Displaying items by tag: GCW206

The small cement industry of Mozambique, in south west Africa must be an interesting place to make cement. On one side the country's producers, like their more vocal South African counterparts, have been fighting off cheap imports from Iran, Pakistan, China et al. On the other side of the coin though, Mozambique has growing domestic demand and is within striking distance of growing markets further into Africa, like Malawi and the Democratic Republic of Congo (DRC).

With the announcement this week that there will be not one but two new integrated cement plants in the country, bringing over 2Mt/yr of new capacity, everything should be set fair for the coming years then, shouldn't it? Domestic production will rise, the price of local cement will fall as a result, competition from imports will drop off and money will be made from new exports.

Except that might not happen. Before the announcement of these two plants, (one of which does not state a capacity), there was around 5.5Mt/yr of grinding and integrated capacity either currently active in Mozambique or due to come onstream in 2015. With the new projects this rises to over 7.5Mt/yr.

The desirable chain of events described above starts to break down due to the fact that domestic demand in Mozambique, while rising, is not currently anywhere near as high as domestic supply. The United States Geological Survey estimated that the country produced just 1.2Mt/yr in 2012. Data for 2013 and 2014, though unavailable, is highly unlikely to show a three-fold increase. Indeed Insitec, a minority shareholder in Cimentos de Moçambique, predicted in 2014 that demand for that year would rise to just 1.5Mt, before hitting the dizzying heights of 1.8Mt in 2018 – And that's still three years away!

So what are the options? Option 1: Some or all of the planned and mooted cement plants will fail to come to fruition. Option 2: Some or all of the plants will be built but will operate at reduced capacity and/or on a campaign basis. Option 3: The Mozambican cement industry becomes a regional powerhouse and starts to export to its neighbours.

Option 1 is certainly possible. Limak Group, one of the parties linked to the new projects, is a Turkish cement producer that is inexperienced outside of Turkey. There has also been a lack of information on the progress of projects by Austral Cimentos ('coming on stream in 2015'), Star Cement and Consolidated Building Materials, although a lack of progress reports does not necessarily imply 'no progress.'

Option 2 is more likely, as some producers already operate on a campaign basis. InterCement's plant at Nacala, formerly an integrated plant, currently operates only as a grinding station. Option 3 is also possible, with Malawi particularly lacking in cement production facilities.
In reality a combination of all three 'Options' is the most likely outcome. However, this will lead to Mozambique becoming yet another player in an increasingly busy African cement market. The desire for self-sufficiency in cement production, a common goal for the region's governments, can easily lead to over-estimates of local demand growth, with resultant over-capacity. Of course the expectation that all African countries can get rid of this extra cement capacity via exports will ultimately backfire.

In southern Africa we already have South Africa exporting. Angola declared 'cement self-sufficiency' in October 2014 and banned imports at the start of 2015. Zambia, Botswana, Zimbabwe and DRC all have large-scale Dangote and/or PCC projects near completion or in production that will greatly reduce their need for imports. Meanwhile, further north, Nigeria is already a gigantic producer and significant cement exporter. Cameroon has recently banned imports and Ghana is thinking of doing the same. Over in the east of Africa, Ethiopia's (and the rest of that region's) rapidly-developing situation was covered in this column just two weeks ago.

Finally, in the north of Africa, Algeria has declared its intention to be self-sufficient in cement by 2016. This news must have 'gone down like a lead balloon' in Italy, Spain and Greece, which have been reliant on north African markets after the bottoms fell out of their own economies. In the north east, Egypt has different problems at present, also described previously. It needs fuel not cement!

So where does this all lead for regional cement dynamics in Africa? Well perhaps the situation in India points the way. There, as in Africa, local and regional producers with the desire to expand grew from their local bases and eventually overlapped. Against a backdrop of lower-than-expected demand, the country now has overcapacity. This has resulted in smaller producers being acquired and leaving the market.

Could this eventually happen in Africa? Only time will tell. However one thing is certain: It's just not possible for every country to export to every other country!

Mexico: Cementos Moctezuma, a joint venture company of Cementos Molins, Buzzi Unicem and Grupo Carso, has ordered a Loesche vertical roller mill LM 53.3+3 C for its cement plant in Apazapan, Veracruz. The mill will produce 205t/hr CPC 30 cement at 4000 Blaine or 195t/hr CPC 40 cement at 3700 Blaine.

