Displaying items by tag: Intercement

Angola made similar noises to Nigeria this week when one of its government ministers declared that the country was self-sufficient in terms of cement production. The comments came from Industry minister Bernarda Martins at a visit by the Angolan president to the China International Fund Luanda Cement plant. Martins' words echoed those made by Joseph Makoju, Chairman of the Cement Manufacturing Association of Nigeria, who declared that his country was making more cement than it consumed back in 2012.

Claims of self-sufficiency are all about context. A major or fast growing economy such as Nigeria declaring self-sufficiency in cement could suggest a potential paradigm shift. A smaller economy might simply have risen from a low production base to a slightly higher one with little consequence. So what does this mean for Angola?

The southern African country has a population far smaller than Nigeria at 19 million. Yet, its gross domestic product (GDP) per capita, in purchasing power parity terms, was estimated to be US$6484 in 2014 by the International Monetary Fund, a figure slightly higher than Nigeria's. In nominal terms its GDP was the fifth biggest in Africa in 2013.

Global Cement Directory 2015 research (to be published in late 2014) gives Angola's four integrated cement plants with a total cement production capacity of just under 6Mt/yr. The plant the politicians have just visited has reportedly just increased its clinker capacity to 3.6Mt/yr and another 0.6Mt/yr capacity is planned to join the market when an InterCement plant expands in 2017. Together this places the country's production at around 8Mt/yr. Domestic cement demand was placed at 6.5Mt/yr in early 2014 giving the country a cement consumption of just under 350kg/capita.

Transnational African bank Ecobank declared than Angola was becoming Central Africa's cement production hub in a commodities report in July 2014. Out of the sub-Saharan countries it has become the fourth largest producer after Nigeria, South Africa and Ethiopia and the third largest consumer after Nigeria and South Africa. Angola too has restricted cement imports, like Nigeria. In 2014 the Ministry of the Economy, Industry, Commerce and Construction implemented a stoppage on imports in a phased manner under the auspices of its local cement association, the Association of Industrial Cement of Angola.

Where Angola is different to Nigeria is in the composition of the companies that produce its cement. There is no large local presence to rival Nigeria's Dangote. The former colonial links are there with a plant operated by Brazil's InterCement, who inheritied it from Portuguese company Cimpor. Of the rest, Chinese and South Korean investors figure prominently.

Finally, it is also worth noting that Angola has none of the main sub-Saharan players present including Dangote, PPC or Lafarge Africa. Roughly half-way between the African cement powerhouses of Nigeria and South Africa and with a handy coastline, Angola deserves further attention.

An update on the algae bioreactor project at Votorantim's St Marys cement plant in Canada this week provides a good opportunity to review this particular aspect of carbon sequestration. The project, run with Pond Biofuels, went live in 2009. It has now reached its third generation bioreactor at the site.

Little or no performance data has been released generally so we have no way at present of knowing how viable the process is commercially. Cement backers, Brazilian firm Votorantim, are certainly excited by the project even if only for the sustainability kudos it gives them. Director Edvaldo Araújo Rabello presented the project as one of the company's highlights at a keynote presentation at the 6°CBC Congresso do Cimento held in São Paulo, Brazil in May 2014.

One hurdle for the St Marys pilot is the relative lack of light, a required input for algae photosynthesis, even in Canada's most southerly state. Pond Biofuels have reportedly dodged this by using continuously flashing LEDs to simulate artificially short days that encourage growth. On paper or powerpoint a process that could potentially cut even a proportion of CO₂ emissions from a cement plant sounds enticing. Yet if it creates more CO₂ than it saves, through electricity requirements for example, than it isn't worth using.

This is probably what shelved Lafarge's Carbon Capture and Transformation project. It ran a pilot project at its Val d'Azergues plant in France in 2009 with Salata GmbH. The pilot worked but the researchers decided that new advances in processes and biotechnology were required to make the economic and environmental results better. Other companies have also had problems. Holcim started its Aurantia – GreenFuel project in late 2007 at its Jerez cement plant in Spain, backing it with an investment US$92m. This project stalled when GreenFuel shut in 2009 citing lack of funding as the recession hit.

ACC in India also reportedly started its own algae project in 2007, mentioning it in its sustainability report, but nothing more has been reported since. Since this burst of interest InterCement has invested US$2.5m towards algae research in 2013 working with the Federal University of São Carlos, the Federal University of Santa Maria and Algae Biotecnologia.

Algae-based carbon projects for cement plants may remain stuck in the research stage but the market for biofuels continues to grow. For example, this week we report that Ohorongo Cement in Namibia plans to increase its use of blackthorn as a biofuel to use as an alternative fuel in co-processing. The prospects of turning waste CO₂ into a valuable commodity remains uncertain, but the rewards are great. Let's wait and see what St Marys can do.

The Brazilian cement industry took a knock last week when the competition watchdog Cade (Administrative Council for Economic Defence) confirmed its intention to issue the sector with fines worth a combined US$1.4bn.

Under the terms of the ruling, Votorantim will have to pay US$672m, Cimpor will pay US$133m, InterCement Brasil will pay US$108m, Itabira will pay US$184m, Holcim will pay US$227m and Itambé will have to pay US$39.4m. The companies involved will be forced on average to sell 24% of their assets. Votorantim, for example, will be compelled to divest 35% of its cement assets or 11Mt/yr of production capacity. In addition a fine of nearly US$2m is to be imposed on the cement associations ABCP and SNIC.

To give these figures some context, Votorantim reported a net profit of US$105m in 2013 across all its business lines including cement, metals, mining and pulp. The fine Cade wants to impose is over six times greater than this! A fine of this size will be a serious setback for Votorantim if it goes through. Votorantim's net revenue for its cement business in 2013 was about US$5.5bn. This places the fine at just over 10% of company annual turnover, a common upper limit for fines imposed by anti-competition authorities around the world. 10% of turnover, for example, is the maximum percentage fine that European Union competition regulators can impose.

Although hard to compare with the other Brazilian cement producers due to differences in financial reporting, the proposed fines seem equally tough on the other companies. Before the acquisition of Cimpor inflated its financial figures, InterCement reported a net revenue of US$1.2bn in 2011. This places its fine at 9% of annual turnover. Holcim's net sales in its Latin American region as a whole, including operations in Brazil, totalled US$3.73bn in 2013.

Both Holcim and Cimpor have issued corporate rebuttals to Cade insisting that they followed and still follow all the necessary competition laws. Both companies intend to fight the decision. Votorantim went further in its response saying that it considering the fine 'unjust and unprecedented' and it warned that the ruling would cripple any investments in the Brazilian cement sector. The ruling also forbids the company from opening new factories within the next five years, places limits on the company taking out new loans and prevents it from consolidating its market share.

Internationally, the Cade fine surpasses the US$1.1bn Competition Commission of India penalty imposed against 11 producers in India in 2013. Other recent anti-trust fines against the cement industry include a Euro80m fine in Poland that was upheld on appeal in 2013 and the US$19.3m Lafarge was charged in South Africa in 2012.

The prosecutors pointed out that work on public roads had been inflated by nearly US$8m. Overall they reckon that the cartel cost the Brazilian economy US$6.3bn. Examples likes this are unlikely to gain sympathy for the accused cement producers from a Brazilian public already angry about the amount of public money spent on building excessive sports stadiums and the like for the Football World Cup later in June 2014 and the Olympic Games in 2016. In the meantime though – over to the lawyers.