Displaying items by tag: Heidelberg Materials

Germany: Heidelberg Materials has begun work on the GeZero project at its Milke plant in Geseke. The €500 million project will implement carbon capture and storage (CCS) technology to prevent the release of CO₂, instead capturing and storing it under the North Sea. According to the Westfälische Rundschau, the project has secured €191m in funding from the EU, with Heidelberg Materials covering the remaining amount. The company anticipates completing the plant conversion by 2029, with interim CO₂ transport via rail and potential future pipeline connections. According to the company, around 700,000t/yr of CO₂ is currently produced by the plant.

There had been potential changes in project partnerships due to the sale of BASF subsidiary Wintershall Dea, which was to provide the transport and storage solutions, to Harbour Energy. However, plant manager Steffen Gajewski expects that planning for the conversion of the plant will be completed in 2025, when the new oxyfuel kilns to capture the CO₂ will be ordered and installed.

Heidelberg Materials announced this week that it is preparing to close its integrated cement plants at Beffes and Villiers-au-Bouin in France by October 2025. It framed the restructuring as a response to ‘a significant decline in cement sales in France’ and a plan to focus on low-carbon products. Unfortunately, local media reported that around 170 jobs will be lost at the two sites. The company says it is looking at ‘socially acceptable solutions’ including redeployment to other locations in the country.

Investment has been forthcoming from Heidelberg Materials France in recent years. It reminded everyone that it initiated a Euro400m scheme at its France-based subsidiary Ciments Calcia in late 2020. Most of this was earmarked towards a new production line at the Airvault plant, which is currently being built. Other schemes at the Beaucaire, Bussac-Forêt and Couvrot integrated plants followed. More recently, Heidelberg Materials launched a carbon capture, utilisation and storage (CCUS) project at Airvault, part of the GOCO2 initiative, with the aim of starting initial capture in 2030 with full 1Mt/yr capture planned later. What the company didn’t mention though was at the time of that 2020 investment it was also preparing to convert the integrated Gargenville plant into a grinding unit, stop white cement production at its Cruas plant with the intention of turning the site into a terminal and it wanted to reduce its workforce by around 140. To be fair to Heidelberg Materials though, it did have the same goal of reducing its specific net CO₂ emissions. The added detail this week was that the group aims to generate half of its revenue from sustainable products that are either low-carbon or circular by 2030.

Heidelberg Materials France is not alone with its ambitions for low-carbon products. Holcim notably opened in early 2023 what it said was the first calcined clay unit in Europe at its Saint-Pierre-la-Cour cement plant. Heidelberg Materials then followed in May 2023 with the announcement of a calcined clay project at its Bussac-Forêt cement plant. Other clay projects from Vicat, NeoCem and Neo-Eco have been reported since then. The other prominent France-based blended cement producer that has steadily been building its business in recent years is Hoffmann Green Cement. More general plant upgrade projects that are also worth mentioning include Eqiom’s (CRH) upgrade to its Lumbres plant in February 2024 and the ignition of a new kiln at Lafarge France’s Martres-Tolosane plant in October 2023. Both of these projects have been framed as driving sustainability.

Graph 1: Cement production in France, 2014 - 2022. Source: France Ciment.

Heidelberg Materials’ assessment about the poor state of the cement market has been confirmed by local media. Sales reportedly started falling in 2022, were down by 6% year-on-year in 2023 and further downward pressure is expected in 2024. Production data shown in Graph 1 above released by France Ciment, the national cement association, doesn’t really show what has been happening with sales. Over the last 20 years production hit a high of around 22Mt in the mid-2000s before settling around 16 - 17Mt/yr from 2015 onwards. The more telling trend, perhaps, has been the increase in CEM II blended cements from 50% in 2012 to 64% in 2022. Cement production may have stayed roughly the same over the last decade but it is using less clinker than it used to. Hence the pressure on companies like Ciments Calcia to reduce clinker capacity.

A further cost pressure facing cement producers in France is the impending end to the price cap on electricity scheduled by the end of 2025. The government enacted the scheme in late 2021 at the end of the Covid-19 pandemic, but then carried on as energy prices spiked following the Russian invasion of Ukraine. France Ciment lobbied in August 2023 for further protection for the sector using the argument that decarbonisation was not possible without electricity available for a reasonable price. It added that decarbonising the cement sector in France with carbon capture would cost around Euro3.5bn. Electricity prices started rising in February 2024 as part of the government’s phase out of the scheme.

