cement volumes increased by 5.6% in 2021, with a 5.1% rise in concrete sales. Prices in the US rose by 8.9% and 5.1% respectively. In Mexico, cement and ready-mix concrete volumes rose by 6.9% and 19.1% respectively. Overall sales increased by 17.9%.
US: GCC plans to fully convert production at its 0.35Mt/yr Trident Plant in Montana to Portland Limestone Cement (PLC) in early 2022. The cement producer estimates that the plant’s production change will reduce its CO2 emissions by almost 25,000t/yr.
“We believe that our industry must continue to provide the homes, roads and infrastructure that shape our world while, simultaneously, addressing the challenge of climate change,” said Ron Henley, president of GCC’s US division. “PLC is one piece of the puzzle to reduce greenhouse gases. Concrete made with PLC is a resilient material that easily meets the needs of our customers for generations to come.” He added that GCC signed the Global Cement and Concrete Association’s (GCCA) net zero pledge earlier in 2021.
Mexico/US: GCC plans to spend US$450 - 500m on upgrade projects to its cement business over the next three years to 2024. It is considering building a new 1.1Mt/yr clinker production line at an unnamed existing plant but the board of directors has yet to make a final decision. Other projects include strengthening the group’s cement distribution network in Minneapolis, Minnesota and Utah in the US. This would also include building two new cement terminals. A debottlenecking project is being planned at the Samalayuca plant in Chihuahua state. This would increase the plant’s production capacity by 0.2Mt/yr and is scheduled for completion by the end of 2022. A final project is also scheduled for the Chihuahua plant to improve operational efficiency, and enhance social and environmental responsibility.
In earnings conference call notes for the second quarter of 2021 the cement producer reported for the US: “Every kiln at GCC is up and running; for practical purposes, our system is sold out.” It also noted bottlenecks in its grinding, storage and shipping installed capacity.
GCC reports strong first half of 2021
28 July 2021Mexico: GCC’s sales rose by 9.7% year-on-year to US$466m in the first half of 2021 from US$424m in the same period in 2020. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) increased by 15.3% to US$147m from US$127m. Cement sales volumes grew by 3.2% and 11.5% in the US and Mexico respectively. Concrete sales volumes fell by 21.1% in the US but grew by 22.8% in Mexico.
“Cement demand is stronger than pre-pandemic levels and construction activity is expected to remain robust throughout the year. Every kiln at GCC is up and running,” said Enrique Escalante, GCC’s chief executive officer.
GCC’s first-quarter sales fall as earnings rise
28 April 2021Mexico: GCC recorded consolidated net sales of US$179m in the first quarter of 2021, down by 2% year-on-year. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 9% to US$49.5m. In Mexico cement sales volumes rose by 6% but in the US they fell by 7.7% due to poor oil well cement sales.
The company’s chief executive officer Enrique Escalante said, "GCC started 2021 with strong financial performance - increasing EBITDA, free cash flow and EBITDA margin. Our results reflect momentum in the industry and show early signs that we are entering into a new phase of the industry's cycle with a stronger demand for most of our products. Therefore, we will focus our efforts in producing cement to supply pent-up demand." Escalante continued "Our backlog and the overall market trends of our business are encouraging in the US and Mexico. Both countries are emerging from tough and uncertain times into brighter months ahead. Our focus continues on maximising production, improving plant reliability, and optimising our logistics network to take advantage of the pent-up demand we are experiencing."