Displaying items by tag: PCA

It’s the end of the year so it’s time to look at trends in the sector news over the last 12 months. It’s also the end of a decade, so for a wider perspective check out the feature in the December 2019 issue of Global Cement Magazine. The map of shifting production capacity and the table of falling CO₂ emissions per tonne are awesome and inspiring in their own way. They also point towards the successes and dangers facing the industry in the next decade.

Back on 2019 here are some of the main themes of the year in the industry news. This is a selective list but if we missed anything crucial let us know.

European multinationals retreat

LafargeHolcim left the Philippines, Malaysia and Indonesia, HeidelbergCement sold up in Ukraine and reduced its stake in Morocco and CRH is reportedly making plans to leave the Philippines and India, if local media speculation can be believed. To be fair to HeidelbergCement it has also instigated some key acquisitions here and there, but there definitely has been a feel of the multinationals cutting their losses in certain places and retreating that bit closer to their heartlands.

CRH’s chief executive officer Albert Manifold summed it up an earnings meeting when he said, “…you're faced with a capital allocation decision of investing in Europe or North America where you've got stability, certainty, overlap, capability, versus going for something a bit more exotic. The returns you need to generate to justify that higher level of risk are extraordinary and we just don't see it.”

The battle for the European Green Deal

One battle that’s happening right now is the lobbying behind the scenes for so-called energy-intensive industries in Europe as part of the forthcoming European Green Deal. The cement industry is very aware that it is walking a tightrope on this one. The European Union (EU) Emissions Trading Scheme (ETS) CO₂ price started to bite in 2019, hitting a high of Euro28/t in August 2019 and plant closures have been blamed on it. The rhetoric from Ursula von der Leyen, the new president of the European Commission, has been bullish on climate legislation and the agitation of Greta Thunberg internationally and groups like Extinction Rebellion has kept the issue in the press. Cembureau, the European Cement Association, is keen to promote the industry’s sustainability credentials but it is concerned that aspects of the proposed deal will create ‘uncertainty and risks.’ Get it wrong and problems like the incoming ban on refuse-derived fuel (RDF) imports into the Netherlands may proliferate. What the Green Deal ends up as could influence the European cement industry for decades.

The managed march of China

Last’s week article on a price spike in Henan province illustrated the tension in China between markets and government intervention. It looks like this was driven by an increase in infrastructure spending with cement sales starting to rise. Cement production growth has also picked up in most provinces in the first three quarters of 2019. This follows a slow fall in cement sales over the last five years as state measures such as consolidation and peak shifting have been implemented. The government dominates the Chinese market and this extends west, as waste importers have previously found out to their cost.

Meanwhile, the Chinese industry has continued to grow internationally. Rather than buying existing assets it has tended to build its own plants, often in joint ventures with junior local partners. LafargeHolcim may have left Indonesia in 2018 but perhaps the real story was Anhui Conch's becoming the country's third biggest producer by local capacity. Coupled with the Chinese dominance in the supplier market this has meant that most new plant projects around the world are either being built by a Chinese company or supplied by one.

India consolidates but watches dust levels

Consolidation has been the continued theme in the world's second largest cement industry, with the auction for Emami Cement and UltraTech Cement’s acquisition of Century Textiles and Industries. Notably, UltraTech Cement has decided to focus its attention on only India despite the overseas assets it acquired previously. Growth in cement sales in the second half of 2019 has slowed and capacity utilisation rates remain low. Indian press reports that CRH is considering selling up. Together with the country's low per capita cement consumption this suggests a continued trend for consolidation for the time being.

Environmental regulations may also play a part in rationalising the local industry, as has already happened in China. The Indian government considered banning petcoke imports in 2018 in an attempt to decrease air pollution. Later, in mid-2019, a pilot emissions trading scheme (ETS) for particulate matter (PM) was launched in Surat, Gujarat. At the same time the state pollution boards have been getting tough with producers for breaching their limits.