Finally, 17 people were arrested on 5 April 2024 in connection with a demonstration at Lafarge France’s Val-de-Reuil ready-mixed concrete plant in Eure. Environmental activists reportedly trespassed on the site, according to local press, causing an estimated Euro450,000 in damages with acts such as spraying foam into machinery, ripping up bags of cement, breaking windows and more. The activists presented their actions as a response to both the environmental impact of cement and concrete production and the ongoing legal allegations about Lafarge’s actions in Syria in the early 2010s. Lafarge France’s La Malle integrated plant was also similarly targeted in December 2022 when around 200 activists stormed the site and caused damage to machinery and property. Lafarge’s response at the time was to remark that there was a feeling of misunderstanding given that the La Malle plant was piloting various decarbonisation methods.
All of this presents a febrile picture of the cement sector in France. Sales are down, electricity costs are set to go up and producers are switching to low-carbon cement products. Alongside this they are also closing clinker production plants but are also investing in new decarbonisation projects. At the same time environmental protestors have also been targeting cement and concrete plants and Lafarge’s association with its former actions in Syria appear to have made it more of a target than the other manufacturers. It is unsurprising then that Holcim, the parent company of Lafarge France, has raised the risk of damage to the group’s reputation, with both the general public and investors, should it fail to meet its targets. Reaching net zero was never going to be easy but setting unrealistic targets is increasingly not an option.

France: Heidelberg Materials has announced plans to close two of its plants in France - Beffes and Villiers-au-Bouin - by October 2025. This move is part of the company's restructuring efforts aimed at accelerating its decarbonisation efforts and focusing more on low-carbon products.

The decision comes amid a decline in cement sales in France, attributed to weak demand in the construction sector. 170 employees are affected by the impending closures of these plants, according to the company.

These closures align with Heidelberg Materials' commitment to focus on lower carbon alternatives, enhance energy efficiency, increase the use of alternative fuels, and reduce the clinker content in its cement products in France.

UK: Over 450 people have signed a petition opposing plans to expand the quarry at Heidelberg Materials’ Ketton cement plant. The company has submitted a planning application for the extension to Rutland County Council, according to the Rutland Times newspaper. Residents including those at the nearby village of Empingham, cited negative effects upon air quality, lighting, noise, dust, sustainability, ecology and economic impacts in their criticism of the plans.

The US Department of Energy (DOE) announced a US$1.6bn investment in the cement sector this week. The funding was part of a total of US$6bn for 33 projects in over 20 states to decarbonise energy-intensive industries also including chemicals and refining, iron and steel, aluminium and metals, food and beverages, glass, process heat applications and pulp and paper. The DOE was keen to link the money to “the President’s Bipartisan Infrastructure Law and Inflation Reduction Act.” Politics is never far away it seems! The projects are part of the Industrial Demonstrations Program, managed by DOE’s Office of Clean Energy Demonstrations (OCED).

Table 1: Summary of US Department of Energy funding announced on March 2024 to decarbonise cement and concrete production

Table 1 above shows the main approaches each of the projects aim to use. The two most expensive ones involve carbon capture and sequestration (CCS) at Heidelberg Materials US’ Mitchell cement plant in Indiana and National Cement’s Lebec plant in California respectively. In a complimentary press release Chris Ward, the CEO of Heidelberg Materials North America, said “This substantial federal funding investment will help create the first full-scale deployment of carbon capture and storage on a cement plant in the US.” The proposed CCS unit at the plant will capture around 2Mt/yr of CO₂ from 2030. If Ward’s forecast is accurate (and no one beats them to it), then Heidelberg Materials will likely have set up the first full-scale CCS units at cement plants in both North America and Europe. This will be a significant achievement. The National Cement project, by contrast, is a mixed bag of approaches to decarbonising cement production that follows the multi-lever approach advocated for in many of the industry net-zero roadmaps. It intends to use agricultural by-products such as pistachio shells, as alternatives fuels to lower the fuel-based emissions, calcined clay to lower the clinker factor and CCS to capture the remaining 950,000t/yr of CO₂ emissions.

The other projects either involve using calcined clay or substituting limestone with calcium silicate. The Summit Materials proposal is noteworthy because it aims to build four clay calcination units in locations in Maryland, Georgia and Texas. None of these appear to be near Summit’s (or Cementos Argos’) cement plants. This suggests that the company may be intending to use calcined clay in ready-mixed concrete production. The Roanoke Cement Company calcined clay project will be baseEuropead at its cement plant in Troutville, Virginia.

The remaining two grant recipients, Brimstone and Sublime Systems, will both test the companies’ different methods of manufacturing cement by using calcium silicate instead of limestone. Brimstone’s method produces ordinary Portland cement (OPC) and supplementary cementitious materials (SCM). The company said in July 2023 that its OPC met the ASTM C150 standards. However, the company has released less information about its actual process. Sublime Systems’ uses an electrolysis approach to create its ASTM C1157-compliant cement. It calls this ‘ambient temperature electrochemical calcination.’

