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International tensions reached a new high this week with Russia’s formal recognition of the breakaway Donetsk and Lugansk regions in eastern Ukraine and its decision to deploy troops accordingly. However, what of the local cement industry in Ukraine going into the current crisis?

Ukrcement, the Ukrainian Cement Association, says that its members reported a record 11Mt of cement production in 2021. Clinker production totalled 8.11Mt during the same period. The cement figure is close to Ukrcement’s forecast in the autumn of 2021 of 11.5Mt, a rise of 17% year-on-year from 9Mt in 2020. At that time association head Pavlo Kachur added that the local cement industry operated at 66% capacity utilisation in the first nine months of 2021.

The big industry story locally was the start of tariffs on cement imports from Turkey that was announced in September 2021. After much complaining by local producers and an investigation the year before in 2020 the Interdepartmental Commission on International Trade (ICIT) introduced anti-dumping duties of 33 - 51% on cement imports from Turkey for five years. Other than this the usual energy preoccupations have been present in Ukraine. In an interview with Interfax in November 2021, Pavlo Kachur expressed alarm that the price of coal had tripled from the start of 2021 to August 2021. At the same time he explained that the biggest driver of cement consumption was infrastructure projects.

CRH, the largest producer locally, rebranded its subsidiary as Cemark in November 2021 with the intention to start shipping cement bags with the new marking from January 2022. It operates three integrated plants at Mykolaiv, Podilsky and Odessa. It reported that its local operating profit grew year-on-year in 2020, despite a “challenging pricing environment” as cost savings initiatives and lower fuel and logistics costs resulted in improved performance. In September 2021 CRH said that sales were up due to growing cement sales volumes resulting from market demand. Although once again it complained about competitive pricing forcing it to lower its prices. Despite this though lower maintenance costs and cost controls had boosted its operating profit.

Buzzi Unicem runs two integrated cement plants in Ukraine, Volyn and Yugcement, as well as terminals at Kiev and Odessa through its Dyckerhoff Ukraine subsidiary. In 2021 it noted recovery in the construction sector, helped by government stimulus and the introduction of tariffs on imports from Turkey. It said that prices fell in the first half of the year before recovering in the second half. Ready-mixed concrete output showed more growth. Dyckerhoff Ukraine’s net sales rose by 9.4% year-on-year to Euro127m in 2021 even despite negative currency exchange effects.

As for the other producers, NEQSOL Holding Ukraine filed an application to the Antimonopoly Committee of Ukraine (AMCU) in October 2021 to acquire a stake in Ivano-Frankivskcement. Azerbaijan-based NEQSOL Holding also operates the Norm Cement plant near Baku in Azerbaijan. HeidelbergCement used to operate in Ukraine, including the Amvrosiyivka Plant in the contested part of Donetsk region, but it sold up in 2019 to local investors. Its two former integrated plants now operate under the Kryvyi Rig Cement brand. Finally, Russia-based Eurocement runs two plants in Ukraine, at Balakleya in Kharkiv region and Kramatorsk in Donetsk region, under its Balcem subsidiary, which formed in 2019. However the status of the second plant is currently uncertain. Balcem said that the Balakleya plant resumed full cycle production in March 2021 when it restarted kiln two. Kiln one was restarted in June 2021 after a down period since 2008. The plant currently has a production capacity of around 1Mt/yr.

Ukrcement’s Pavlo Kachur said that the cement market in Ukraine was experiencing a positive period in November 2021. Whether this continues is very much in the balance given events in the east of the country. The wider implications for cement producers in the rest of Europe and Russia are the fallout from the economic warfare between both sides. A number of countries have started to react to Russia’s actions with the US, European Union, UK, Japan and Australia announcing economic sanctions and Germany halting approval of the Nord Stream 2 gas pipeline. However, Russia supplies a significant share of Europe’s gas supply. All of this could disrupt energy supplies and force input costs up. This has already been reflected in higher oil prices.

Meanwhile, one aspect of the current situation to watch is how multinational cement producers with a presence in Russia will cope. Moving money in or out of the country is likely to become harder. HeidelbergCement told Reuters this week that it did not expect any major impact on its Russian operations, even if the conflict escalated. Its three cement plants supply local markets and do not export outside of Russia, it added. Other companies straddling the potential sanctions divide include Holcim, Buzzi Unicem and Eurocement.

The crisis continues.

