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Congratulations to Lafarge France for launching the first calcined clay cement unit in Europe. The subsidiary of Holcim says that the unit, based at the integrated Saint-Pierre-la-Cour cement plant, is the first of its kind on the continent. It is using the company’s proprietary proximA Tech technology and will produce up to 500,000t/yr of cement in its ECOPlanet range. The operation is also powered with biomass alternative fuels and uses a waste recovery system to further drive down overall CO₂ emissions. Once production ramps-up the producer expects that 30% of cement from the Saint-Pierre-la-Cour plant will be from the ECOPlanet range by 2024.

The investment at Saint-Pierre-la-Cour was Euro40m. Holcim is also producing calcined clay cement at its La Malle plant in France. It received an investment of Euro6m in 2022 to produce low-carbon cements. Together, both plants are aiming to produce over 2Mt/yr of calcined clay cement by 2024. As is usual for these kinds of projects, the French government partly funded the clay calcination unit at Saint-Pierre-la-Cour as part of the ‘France Relance’ scheme investing in large-scale decarbonisation and energy efficiency initiatives.

Calcined clay cements in Europe aren’t exactly new, but Holcim’s new unit in France does appear to be the first full-scale line located at a cement plant. Research by OneStone Consulting, for example, reckons that the first flash activated clay unit expressly set up to supply the cement sector was commissioned in 1995 in Toulouse, France. More recently, Hoffmann Green Cement inaugurated its 50,000t/yr pilot plant at Bournezeau in France in 2018. This site produces cements made from flash calcined clay and blast furnace slag, although it is unclear how demand for the different products varies. A new 0.25Mt/yr plant in the Vendée department was scheduled for commissioning in the second half of 2022. Another 0.25Mt/yr plant in Dunkirk is expected to be commissioned in the second half of 2024.

Cementir Group launched its calcined clay cement product FUTURECEM in Denmark in 2021 with production via a pilot plant. It then extended this to the Benelux and French cement markets in 2022. As part of its industrial plan for 2021 - 2023 it was planning to build a clay calcination unit to support the growth of FutureCem. FLSmidth revealed in June 2021 that it had won a contract to build a 400t/day clay calcination unit for Vicat’s Xeuilley integrated cement plant. The deal was worth around Euro27m and commissioning is scheduled for 2023.

Firstly, it is interesting to see a focus on France for some of the projects above. The presence of Lafarge’s technical centre in Lyon may explain the interest for that company. However, Hoffmann Green Cement and Vicat are also active in the field. It is worth noting that France also holds a busy secondary cementitious material market with standalone operators including Ecocem, Cem’In’Eu and Hoffmann Green Cement. Secondly, despite the early start, clay calcination for cement is currently more active outside of Europe. In Africa, for example, there is at least one live full production line and a number of other projects on the way. Various other pilots and projects are also happening elsewhere around the world, often in conjunction with the limestone calcined clay cement (LC3) initiative. Where calcined clay cement production in Europe goes from here is uncertain at present as it is one solution among many for lower carbon cement products in the future. Yet, the projects that have made it so far to the commercial scale will be watched closely by the companies that have invested in them - and their competitors.

UK: Neville Roberts, a former Technical Director of Cemex UK, has died on 10 February 2023, at the age of 66. He was a notable figure in the alternative fuels sector for the cement industry.

Neville attended Holyhead County School 1969 - 1975, taking Maths, Physics and Chemistry 'A' Levels, as well as representing the school in rugby, football and athletics. Roberts trained as a chemical engineer at Loughborough University and had worked in the cement industry for over 35 years. During his career he started as a process engineer, became a plant manager at a number of cement plants around the world including Chelm, Poland, and was appointed to five director roles for three cement companies. The companies he worked for included Rugby Cement, Castle Cement, RMC, Cemex and Saudi Cement Company. His later roles for Cemex included UK Technical Director (2004 - 12) and Energy Business Development Director (2012 - 13). He worked in the UK, Poland and Saudi Arabia. After leaving Cemex, Roberts set up his own consultancy and later became the managing director for the UK of Netherlands-based N+P Alternative Fuels.

He was a passionate supporter of all things Welsh, especially rugby, and was awarded the Global CemFuels ‘Personality of the Year’ award in 2013. Neville was husband to Patricia, father to Katie and Holly and grandad to Martha, Edie and Albee. He was known to his grandkids as 'Wowo.' Neville Roberts was great company, mentored and influenced many colleagues around the world and will be sorely missed.

Germany: Aumund Group has reported that its chair Franz-Walter Aumund died on 4 February 2023. He was 78 years old. He was the third generation of the Aumund family to run the company after his grandfather Heinrich Aumund founded Aumund Patente in 1922.

A farewell ceremony will be held at Aumund Group’s headquarters in Rheinberg, North Rhine-Westphalia, on 14 February 2023.

India: Grasim Industries, a subsidiary of Aditya Birla Group, has posted a 44% year-on-year rise in its consolidated net profit to US$303m for the third quarter of the 2023 Indian fiscal year, a period that ended on 31 December 2022.

During the quarter under review, the company’s consolidated revenue rose by 17% to US$3.45bn. Grasim Industries said that the growth in revenue was driven by strong performances by its subsidiaries UltraTech Cement and Aditya Birla Capital. UltraTech Cement’s sales for the quarter rise by 12% year-on-year to 26Mt. This led to an increase in capacity utilisation rate from 75% to 83%.

