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In case you missed it, last week we covered a news story about Taiheiyo Cement’s plans to step up its lithium-ion battery recycling business at its integrated Tsuruga plant. It’s the latest step in the Japan-based cement producer’s collaboration with recycling company Matsuda Sangyo. The work is timely given that electric cars accounted for 2.6% of global car sales in 2019 and this share is growing. Many of these electric vehicles use lithium-ion batteries and moving away from fossil fuel powered transport creates new problems such as how to manage old batteries that can no longer be used.

Figure 1: Lithium-ion battery recycling process by Taiheiyo Cement and Matsuda Sangyo. Source: Translated from Taiheiyo Cement CEMS technical magazine.

Taiheiyo Cement and Matsuda Sangyo have been working on their process since 2011. First, they dismantle the batteries to extract base metals and plastics. They then heat the batteries in a dedicated ‘roaster’ using waste heat from the cement production process, before crushing and sorting them to remove cobalt, lithium, aluminium and scrap iron. Hydrogen fluoride produced in this stage is sent to the kiln where it is detoxified by calcium. Remaining elements from the battery that are not reclaimed are then used as an alternative fuel by the cement plant.

Taiheiyo Cement says that its roasting equipment can process up to 10t/day but it’s difficult at this stage to assess what demand for this service they might encounter. If, one estimate of 2m/yr used lithium-ion batteries by 2030 is correct and Taiheiyo Cement’s processing rate doesn’t get much higher, then 500 cement plants could possibly solve this problem. Yet, Taiheiyo Cement and Matsuda Sangyo have made no mention of the economics of their process. Other recycling methods also exist and research into new ones is ongoing. Cement plants recycling batteries might be economic compared to these alternatives or it might not, only time will tell.

The wider point here is that here is yet another industrial and logistical process that can potentially be linked to cement production. It follows well known ones, such as using alternatives fuels or captive power plants, or more novel ones, such as CO₂ or hydrogen networks. In each case the business of making cement changes as new methods are learned, new commodities are sought and new markets are connected. The cement company then has a choice about how involved it wants to become with each new process. The classic example here is the waste processing companies that surround co-processing, with some cement companies having their own dedicated subsidiaries, for example LafargeHolcim and Geocycle.

As it all becomes more complicated the role of a cement plant slowly becomes redefined. If a cement plant disposes of municipal waste and car batteries for its local community, generates electricity from its solar or wind plant for a nearby city and uses its CO₂ to either produce biofuels, plastics or baking soda is it still just a cement plant? The pivot by building materials manufacturers in recent years from a focus on cement to concrete suggests that once the societal or economic conditions are right it could change. For the time being cement plants remain cement plants but give it a thought next time you buy a new car.

Turkey: Sabancı Holding has appointed Umut Zenar as the general manager of Çimsa following the departure of Ülkü Özcan. Zenar’s previous role as the general manager of Akçansa, a joint venture between Sabancı and HeidelbergCement, will be filled by Mehmet Zeki Kanadıkırık. The changes will take effect from the start of September 2020.

Zenar holds a Master of Business Administration (MBA) from Boğaziçi University in Istanbul. He started his professional career in 2003 as a Business Development Specialist at Zorlu Holding before joining Akçansa in 2004. After working in sales, marketing and business development roles he moved to Oyak Cement Concrete Paper Group in 2016 as a general coordinator before returning to Akçansa as its general manager in 2018.

Kanadıkırık holds a degree in mechanical engineering from Middle East Technical University in Ankara. He started his career worked for Çukurova İthalat, Brisa, Lubrekip, Kordsa and Tekstil Servis. In 2006 he became the Production Manager at Kordsa Turkey and subsequently became the Manufacturing Director of Kordsa Turkey, the Operations Director of Thai Indo Kordsa and the Chief Operating Officer (CEO) of Asia Pacific for Kordsa in 2015.

Australia: The SmartCrete Cooperative Research Centre (CRC) has appointed Warren South as its chief executive officer (CEO). He will join the cement and concrete research organisation in mid-September 2020 and lead the consolidation of its central services function, initially supporting the ‘Fast Start’ and Round 1 research projects. South joins the SmartCrete CRC following nine years as Director – Research and Technical Services with Cement Concrete and Aggregates Australia (CCAA).