China: Nanjing Kisen International Engineering has secured a collaboration agreement with Canada-based Delta CleanTech for the implementation of the latter’s carbon capture and storage (CCS) systems at two China National Building Material (CNBM) cement plants. SCMP News has reported that there is a one-time licencing fee - which is not paid by Nanjing Kisen International Engineering but is traditionally paid by the CO₂ capture plant customer - of 4.5 - 5% of capital costs. Installations cost upward of US$40m, depending on capacity.

There are currently 40 operational or upcoming CCS installations nationally with a total capture capacity of 3Mt/yr, chiefly in the oil, coal chemicals and energy sectors.The Chinese Academy of Environmental Planning has forecast that China’s cement industry CCS demand will reach 200Mt/yr by 2060. Delta CleanTech president Jeff Allison said that current challenges for Chinese cement producers seeking to reduce their CO₂ emissions include difficulties disposing of captured CO₂ and a lack of rewards and penalties around emissions control beyond the basic national efficiency requirements.

Nanjing Kisen International Engineering previously launched its first 155kg/day pilot CCS study in partnership with the Canada-based International CCS Knowledge Centre in July 2021.

Mexico: The Mexican Chamber of the Construction Industry (CMIC) has voiced cement price concerns following the introduction of a new environmental tax on mining activity in the state of Nuevo León. Cemex operates a quarry in the state, and has resultingly experienced a rise in the cost of its cement production. The El Norte newspaper has reported that the producer’s Monterrey, Nuevo León, cement plant supplies cement across northeastern Mexico.

CMIC also lobbied the government to begin awarding public works contracts to private investors instead of the Mexican armed forces. It argued that this would help to generate jobs.

Mexico: 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.

Peru: The Ministry of Labour and Employment Promotion has initiated talks with cement producers, exporters and unions with a view to changing the standard national cement bag weight. The ministry recognised the 42.5kg/bag standard as a historical anachronism and unsafe. The Federation of Civil Construction Workers (FTCCP) has reported lower back injury as the main cause of ‘desertion of construction site.’ Beside the risk of injury, the standard has allegedly contributed to discrimination against older builders, because site managers often consider even those well below the state early retirement age of 55 to beunfit. The union has argued that 25kg bags would reduce the risk of harm to quality of life to 15%, while 15kg bags would entail a risk of just 5%.

Standards authority Produce will now hold a round table with stakeholders to review the possibility of a 41% weight reduction to the international standard of 25kg. Federation of Cement and Ready-Mix Workers of Peru (FETRACEPPE) general secretary Luis Gilvonio said that this will not solve problems overnight: where firms start instructing workers to carry two bags at a time, their net load will have increased. As such, he argued for continued awareness-raising alongside the law change.

Bagged cement accounted for 70% of Peruvian producers’ cement sales in 2021.

Canada: Lafarge Canada is supplying its ECOPact reduced-CO₂ concrete to contractor PCL for its construction of the upcoming Genesee power plant in Alberta.

Lafarge North America president and general manager Prez Skiba said "The original concrete proposed was already a low carbon design, but we knew we could take it further. We brought in further emissions reductions with our ECOPact design, and we were able to reduce embodied CO₂ by an additional 20%. That's 20% over and above the original design, which already offered a 20% reduction. The combined 36% CO₂ reduction is equivalent to the energy used by 70 houses in a year."

France: Hoffmann Green Cement Technologies has signed a 25-year occupation permit in the port of La Rochelle. The agreement will allow the company to build storage silos at the port near to its Bournezeau plant. Construction of the first two 3500t silos will begin in mid-2022 and are expected to be completed in the spring of 2023. The company intends to build a further two silos subsequently. The project investment is around Euro10m.

The cement producer says it met its target and sold 10,000t of cement in 2021. Sales were mainly of its H-UKR blast-furnace slag product.

Algeria: Lafarge Algeria says it exported 2.6Mt of cement in 2021, more than double the 1.18Mt it exported in 2020. It aims to export over 3Mt in 2022. The subsidiary of Holcim also announced that it will carry out two new large simultaneous shipments from the port of Oran, one of 35,000t of cement in bulk, and the other of 30,000t of white cement in big bags. Both shipments will be exported to the Americas.

Kazakhstan: A new 0.58Mt/yr cement plant is being considered in West Kazakhstan Province. The project has an estimated investment value of US$170m, according to local government and Kazakhstan Newsline. Negotiations are underway with foreign investors. The plant has been included in plans to develop the region. It is expected to create 60 jobs.

Bangladesh: Seven Rings Cement has signed an agreement to supply cement to Soyo BD International. The China-based ready-mixed concrete supplier has recently started business in Bangladesh and is supplying different projects locally, according to the Daily Star newspaper.