The order also includes a LDC classifier (Loesche Dynamic Classifier), as well as the COPE gearbox, including gearbox drive motors, developed in cooperation with RENK AG. The COPE gearbox features a redundancy of eight motors. With all eight motors in operation, an output totaling 4.6MW is achieved. The customer advantage lies in the fact that the COPE gearbox can reach up to 100% of the mill capacity performance even with a reduced number of motors. The COPE gearbox has the same external dimensions as a conventional planetary gear system and thus requires no extensive enlargement of the mill foundations.

Mozambique: According to Agence de Presse Africaine, two new cement plants are planned for Mozambique in the coming years.

Turkey's Limak Holding plans to invest US$150m in a 2Mt/yr capacity cement plant in the Maputo Port area of Mozambique. Limak chairperson Nihat Ozdemir said that his company would create least 500 jobs during the first phase of the plant." Limak is also interested in entering the Mozambican energy sector and later intends to assess the viability of investment in ports, railways and tourism," said Ozdemir. Mozambique's Industry and Trade minister Max Tonela pledged the Mozambican government's support for Limak.

Meanwhile, Portugal's Cimpor Cimentos group, via its subsidiary Cimentos de Moçambique, has announced plans to build a new integrated cement plant in Nacala, Nampula for an estimated investment of around U$250m. It already owns an integrated cement plant in Matola and also operates four grinding units.

India: According to the Financial Express, Jaiprakash Associates is close to selling its 1Mt/yr capacity cement plant at Sikandarabad, Uttar Pradesh to HeidelbergCement for around US$78.6m.

If the deal materialises, it would be the fifth cement asset sale by Jaiprakash Associates in little over a year. The group is looking to sell assets, including cement and power plants, to reduce its large debt. The aggregate debt of the group at the end of the 2014 financial year, which ended on 31 March 2014, stood at around US$8.65bn. Though it has so far divested assets worth US$2.36bn, the impact of the asset sales is yet to reflect on the group's balance sheet. It aims to cut down debt further by around US$1.57bn by the end of the current 2016 fiscal year, which ends on 31 March 2016. So far, Jaiprakash Associates has divested around 13Mt/yr of its overall cement capacity and is left with around 23Mt/yr.

Unnamed sources have said that Jaiprakash Associates also plans to sell two more of its cement plants, in Baga and Bagheri in Himachal Pradesh and Balaji in Andhra Pradesh, but the matter is stuck due to valuation issues. Aditya Birla Group's UltraTech Cement and HeidelbergCement have reportedly been in talks regarding their acquisition.

Turkey: Biberci Insaat is building its first cement plant in Konya, Turkey and it has ordered Loesche's LM 56.3+3 vertical roller mill for clinker grinding. Biberci Insaat specialises in infrastructure works including road construction, interchange, water conduction lines, sewerage, natural gas and other energy transfer lines.

One of Biberci Insaat's first investments for the new greenfield cement plant is the order of Loesche's LM 56.3+3 cement mill for clinker grinding. The mill will produce 200t/hr of Ordinary Portland Cement at 3,800 Blaine. The gearbox is planned with a capacity of 5400kW. Delivery is scheduled for the third quarter of 2015.

Nigeria: According to All Africa, Cement Company of Northern Nigeria (CCNN) in Sokoto will invest US$600m to expand its power plant from 12MW to 16MW.

The Bureau of Public Enterprise (BPE) Media head Alex Okoh said that CCNN principal manager of corporate affairs Alhaji Suleiman disclosed this while addressing BPE's post-privatisation monitoring team during a recent visit to the plant. Suleiman said that the expanded plant will be built in partnership with China's CBMI. "CCNN's plant does not generate sufficient power when the plant is run at full capacity utilisation," said Suleiman.

India: According to Live Mint, the majority of 3261 highly-polluting industries in India, including the cement and steel sectors, are set to miss the June 2015 deadline set by the ministry of environment, forests and climate change (MoEFCC) to install online effluent and emission monitoring systems.

