Displaying items by tag: Gas

Najmat Al Samawa Cement (NAS Cement) in Iraq announced this week that its second production line was successfully fired up on 13 May 2025. The new 5500t/day line was formally announced in May 2023. It joins the existing line at the site and should bring the plant’s total production capacity to around 3Mt/yr. The plant is a joint-venture between Pakistan-based Lucky Cement Limited and the Al Shumookh Company in Dubai and its representatives in Iraq.

Global Cement Magazine interviewed Intezar Ahmad, the Director of Operations at NAS Cement, in the November 2024 issue. He explained that China-based TCDRI was the main contractor for both the original and new lines. Equipment for Line 2 was also supplied by Fives Pillard, Loesche and IKN. Commissioning was scheduled for the second quarter of 2025. This, nicely, appears to be spot on. Lucky Cement added in its statement about the new line this week that it is also building a new 0.65Mt/yr cement grinding mill at the plant. This addition is expected to be commissioned during the second half of the 2025 calendar year. Lucky Cement also operates a cement grinding plant, under a joint-venture, in Basra.

The expansion at NAS Cement is by no means the only one as there have been a number of project announcements over the last three months. Germany-based Gebr. Pfeiffer revealed in late-March 2025 that it had won an order to supply a vertical roller mill for the Al Amir cement plant in Najaf. This contract was awarded through the China-based contractor Sinoma Suzhou. Commissioning is planned for the second half of 2026. Then, one month later in April 2025, Prime Minister Mohammed Shia Al-Sudani made a statement launching ‘implementation works’ at four cement plants in Al-Muthanna Province. This included the 6000t/day Al-Arabi Cement Plant, the 6000t/day Al-Khairat Al-Muthanna Cement Plant, the 6600t/day Al-Samawa Cement Plant and the 6000t/day Al-Etihad Cement Plant. Al-Sudani also mentioned the start of commercial operations at NAS Cement’s second line. Subsequently, IVI Holding signed a US$240m deal with Sinoma Overseas in mid-May 2025 to build a 6000t/day plant in Al-Muthanna Province. Presumably, this is one of the projects that the government highlighted. Finally, the Kurdistan Region prime minister Masrour Barzani inaugurated the 6300t/day Dabin cement plant at around the same time. This last project was built by PowerChina together with a power station.

The Iraqi economy has been doing well in recent years. The International Monetary Fund (IMF) reported in May 2025 that the non-oil sector experienced “very strong growth” of 13.8% in 2023. This slowed down to 2.5% in 2024 due to a slowdown in public investment and in the services sector, and a weaker trade balance. However, the IMF noted that the agriculture, manufacturing, and construction sectors had remained resilient. Non-oil sector growth is forecast to remain subdued in 2025 amid a “...challenging global environment and financing constraints.” In its coverage of the new line at NAS Cement, Pakistan Today reported that the country has a notional cement production capacity of around 40Mt/yr but that many of the older plants have suffered from under-investment. Accordingly, the domestic market is around 25Mt/yr supported by state-funded housing projects, oil-field infrastructure schemes and reconstruction in Mosul. 3 - 4Mt of this is supplied via imports from Iran and Türkiye. The newspaper also noted the risk that all these new cement plant projects may face from variable gas supplies from the government. NAS Cement, for example, switched from heavy fuel oil (HFO) to gas in 2022.

Cement sector capacity expansion is coming in Iraq following a revived local economy. Risks abound though due to the country’s economic outlook, its dependence on oil and an geopolitical uncertainty. Yet money is being spent and new projects are starting to be commissioned. Onwards!

Bangladesh: Chhatak Cement’s plant in Sunamganj remains idle despite construction completing in March 2023, with production suspended due to unresolved gas and limestone supply issues, according to the Prothom Alo newspaper. The plant project began in 2016. New details confirm that the Bangladesh government has approved subcontracting of a cross-border ropeway to import limestone from India. Local firm Komorah Limestone Mining Company (KLMC), which already supplies limestone to Chhatak Cement, is in talks regarding the role. China-based contractor for the project, Nanjing Sea-Hope Cement Engineering, has agreed ‘in principle’ to this handover as of 18 March 2025, according to Chhatak Cement managing director Abdur Rahman.

Project officials stated that, once the new plant begins operations, it will be capable of producing 1500t/day of clinker and 500t/day of cement, triple its previous capacity. Reporters conducted a site visit on 8 April 2025, observing that a jetty had been constructed on the riverbank to unload clinker from the plant for grinding elsewhere. A conveyor system has been set up to move cement bags directly from the plant to transport, and a new conveyor belt has also been installed alongside the existing belt.

