Displaying items by tag: Malawi

Zimbabwe: PPC Zimbabwe has appointed Albert Sigei as its managing director from the start of 2024. He succeeds Kelibone Masiyane in the post, according to the Chronicle newspaper. Masiyane was appointed as the managing director of the subsidiary of South-Africa based PPC in 2016, having joined the company in 1994 as a trainee electrical engineer at the Colleen Bawn Plant.

Sigei is currently PPC’s Head of Strategic Initiatives, a post he has held since February 2023. Before this he was the chief executive officer (CEO) of Cimerwa PPC in Rwanda from 2000. He worked for over 17 years for LafargeHolcim and its subsidiaries becoming the CEO of LafargeHolcim Malawi from 2016 to 2019 and the chief operations officer of the East African Portland Cement Company (EAPCC) in Kenya in 2015. Earlier in his career he worked for PriceWaterhousCoopers. A graduate in mechanical engineering from the University of Nairobi, Sigei holds a number of qualifications in accountancy and business.

China: Huaxin Cement’s revenue fell by 6% year-on-year to US$4.43bn in 2022 from US$4.72bn in 2021. Its net profit decreased by 50% to US$393m from US$780m. Its sales volumes of cement and clinker declined by 20% to 75.3Mt and concrete sales volumes nearly doubled to 16.4Mm³. Despite flat cement demand the company expects a general domestic economic improvement, real estate market reforms and a focus on infrastructure to improve its fortunes in 2023.

During the reporting period the subsidiary of Switzerland-based Holcim started operating a 3000t/day production line at Nepal Narayani in early 2022 and commenced the second stage of a project to build a 4000t/day clinker line at Maweni in Tanzania in July 2022. Preparation work for a new clinker line project in Malawi also began. The company added that it has completed the investment and verification for ten additional projects in Africa, the Middle East and elsewhere in preparation of future business expansion. Overall, 13% of the group’s operating revenue derived from business outside of China in 2022 compared to 8% in 2021.

Denmark: Switzerland-based Holcim has made an investment in 3D concrete printer supplier COBOD International. Holcim hopes that the investment will help it to further expand its TectorPrint 3D printing ink range. Holcim and COBOD International's collaboration dates to 2019, since which time the partners have 3D printed windmill tower bases in Denmark, a school in Malawi and a housing development in Kenya.

Holcim's head of global research and development Edelio Bermejo said “At Holcim, we are continuously expanding our range of building solutions to build better with less, working to improve living standards for all in a sustainable way. 3D concrete printing will help us meet these goals."

African cement producers have confirmed their interest in calcined clay over the last month with two new projects. The big one was announced last week when FLSmidth revealed that it had received an order from CBI Ghana. This follows the launch of a Limestone Calcined Clay (LC3) project in Malawi in mid-March 2022 in conjunction with Lafarge Cement Malawi.

FLSmidth says that its order includes the world’s largest gas suspension calciner system and a complete grinding station. The kit will be installed at CBI Ghana’s plant near Accra in the south of the country. The new clay calciner system is expected to substitute 30 - 40% of the clinker in the final product, resulting in a reduction of up to 40% CO₂/t of blended cement compared to Ordinary Portland Cement (OPC). Overall the equipment manufacturers reckon that the grinding plant will reduce its CO₂ emissions by 20% compared to its current output. There has been no indication of how much the order costs but CBI Ghana expects energy and fuel savings, as well as lower overheads from clinker imports.

The public announcement of the Ghana project was also foreshadowed by the visit of Professor Karen Scrivener to the Ghana Standards Authority in February 2022. This was significant because Scrivener is the head of the Laboratory of Construction Materials at the Ecole Polytechnique Fédérale de Lausanne (EPFL) and has been one of the key instigators of the LC3 initiative since the early 2000s. Other calcined clay cements are available such as Futurecem or polysius activated clay (see below) but LC3 is arguably the most famous given its promotion in developing countries.

The Malawi project is at a much earlier stage. The government launched the public private partnership LC3 project in mid-March 2022 in conjunction with Lafarge Cement Malawi and Terrastone, a brick manufacturer. The Ministry of Mining is currently developing a memorandum of understanding with the Gesellschaft für Internationale Zusammenarbeit (GIZ), a Germany-based development agency. India-based Tara Engineering has also been linked to the scheme.