Steady growth in the US

The US market has been a dependable one over the last year, generally propping up the balance sheets of the multinational producers. Cement shipments grew in the first eight months of the year with increases reported in the North-Eastern and Southern regions. Imports also mounted as the US-China trade war benefitted Turkey and Mexico at the expense of China. Alongside this a modest trade in cement plants has been going on with upgrades also underway. Ed Sullivan at the Portland Cement Association forecasts slowing growth in the early 2020s but he doesn’t think a recession is coming anytime soon.

Mixed picture in Latin America

There have been winners and losers south of the Rio Grande in 2019. Mexico was struggling with lower government infrastructure spending hitting cement sales volumes in the first half of the year although US threats to block exports haven’t come to pass so far. Far to the south Argentina’s economy has been holding the cement industry back leading to a 7% fall in cement sales in the first 11 months of the year. Both of these countries’ travails pale in comparison to Venezuela’s estimated capacity utilisation of just 12.5%. There have been bright spots in the region though with Brazil’s gradual return to growth in 2019. The November 2019 figures suggest sales growth of just under 4% for the year. Peru, meanwhile, continues to shine with continued production and sales growth.

North and south divide in Africa and the Middle East

The divide between the Middle East and North African (MENA) and Sub-Saharan regions has grown starker as more MENA countries have become cement exporters, particularly in North Africa. The economy in Turkey has held back the industry there and the sector has pivoted to exports, Egypt remains beset by overcapacity and Saudi Arabian producers have continued to renew their clinker export licences.

South of the Sahara key countries, including Nigeria, Kenya and South Africa, have suffered from poor sales due to a variety of reasons, including competition and the local economies. Other countries with smaller cement industries have continued to propose and build new plants as the race to reduce the price of cement in the interior drives change.

Changes in shipping regulations

One of the warning signs that flashed up at the CemProspects conference this year was the uncertainty surrounding the new International Maritime Organistaion (IMO) 2020 environmental regulations for shipping. A meeting of commodity traders for fuels for the cement industry would be expected to be wary of this kind of thing. Their job is to minimise the risk of fluctuating fuel prices for their employers after all. Yet, given that the global cement industry produces too much cement, this has implications for the clinker and cement traders too. This could potentially affect the price of fuels, input materials and clinker if shipping patterns change. Ultimately, IMO 2020 comes down to enforcement but already ship operators have to decide whether and when to act.

Do androids dream of working in cement plants?

There’s a been a steady drip of digitisation stories in the sector news this year, from LafargeHolcim’s Industry 4.0 plan to Cemex’s various initiatives and more. At present the question appears to be: how far can Industry 4.0 / internet of things style developments go in a heavy industrial setting like cement? Will it just manage discrete parts of the process such as logistics and mills or could it end up controlling larger parts of the process? Work by companies like Petuum show that autonomous plant operation is happening but it’s still very uncertain whether the machines will replace us all in the 2020s.

On that cheery note - enjoy the winter break if you have one.

Global Cement Weekly will return on 8 January 2020

US: The Portland Cement Association (PCA) has releases a two-year forecast of moderate growth in cement consumption between 1 January 2020 and 31 December 2021. It projected growth of 1.7% in 2020, slowing slightly to 1.4% in 2021, corresponding to 2.1% and 1.7% GDP growth annually. Speaking at the 38th International Cement Seminar in Atlanta, PCA senior vice president and chief economist Ed Sullivan projected consumption growth of 1.6% - 2.3% in 2019 against GDP growth of 2.4% over the period, with consumption bolstered by the 2018 Federal Budget, which allowed for US$20bn in infrastructure investments in 2018 and 2019. He noted growing uncertainty (21% in 2019) with the expiry of the ‘pent-up demand zip that invigorates the initial stages of economic recovery long past.’

Rising house prices and mild inflation signify the continuation of the US economy’s longest expansion post-World War Two, with 161,000 net new jobs generated so far in 2019. With a forecasted population increase of 60m by 2040, US cement producers appears still have their work cut out in keeping up with demand.