Bangladesh: Chhatak Cement Factory has ceased production due to severe gas and limestone shortages, despite a modernisation project having reached 91% completion.

The Bangladesh Chemical Industries Corporation (BCIC) began a US$54.7m project to convert the plant’s production process from wet to dry in 2016, in order to increase capacity to 1500t/day (0.45Mt/yr). The project cost rose to US$116m, with US$68m spent by November 2024. However, the plant remains idle despite the completion of construction works over a year ago, due to the lack of a new gas pipeline and ropeway to import limestone from India. This ropeway was supposed to transport limestone from the Komorrah Limestone Mining Company in Meghalaya.

The project's committee has proposed extending the deadline to June 2026 and allocating an additional US$25m for a 43km gas pipeline from Sylhet to Chhatak. Trial runs are now being conducted every 15 days in order to prevent the plant’s machinery from rusting.

Project director Abdur Rahman Badsha said that the Chinese contractor responsible for the ropeway construction, Nanjing C-Hope Cement Engineering Group, is awaiting a subcontracting agreement with KLMC to begin work in India.

Alpacem said this week that it had completed its acquisition of the Fanna cement plant near Pordenone. The 0.66Mt/yr integrated plant and a number of ready-mixed concrete plants became part of the Austria-headquartered group at the start of February 2025. Alpacem now has three integrated plants, with units at Wietersdorf in Austria and Anhovo in Slovenia, in addition to Fanna.

The deal dates back to mid-2023 when Alpacem said it had signed an agreement with Buzzi. In return Buzzi was set to receive a 25% stake in Alpacem Zement Austria. Prior to this the two companies had a strategic partnership in Austria and Slovenia that dated back to 2014. At the time of the agreement Buzzi held a 25% share in each of two Alpacem subsidiaries: Salonit Anhovo in Slovenia; and W&P Cementi in Italy. The Fanna plant was originally owned by Cementizillo before it was bought by Buzzi in 2018.

Also this week, Federbeton warned that the high cost of gas would add €80m/yr to the cost of cement production. Nicola Zampella, General Manager of Federbeton and the cement association AITEC, noted that local energy costs would reduce the competitiveness of producers against imports from outside of the European Union (EU). This ties into comments Stefano Gallini, the president of Federbeton, made in December 2024 when he highlighted the growing share of imports from outside the EU.

Federbeton raised the issue in its annual report for 2023, showing that imports rose to a 19% production share in 2023. Italy produced 18.8Mt of and imported 3.6Mt of cement and clinker in 2023. This is its highest level of imports for at least a decade. Over the same period the country’s cement exports, as a share of production, have remained steady at around 10 - 11%. In 2023 Türkiye was the biggest source of imports (25%) followed by Greece (17%), Slovenia (17%), Tunisia (12%) and Algeria (10%).

Graph 1: Cement production, imports and exports in Italy, 2019 - 2023. Source: Federbeton.

It is worth recalling that the cement sector in Italy used to be larger before it started consolidating in the late 2000s. Italcementi was acquired by Germany-based Heidelberg Materials. Operations by Sacci, Cementir and Cemenzillo were all bought out too. Local cement production reached a high of 47.9Mt in 2006 before it stabilised at around 20Mt/yr from 2015 onwards.

In its preliminary results for 2024, out this week too, Buzzi reported that the construction market In Italy probably shrank in 2024 due to a poor residential housing market. However, the cement company managed to keep its local net sales stable by raising prices and focusing on exports. Despite this, it noted a drop in cement and concrete sales volumes at the end of 2024. More data on the construction market in Italy may emerge when Heidelberg Materials releases its 2024 financial results at the end of February 2025.

The backdrop to this has been a rise in gas prices in Europe towards the end of 2024 as the EU ‘emergency’ price cap finished on 31 January 2025. Around the same time the EU is preparing to reveal information on its Clean Industry Deal towards the end of February 2025. Plus, the first active phase of EU Carbon Border Adjustment Mechanism (CBAM) is preparing to enter into force from the start of 2026. Each of these issues has implications for the cement sector in Italy as the location associations have been highlighting. One question will be whether the Clean Industry Deal can help producers cope with mounting energy prices. Another will be whether CBAM will change the proportion of imports for countries like Italy or will the sources of the imports simply change. Plenty to consider for the year ahead.