One thing to note about the Malawi project is that it is the first calcined clay project in the cement industry based in East Africa. All the other African ones are based in West Africa. The other two projects in this region are run by Turkey-based Oyak Çimento and its subsidiary Cimpor. The first of these is a 0.3Mt/yr calcined clay and a 2400t/day cement grinding production line that was commissioned in mid-2020. This plant is based at Abidjan in Ivory Coast. The second is a new plant that Germany-based ThyssenKrupp Industrial Solutions is building for Oyak Çimento at Kribi in Cameroon. This unit has a 720t/day calcined clay and a 2400t/day cement production capacity and it will use the supplier’s ‘polysius activated clay’ technology. ThyssenKrupp’s involvement came to light in early 2020 and commissioning was scheduled for late 2021. However, no update on the state of the project has been issued so far in 2022.

As the above examples show, Sub-Saharan Africa has at least one live calcined clay plant, two plants are being built and there’s one more at the development stage. This puts the region neck-and-neck with Europe, which has a similar mixture of current and developing projects. This column has been covering the wider trend of the growing usage of various types of blended cements recently, particularly in Europe and the US, with slag cements, Portland Limestone Cement (PLC) and more. With PLC, for example, note the transition of another two North American cement plants to PLC this week alone. As for calcined clay cement, it is fascinating to see the focus move to a different part of the world. Several commentators have predicted that the future looks set to be dominated by blended cements using whichever supplementary cementitious material (SCM) is most available for each plant. The growth in calcined clay confirms this view.

Global Cement is researching clay calcination use in the cement industry for the next edition of the Global Cement Directory. Email This email address is being protected from spambots. You need JavaScript enabled to view it. with any information on new industrial and research installations.

Malawi: The Germany-based Gesellschaft für Internationale Zusammenarbeit (GIZ) has launched the construction of a clay calcination plant in Malawi, called the Limestone Calcined Clay Project. The Nyasa Times newspaper has reported that the government has said that increased calcined clay use can reduce domestic cement production’s carbon footprint by a third.

Malawi: Lafarge Cement Malawi, which Huaxin Cement acquired from Holcim in December 2021, has renamed itself Portland Cement Malawi.

The Nyasa Times newspaper has reported that company secretary Constance Musopole said "Portland Cement Malawi will remain the home of our trusted brands which include DuraCrete, SupaSet, Kumanga and Khoma. We wish to inform the general public that the reputable legacy and the superior quality of goods and services that have been built over 65 years of existence in Malawi will indeed continue and also improve.” She added "Huaxin is among the 10 largest cement manufacturing companies globally with 115Mt/yr in capacity. We are excited to begin this new chapter in the legacy of the company."

Malawi/Zambia: Huaxin Cement says it has completed its acquisition of Lafarge Zambia and Lafarge Cement Malawi. In late December 2021 the Chinese cement producer completed the equity delivery conditions for Lafarge Cement Malawi. This follows a similar process for Lafarge Zambia in late November 2021.

In June 2021 Huaxin Cement said it had agreed to spend US$150m on purchasing a 75% stake in Lafarge Zambia and US$10m on acquiring Pan African Cement from Lafarge Cement Malawi. The former operates two integrated cement plants in Zambia with a combined production capacity of 1.5Mt/yr. The latter operates a 0.25Mt/yr grinding plant at Blantyre in Malawi. Following the completion of the takeover Huaxin Cement now intends to increase its cement grinding capacity in Malawi by 0.25Mt/yr.

Switzerland: Holcim’s sales rose by 17.4% year-on-year to Euro11.7bn in the first half of 2021 from Euro9.92bn in the same period in 2020. Its recurring earnings interest before taxation (EBIT) increased by 66% to Euro1.84bn from Euro1.12bn. Cement and concrete sales volumes grew by 13.5% to 99Mt and 15.6% to 22.1Mm³ respectively. Sales of all business segments grew in all regions on a like-for-like basis with the exception of aggregate sales in North America, where they fell slightly.