France: Vicat’s full year results for 2022 show a 16.6% year-on-year rise in consolidated sales, from Euro3.12bn to Euro3.12bn. Its earnings before interest, tax, depreciation and amortisation (EBIDTA) came to Euro570m, a 7.9% fall compared to Euro619m in 2021. Its net income for 2022 was Euro156m, a fall of 23.6% year-on-year from Euro204m in 2021.

Commenting on these figures, Guy Sidos, the Group’s chair and chief executive officer, said “In 2022, the Vicat Group demonstrated resilience amid tough conditions. Faced with an unfavourable basis of comparison as a result of the sharp post-Covid rebound in business trends during 2021, a very strong increase in energy costs and non-recurring industrial costs in the US, France and India, we responded rapidly, raising our selling prices significantly across almost all the markets in which we operate to offset the impact of inflation. We have made progress with our policy of lowering our greenhouse gas emissions by harnessing existing solutions and investing in technologies that will enable us to reach our new 2030 targets.”

Australia: Rampant inflation, restructuring costs and a softening US housing market have been blamed for a third earnings downgrade at building materials group James Hardie. The company’s new chief executive officer Aaron Erter has also warned of ongoing challenges for the business in Australia, where the housing boom is grinding to a halt in the face of surging interest rates and the end of the federal government’s HomeBuilder stimulus.

James Hardie reported an adjusted net income of US$129.2m in the three months to December 2022, down by 16% year-on-year from the same quarter of 2021. Global net sales of its fibre cement and cladding products were down 4% during the quarter, at US$860.8m, driven down by falling sales volumes in its largest market in the US, as well as in Europe and the Asia-Pacific region.

More widely, price increases partially offset an 11% decline in global sales volumes across James Hardie’s entire range of business lines. The challenging conditions led to full-year earnings guidance for the 12 months to 31 March 2023 being cut for a third time, to US$600 - 620m, in line with the prior fiscal year.

Peru: Cementos Pacasmayo’s revenue rose by 1.7% year-on-year in the fourth quarter of 2022, mainly on the back of higher bagged cement sales prices, although inflation affected raw material and energy costs. However, its sales volume of cement, ready-mix concrete and pre-cast elements fell by 7.7% partly due to high sales in the comparable quarter of 2021, although road blockages as part of political disruption in December 2022 also reduced sales. Its net profit for the quarter was US$10.1m, a 24.6% rise.

Across the whole of 2022, the company’s revenues were up by 9.2% year-on-year, while sales of cement, concrete and pre-cast elements rose by 5.3%. Consolidated earnings before interest, tax, depreciation and amortisation (EBITDA) rose by 8.8% to US$128m, mainly due to performances in the first nine months of the year. It made a net profit of US$45.8m, an increase of 15.4%.

India: Adani Group is in talks with lenders to repay a US$500m bridging loan facility it used to buy controlling stakes in ACC and Ambuja Cements in 2022. Adani is looking to repay the loan with cash during February 2023, according to the Economic Times. The loan was underwritten by Barclays, Deutsche Bank and Standard Chartered. The financial consortium lending to Adani also includes DBS, MUFG, Sumitomo Mitsui Banking Corp, First Abu Dhabi Bank, Intesa and Mizuho.

The Economic Times’ report comes a day after the group said its companies face no material refinancing risk or near-term liquidity issues, in its latest attempt to calm investors spooked by Hindenburg Research’s critical report on its business practices.

Pakistan: Balochistan's local government minister has called for the cancellation of the allotment of a large area of land to a cement plant in Hub, adding that he would take the matter to court. Mohammad Saleh Bhootani said the Mines and Minerals Development Department had allotted 18,200 hectares of land that he says belonged to the people of Hub and Lasbela districts.

The allotted land comprises mountains, agriculture lands, hundreds of villages, farms and graveyards, he said, arguing that there was no justification for allotting such a vast area to a cement plant. Bhootani warned locals that fences would soon be erected around the site, forcing those that live there out of their homes. He urged Chief Minister Abdul Qudoos Bizenjo to “show mercy on the poor people of the area and cancel the allotment.” The minister said that if the allotment was not cancelled, he and the people of the area would take legal action.

The parliamentary leader of the Balochistan National Party-Mengal, Naseer Ahmed Shahwani, condemned the allotment and demanded the government withdraw its decision. 'If such practices continue, what will be the future of Balochistan?' he wondered.

Kenya: Holcim has announced the successful completion of the largest 3D-printed affordable housing to date through 14Trees, its joint venture with British International Investment, the UK’s Development Finance Institution (DFI) and impact investor. The 3D printing of the 10 housing units in Kenya’s Mvule Gardens project was made possible with TectorPrint, Holcim’s 3D printing ink product, produced in Kenya for the first time. The project’s advanced sustainability profile has attained an EDGE Advanced sustainable design certification by IFC, the World Bank's development finance institution, which recognises resource-efficient buildings with the potential to be zero-carbon. It is the first time a 3D-printed housing project has attained this certification.

François Perrot, managing director of 14Trees, said “With 3D printing, you can solve two problems at once. You can build faster and with better cost efficiency, which will help make affordable housing a reality for the majority. In addition, you can build with less materials, which preserves the resources of the planet for future generations.”

Miljan Gutovic, Region Head for Europe at Holcim, added “I am very proud of the work done by 14Trees in Africa, where their innovations in 3D printing technology are accelerating affordable and sustainable building. I look forward to 14Trees replicating these successes in Europe and other parts of Africa in the very near future.”