Italy: Federbeton, the Italian cement association, has expressed alarm that the high price of gas is adding €80m/yr to the cost of cement production. Nicola Zampella, the general manager of Federbeton, called for an ‘urgent’ change to the national energy system to make it more equitable, sustainable and competitive, according to Adnkronos. He recommended energy diversification, further encouraging the use of alternative fuels, simplifying regulations, making investing and supporting sustainable technologies easier and adding incentives to use carbon capture and storage.

Moldova: The Rybnitsa cement plant has closed amid a cutoff of gas supply to the Transnistrian region, leaving half of its 650 employees at home with 66% of their pay, while the rest carry out equipment repairs and cleaning, according to IPN news.

Interim director Oksana Baka said “The plant had a plan to produce about 30,000t of cement during this period. This stock would have ensured our protection on the market, but now the situation is critical because our supplies are insufficient.” Contributions to the local budget will decrease if gas supplies are not restored by February 2025.

The plant is modernising its dust filtration system and preparing for resumption once gas supplies are restored. On 1 January 2025, Gazprom stopped supplying gas to the Transnistrian region, after gas transit through Ukraine ended. The region remains under a state of emergency until 8 February 2025.

Iran: Ali Akbar Alvandian, the Secretary of the Cement Industry Employers' Association, says that cement plants have been forced to cut production due to a shortage of gas. He said that plants near cities had been forced to halve production, according to comments made to the ILNA news agency. Plants in the countryside, however, have been able to cope better by using mazut heavy fuel oil. In addition cement companies were also negatively affected by electricity rationing over the summer. At its peak, in August 2024, 70% of kilns were closed.

Despite these issues there have been no significant changes in the price of cement due to the country’s use of commodity exchanges. However, exports have decreased by 17% year-on-year in the first seven months of the year. Most of the country’s clinker is exported to Iraq, Kuwait and India. The main destinations for cement include Afghanistan, Russia, Kuwait, Armenia, Turkmenistan and Pakistan.

Nigeria: Finland-based Wärtsilä has signed a 10-year operations and maintenance (O&M) agreement for a captive power plant that provides the energy for Mangal Industries’ cement plant located in Kogi State. The cement plant has limited access to the local electricity grid and its power plant operates with five Wärtsilä 34DF dual-fuel engines delivering an output of 50MW. The O&M agreement is designed to ensure that the facility can reliably maintain its cement production target of 3Mt/yr.

The 10-year agreement starts immediately as the unit commences operations in the second quarter of 2024. It will run on liquid fuel initially but then switch to gas operation when a natural gas pipeline is commissioned. The power plant’s dual-fuel engines can be operated both on liquid fuel and natural gas. They could also be potentially converted to operate with low- or zero-carbon fuels in the future subject to availability.

Patrick Borstner, Director, Operations Africa at Wärtsilä Energy said, “Wärtsilä now has more than 400MW of installed capacity for the cement industry in Nigeria, and we are operating three captive power plants in three different states. This successful track record clearly indicates our capabilities and highlights the added value we can deliver to our customers through our experience and expertise in supporting their operations.”

Mangal Industries signed a contract with China-based Sinoma International Engineering in 2021 for the construction of a 3Mt/yr new integrated cement plant. Construction at the site commenced in mid-2022.

Uzbekistan: Investigative reporting by Radio Free Europe/Radio Liberty (RFE/RL) has found evidence of a company linked to President Shavkat Mirziyoyev's son-in-law carrying out ‘secret state contracts.’ These included a US$36m ‘overpriced’ natural gas supply contract for Qizilqumsement. The company, Ultimo Group, is reportedly without website or public profile and co-owned by a retiree with no business background. RFE/RL described its network of associated international companies as ‘Byzantine.’

US: Furno Materials completed an oversubscribed US$6.5m seed funding round on 13 March 2023. Subsequently, the start-up unveiled plans for its Furno Brick carbon-neutral modular cement plant, which can use a variety of gaseous fuels. The plant scales on demand, drastically reducing the barrier to entry for local or small-scale cement production.

Furno CEO Gurinder Nagra said “At Furno, we have the ability to produce ordinary Portland cement now, to adapt to a range of gas-based fuels and materials innovations as they emerge and to meet demand where it exists, while still abiding by a shifting regulatory landscape. Our mission is to go the distance by innovating at the heart of cement production and operating as a complement to other technological developments in the cement space. Our cement far exceeds ASTM International standards, a bare-minimum quality threshold. While most companies tout meeting these standards and stop there, we have continued to refine our process and are on target to surpass the even higher commercial requirements set by significantly-sized customers eager for our solution.”