Investment on the same scale of the DOE has also been happening in Europe. In July 2023, for example, the European Commission announced an investment of Euro3.6bn in clean tech projects to be funded from the proceeds of the European Union emissions trading scheme (ETS). This was the third call for large-scale projects following previous announcements of recipients in 2021 and 2022. Euro1.6bn of the third call funding went towards cement and refining projects including five cement and lime projects in Belgium, Croatia, Germany and Greece. The money granted for each of these schemes was in the region of Euro115 - 235m.

Both the US and Europe are throwing serious finance at the cement industry to try and kickstart the various pathways towards net zero. They are also doing it in different ways, with the US aiming to boost its economy by onshoring sustainable industry, and Europe hoping to fund its approach via carbon taxation. Government-driven decarbonisation investment for cement in other large countries and regions around the world appears to be lagging behind the US and Europe but these may spring up as net zero targets are set, roadmaps drawn up and government policy formulated. These places could also benefit from watching what works and does not work elsewhere first. Back in the US and Europe the next tricky part of this process will be bridging the gap between government subsidy and commercial viability.

Germany: The Supervisory Board of Heidelberg Materials has extended the mandate of Dr Dominik von Achten as chair of the Managing Board for an additional three years, until 31 January 2028. Dr von Achten has been leading the company since February 2020 and according to Heidelberg Materials, he has been instrumental in its global growth and the digitalisation and decarbonisation of the building materials industry, complemented by strong financial performance.

Dr Bernd Scheifele, chair of the Supervisory Board said “With Dr von Achten, we have an experienced manager at the helm of the company who has excellently positioned Heidelberg Materials on a global scale and set the course for the future with great commitment.” He continued "We look forward to continuing the trustful work with him. We are convinced that he will keep driving the transformation into a sustainable and digital future with verve and continue to successfully lead the company in the coming years.”

Dr von Achten has been part of Heidelberg Materials' Managing Board since 2007, serving as deputy chair since 2015 and as chair since 2020.

Italy: Heidelberg Materials Italy, formerly Italcementi, has entered into a seven-year supply agreement with Ox2. Under the deal, Ox2 will sell up to 70% of the energy generated at the Stornarella wind farm in Foggia. The farm was developed in partnership with Nuveen Infrastructure.

The Stornarella wind farm will be constructed in 2024. Once operational, it will provide an average of 37 - 51GWh/yr of clean energy from 2025 to 2032. Nuveen Infrastructure has purchased the wind farm, which will feature six turbines with a total installed capacity of 27MW and an estimated output of 73GWh/yr.

Stefano Gallini, CEO of Heidelberg Materials Italy, said "Energy is a fundamental component of our industrial process and represents one of the main levers of decarbonisation for the entire cement sector. The electrical component can also contribute significantly to this purpose, and we have identified reliable partners like Ox2 and Nuveen to accompany us on this journey."

France: Heidelberg Materials France plans to install a 1Mt/yr carbon capture system at its Airvault cement plant in the New Aquitaine. The Airvault cement plant is undergoing an upgrade, including the replacement of two pre-existing semi-dry lines with a new dry line and pre-calciner. This will reduce the plant’s CO₂ emissions by 30% per tonne, reduce its energy consumption by 10% per tonne, reduce its clinker factor and raise its alternative fuel substitution rate to 90%. CO₂ capture is set to commence in 2030. The project is one of several, under the GOCO₂ carbon capture, storage and utilisation (CCUS) cluster, which also includes installations at Holcim France’s Saint-Pierre-La-Cour plant and Lhoist France’s Réty lime plant.

Chair Dominik von Achten said “We started an ambitious modernisation programme for our sites in France several years ago, with a planned investment of more than €400m. With the integration of AirvaultGOCO₂, we are now adding a cutting-edge project in the field of carbon capture to our previous efforts, which will enable a further, massive reduction of Heidelberg Materials’ carbon footprint in France.”

Chief sustainability officer Nicola Kimm added “Our approach in Airvault is a perfect example of Heidelberg Materials’ strategy to implement dedicated carbon reduction roadmaps. We are taking every possible step to reduce CO₂ emissions: Phasing out fossil fuels, reducing the clinker content of our cements, and improving energy efficiency. To mitigate the remaining residual emissions, we rely on CCUS – as part of an integrated scheme and with our strong partners in GOCO₂.”

UK: Heidelberg Materials' Ribblesdale cement works in Lancashire is participating in a pioneering study to assess the use of ammonia as a hydrogen source for fuelling cement kilns. This 12-month feasibility project, conducted in collaboration with engineering consultants Stopford and Cranfield University, has received funding from Innovate UK through its UK Research and Innovation fund.