Senegal: Sinoma subsidiaries Sinoma International Engineering and Sinoma Construction have signed a contract with Les Ciments Du Sahel for the upgrade of its 3.0Mt/yr Kirene cement plant in Dakar Region. The Euro245m contract stipulates that a new 6000t/day capacity cement production line will replace the plant’s old third line. Sinoma says that the new line will grind its first batch of cement from clinker in February 2022 and produce its own cement and clinker from October 2022. The group said, “We believe that the contract ought to present no significant challenge for the company.”

South Africa: PPC has delayed the publication of its annual results for the year to 31 March 2020 for a second time due to a “restructuring and refinance project.” It now expects to publish the results by late September 2020. It previously delayed reporting its financial results when the Johannesburg Stock Exchange allowed it to delay releasing the figures because of challenges created by the coronavrius pandemic. The cement producer also said it has found errors in its financial reporting for the year that ended in March 2019 due to mistakes made in valuing operations in Ethiopia and Zimbabwe and a miscalculation of the accounting of a foreign-exchange transaction in the Democratic Republic of Congo (DRC).

The group expects that revenue for the year to 31 March 2020 will decline by no more than 5% year-on-year from US$605m in the same period in 2019. Earnings before interest, taxation, depreciation and amortisation (EBITDA) are expected to fall by up to 20% from US$113m.

In an operational update for April to July 2020 the group said that it ramped up cement operations in May 2020 following the relaxation of coronavirus-related lockdowns in most of its territories. It attributed strong growth in cement sales volumes in June and July 2020 due to a reduction in imports as well as pent-up demand. Similarly, sales volumes were strong outside of South Africa, particularly in Zimbabwe and Rwanda, and in the DRC to a lesser extent.

Democratic Republic of Congo: Police are investigating the murder of a Chinese worker at the quarry of a cement plant that is being built near Kolwezi, the capital of Lualaba province. The employee of Carrilu was killed in an attack on the site by ‘bandits,’ according to the Agence France Presse. Two other people were also assaulted in the incident. Armed attacks against businesses and residents have been reported regularly in the region.

The Lualaba Carrilu cement and lime plant is a project being managed by China-based Zijin Mining Group. It is expected to start operation in autumn 2020.

Zimbabwe: The Environmental Management Agency (EMA) has ordered Lafarge Cement Zimbabwe to stop operations at its integrated Harare plant due to abnormal dust emissions. As part of the order the plant has been requested to notify local stakeholders and the community of any new developments or incident that may affect them, according to the NewsDay newspaper. It will also be required to report daily dust emissions readings to the EMA every two weeks.

The cement producer said it experienced an unexpected surge in dust emissions during a trial of using saw dust as an alternative fuel at the plant between July 30 and 1 August 2020. It added that immediate action was taken to control and contain the emissions and the incident was reported to EMA in line with regulatory requirements.

China: Tangshan Jidong’s net profit in the first half of 2020 was US$140m, down by 33% year-on-year from US$210m to US$246m. Cement sales fell by 14% to US$1.58bn from US$1.83bn, while clinker sales fell by 11% to US$218m from US$246m. The Hebei Province-based group attributed the sales fall to the effects of the coronavirus lockdown in early 2020.

Philippines: LafargeHolcim subsidiary Holcim Philippines says that it has partnered with digital news platform providers Pinoy Builders. The commercial partnership involves Holcim Philippines providing Pinoy Builders with its cement, concrete and health and safety expertise.

Marketing and innovation senior vice president Ram Maganti said, “The Philippines is a very digitally-savvy country and the majority of professionals in the Philippines' construction industry are millennials who are 'digital natives.' With its steadily-growing number of subscribers and followers, Pinoy Builders is helpful in our efforts in engaging and positively influencing the construction industry. We are excited in continuing to contribute to this platform to let Filipino building professionals know how our offerings and solutions can help them in their projects.”

Azerbaijan: Azerbaijan produced 1.56Mt of cement in the first half of 2020, representing a 2.7% year-on-year decline from 1.60Mt in the half of 2019. Concrete sales increased by 6.5% to 0.83Mt from 0.78Mt, while the total value of construction materials sales fell by 4.8% to US$251m from US$264m.