Most industries have recently sought an extension to September 2015, although some from sectors like petrochemicals and refinery asked the deadline to be extended to June 2016. The environment ministry is considering the former plea. "The ministry is favourably considering extending the deadline until September 2015 for the majority of industries. But we are not sure about extending it to June 2016 for certain industries. A final call will be taken soon in this regard," said a senior environment ministry official.

On 16 - 17 June 2015, the Central Pollution Control Board (CPCB) held a meeting of industrial associations and common waste management facilities to review the status of compliance of their directions regarding the installation of online effluent and emission monitoring devices. According to the minutes of the meeting, 'By-and-large, associations have agreed to meet the deadlines by September 2015, except in the case of mini cement plants, refinery, petrochemicals and common bio-medical facilities.'

In December 2014 the CPCB identified 3261 industries in 17 categories of highly-polluting industries, including the cement, iron and steel, thermal power plants, sugar, tannery, distillery, fertilisers and pesticide sectors. The CPCB had asked the industries to install online effluent and emission monitoring systems by June 2015, failing which bank guarantees of 100% of the cost of online systems (emission or effluent) would be forfeited. The CPCB had also said that its 'consent to operate' would be withdrawn from non-complaint industries.

India: According to Focus News, cement carrier MV Coastal Pride has sunk 45km south of Daman, Gujarat on 24 June 2015. The Navy and Coast Guard rescued 14 crew members of the vessel. The Coast Guard picked up six persons before the ship sank, a helicopter saved six crew members from the water and the Coast Guard rescued two further people after the boat sank. The rescued crew were evacuated to Umargaon, Gujarat.

US: According to Charlotte Business Journal, Duke Energy has proposed excavating 12 more of its 36 coal ash ponds in North and South Carolina and burying the waste in a fully-lined landfills or structural fill projects.

To date, Duke has proposed closure plans for 24 of the 36 ash ponds. In every case, it has proposed excavation and reburial. However, Garry Miller, head of closure engineering for Duke, said that might not be the case for the remaining 12 ponds. He said that the engineering work that remains to be done at those plants could yet show that a 'cap in place' process, which critics have said would be insufficient to protect against further contamination of groundwater, can effectively close them.

Miller said that none of the waste ash from Duke's 36 ash ponds would undergo beneficial reuse, the process of using the ash for commercial products such as a replacement for Portland cement in concrete and gypsum board. However, he added that Duke does send a portion of the dry ash it is currently producing at its largest plants for reuse. However, the time constraints imposed by North Carolina's Coal Ash Management Act of 2014 make it impossible for the existing ash ponds. "As we close these basins, the quantity in them is such that the market cannot handle it in a timely manner," said Miller.

Duke's current cost estimate for closing the ponds is US$3.4bn, although this is subject to revision.

Colombia: Cemex Latam Holdings, the Latin American arm of Mexico's Cemex, has reported unfavourable results in the first quarter of 2015 in Colombia and said that its stocks have been affected, despite the fact that the region turned towards infrastructure improvement projects. As the company's share value in Pesos has dropped by 30% and it has recorded another 35% decline due to depreciation, Cemex Latam Holdings' value in US Dollars is 70% lower.

Company president Carlos Jacks has attributed the poor results in January - March 2015 to the 25% depreciation against the US Dollar, as well as the fact that its 31% growth in 2014 was far higher than the industry average. Another factor was the decision that Colombia should return or generate the same cash flow or the same amount of US Dollars before the depreciation and so it raised its prices, thinking that there would not be a reversal of the exchange rate.

Cemex Latam Holdings will work to recover the price in June 2015 and Jacks feels more confident about the second half of the year. Better sales volumes are expected if its efforts are successful. The company hopes that its local division will return to levels prior to the depreciation of the exchange rate in terms of its cash flow in US Dollars as a result. The business anticipates some momentum in housing programmes over 2016, as well as participation in the first wave of 4G motorway projects and possibly the second wave towards the close of 2015. It projects that around US$5bn/yr will be spent on cement, or US$500m each, while the projects will require some 3.50Mt of cement. The entire market consumes 13Mt/yr of cement. Cemex Latam Holdings will invest around US$180m in 2015 and the funds will mainly be used to expand the production capacity at its plant in Maceo, Colombia or premises in Monterrey, Mexico.