Jan Jenisch, the chief executive officer of Holcim, said, “In the first half of 2021 we set new records in recurring EBIT, free cash flow and earnings per share.”The group’s acquisition of Firestone Building Products officially closed at the end of March 2021 and the company has also made seven ‘bolt-on’ acquisitions so far in 2021, mainly in aggregate and ready-mixed concrete markets in Europe and North America. The group also agreed to divest operations in Zambia, Malawi and the Indian Ocean in the reporting period and these are all expected to complete by the end of 2021.

Malawi: Switzerland-based Holcim says that the world’s first 3D printed school has opened in Salima district’s Kalonga village after a build time of just 18 hours. The EcoPact green concrete producer says the building provides a much-needed thirteenth school in Yambe, which still needs three more. Holcim’s green construction subsidiary 14Trees estimates that its 3D printing technology can meet Malawi’s school building needs by 2031, compared to after 2090 by conventional methods. The group said that the school proves that “3D printing can play a key role in bridging our world’s education infrastructure gap” with high-quality, sustainable, affordable and fast-paced construction, at scale.

Europe, Middle East and Africa regional head Miljan Gutovic said, “I am very proud of how our colleagues at 14Trees have deployed cutting-edge 3D printing technology to solve such an essential infrastructure need. Now that we’ve proven the concept in Malawi, we look forward to scaling up this technology across the broader region, with projects already in the pipeline in Kenya and Zimbabwe.”

The latest piece of China-based Huaxin Cement’s global ambitions slotted into place this week with the news that it is preparing to buy plants in Zambia and Malawi. Its board of directors has approved plans to spend US$150m towards acquiring a 75% stake in Lafarge Zambia and US$10m on a 100% stake in Lafarge Cement Malawi. The move will gain it two integrated plants with a combined production capacity of 1.5Mt/yr in Zambia, and a 0.25Mt/yr grinding plant in Malawi.

This latest proposed acquisition represents the next step for Huaxin Cement in Africa following its purchase of African Tanzanian Maweni Limestone from ARM Cement in mid-2020. The company has also been busy along the more traditional Belt and Road Initiative land routes in Asia. It started up the kiln at its new 2Mt/yr Jizzakh cement plant in mid-2020. Elsewhere in Central Asia it runs two plants in Tajikistan and one plant in Kyrgyzstan via various indirectly-owned subsidiaries. While in South Asia it runs a plant in Nepal and in South-East Asia it runs one in Cambodia. If the plans in Zambia and Malawi pay off then it will give the Chinese producer a growing presence in East Africa, with plants in three countries.

The China Cement Association ranked Huaxin Cement as the country’s fifth largest clinker producer in 2021 with an integrated capacity base of just under 63Mt/yr. Domestically, the company operates 57 cement plants and most of these are based in the Yangtze River Economic Belt region. In 2020 it reported cement and clinker sales of 76Mt, a small decrease from 2019. Its operating income fell by 6.6% year-on-year to US$4.58bn and profit dropped by 12% to US$1.2bn. This performance was blamed on the emergence of Covid-19 at the start of 2020 and then floods later in the year.

Compared to the other larger Chinese cement producers, Huaxin Cement roughly appears to be holding rank with its overseas expansions. The leaders, CNBM and Anhui Conch, hold subsidiaries with plants in South-East and Central Asia and CNBM’s engineering wing, Sinoma, has a far bigger reach, building plants all over the place. Information has been scarce since mid-2020 on the long heralded 7Mt/yr plant in Tanzania due to be built by Sinoma and local subsidiary Hengya Cement. At that time local residents in Mtimbwani, Mkinga District were reportedly being compensated for their land. Other than this, one of the other big players internationally is Taiwan Cement. In 2018 it invested around US$1.1bn for a 40% stake in Turkey-based Oyak Cement. As well as a presence in Turkey this also gave it a share of plants in Portugal in 2019 when Oyak completed its acquisition of Cimpor.

Elsewhere this week, carrying some of the themes above with expansion in Central Asia, two new integrated cement plant projects were announced in Kyrgyzstan and Turkmenistan respectively. Meanwhile, Italcementi said it will invest Euro5.0m to restart clinker production at its Trentino cement plant in Sarche di Madruzzo, Italy. The unit has been operating as a grinding plant since 2015. This might be viewed as an unexpected decision considering the high local CO2 price but it shows some level of confidence in the local market by Italcementi and its parent company, HeidelbergCement. The next step will be when or if a European producer decides to build a brand new integrated plant in Italy or elsewhere.