The research aims to investigate ammonia as a potentially energy-dense, cost-effective hydrogen carrier for cement manufacturing and other industries. Building on Ribblesdale's successful demonstration of using hydrogen in a net-zero fuel mix for a cement kiln, the new project will focus on the most efficient methods for on-site 'cracking' of ammonia to release hydrogen as kiln fuel.

Marian Garfield, Sustainability Director at Heidelberg Materials UK, said “We have already proved the success of using hydrogen as part of a lower carbon fuel mix, but its storage and transportation are currently technically challenging and expensive. Ammonia could offer a more viable hydrogen source that enhances fuel usage and reduces CO₂ emissions. If successful, this project will pave the way for further investigations into the commercial viability of using ammonia as a hydrogen carrier for combustion in cement production and beyond.”

Cement producers appear to have doubled down on the lessons they learned in 2022 by seeking profits wherever they could in 2023, despite stagnant markets in certain key places. Even with sales volumes of cement going down for most of the multinational cement companies covered here, revenues and earnings rose through price rises or business realignment.

Heidelberg Materials can often be relied upon to sprinkle a bit less sugar on its financial commentary compared to some of its competitors. Thus it is always worth reflecting on what it says. In its view, “In 2023, high inflation rates across the globe, increased financing costs, and persistently high energy and raw material prices significantly impaired construction activity and thus demand for our building materials. The decline in demand in private residential construction, which was massive in some cases, could not be offset by a solid development in industrial commercial construction and infrastructure projects.” Other opinions are available.

Graph 1: Sales revenue from selected cement producers in 2022 and 2023. Source: Company reports. Note: Figures calculated for UltraTech Cement.

Heidelberg Materials is notably missing in Graph 2 (below), though as the company is likely to be holding back its cement sales volume numbers until it releases its full annual report for 2023 towards the end of March 2024. However, Holcim and Heidelberg Materials reached similar sales volumes of cement in 2022 and this looks likely to have continued in 2023, or even gone further. Holcim divested its India-based and Brazil-based operations in 2022 and Africa-based ones in South Africa, Tanzania and Uganda in 2023. Heidelberg Materials has also slimmed down, albeit at a slower pace, with the sale of its businesses in Southern Spain in 2022 and The Gambia in 2023. Note that CRH and Holcim have swapped places in terms of sales revenue from 2022 to 2023. 65% of CRH’s sales came from its Americas divisions.

The outlier here is UltraTech Cement. It increased its sales volumes as the India-based market continues to push forward. Dangote Cement, meanwhile, delivered a surprise with a fall in volumes, due to poor trading at home in Nigeria. Sales outside of Nigeria grew significantly though. A real key moment for the evolution of Dangote Cement as a multinational player will be when its sales, volumes and earnings outside of Nigeria surpass those from back home. It’s not there yet but it looks likely to happen in the next few years.

Graph 2: Cement sales volumes from selected cement producers in 2022 and 2023. Source: Company reports. Note: Figures calculated for CRH and UltraTech Cement.

The progress of the construction market in the US compared to elsewhere has wielded an outsized effect on balance sheets for companies. Signs of this have been apparent for several years but it really picked up in 2023 with CRH switching its primary listing to the US in September 2023 and then Holcim announcing that it is planning to spin-off its North American business (for more on this see GCW 645). Heidelberg Materials was asked during its analysts’ conference call for its 2023 financial results what its plans were for the US. Chair Dominik von Achten said he was against splitting the business off from the rest of the group but that all other options were on the table. Various media outlets have interpreted this to mean that an initial public offering in the US is a likely possibility.

What Cemex does with this situation, if anything, might be worth watching. The company is already North America-focused. Its key markets are in Mexico, the US and Europe, and it is already listed in Mexico and the US. Subsequently in 2023 the market in Mexico bounced back and operating earnings rose sharply in both Mexico and the US. Finally on this theme, Buzzi, the fifth largest cement producer in the US by capacity, may also face a similar dilemma to its peers about what to do with its largest earning business area.

The increasing dominance of the US market for western-based multinational cement producers may be accelerating a trend towards large regional companies everywhere. China-based cement players already dominate the top 10 list of the world’s largest cement producers by capacity. Companies from India and elsewhere are on the way to do likewise as they grow and concentrate on one geographic area. The situation in the US meanwhile is persuading the multinationals to do the same thing in reverse as they reconfigure themselves based on market demand. In financial terms, this may mean chasing growth in the US, learning to cope with high carbon prices in Europe or diversifying away from heavy building materials. Elsewhere, despite the proliferation of regional giants, such as the China-based cement companies, few seem keen to become truly multinational in a hurry, although opportunities, such as the ongoing sale of InterCement in Brazil or CRH’s acquisition of AdBri in Australia, are still present.

Global Cement Weekly will return to look at the large China-based cement companies when they release their financial results later in March 2024