US: The Portland Cement Association (PCA) has appointed Libby Pritchard as Director of Construction Materials Safety & Policy in its PCA Government Affairs team. She will also hold the same position in a joint role at the National Stone, Sand and Gravel Association.

Previously, Pritchard worked as a social scientist at the National Science Foundation (NSF) responsible for writing briefs highlighting NSF-funded projects for dissemination to US Congress and conducting data analyses. She also worked as the Environmental Services & Land Use Coordinator at Wildish Sand & Gravel and was chair of Oregon Concrete & Aggregate Producers Association ESH Committee from 2017 - 2018. Pritchard holds two Masters of Science degrees in the fields of Geography and Water Resources Policy & Management from Oregon State University.

US: Robert McCaffrey, the editorial director of Global Cement, has presented ‘The global cement industry in 2050’ at the 61st IEEE-IAS/PCA Cement Technical Conference 2019 taking place at St Louis in Missouri. The presentation used data from a variety of sources to explore how the cement and concrete industries could look in 2050 including shifts in societies, demographics, technologies, business and the environment.

For more information about the presentation and to download a copy visit: www.globalcement.com/reports/cement-2050

Global Cement is exhibiting at the IEEE-IAS/PCA at Booth 128

US: The Portland Cement Association (PCA) has announced the winners of the 2019 Energy and Environment (E&E) Awards. The awards recognised environmental and community relations projects that were completed in 2018 and were presented at the 3rd Annual Cement and Concrete Fly-In.

The CalPortland Mojave cement plant in California won the Energy Efficiency award for the installation of a new classifier system for its vertical roller mill that increased energy efficiency by reducing fan power requirements. The plant also installed a control system for the finish mill that will maximise performance and help reduce wear on equipment. The classifier installation reduced the finish mill energy intensity by 1.5 to 2.0kWh/t, and the control system reduced energy intensity by 13%. In 2018 22% of the electricity consumed by the plant came from on-site renewable wind energy generation. CalPortland has implemented significant energy efficiency measures and its energy management program has been recognised by the Environmental Protection Agency Energy Star program as the Energy Star Partner of the Year for 15 years in a row.

Roanoke Cement Company and Titan America’s Troutville plant in Virginia won the Environmental Performance award for being the first cement manufacturing plant in the US to receive ISO 50001 certification for energy management of all aspects of energy procurement, design and use. The plant reduced its total electrical consumption by 10% and fossil fuels use by more than 12%. The plant has also implemented an alternative fuels program as part of its certification for the True Zero Waste Program, administered by Green Business Certification and has received silver status achieving a 96% rate of waste divergence from landfills.

Lehigh Hanson’s Permanente cement plant at Cupertino in California won the Innovation award for the installation of a water treatment system reducing concentrations of metals, including selenium, to meet permit limits. Lehigh Hanson developed a treatment system that combined ultrafiltration and reverse osmosis (UF/RO) technology in conjunction with biological treatment technology to remove metals, including selenium and dissolved solids. This ensured applicable effluent limits were met while optimising treatment capacity and efficiency. This treatment system is the first of its kind in the cement industry ensuring that effluent limits are met while, at the same time, limiting the quantity of waste needed to be managed.

Buzzi Unicem USA’s Greencastle cement plant in Indiana won the Land Stewardship award for opening a 4km smooth packed stone trail in conjunction with the not-for-profit People Pathways organisation as Phase 2 of the Putnam Nature Trail. Buzzi Unicem USA staff and People Pathways used heavy equipment for rough clearing and grading of the overgrown former railroad bed and improved and expanded the physical trail. These areas were then landscaped with trees, native prairie vegetation plugs, interpretive signage, benches, birdhouses and other features. Additional nature trail enhancements include placement of wildlife monitoring cameras along the trail, installation of nesting boxes and interpretive signage, and maintenance of the recently completed restoration of native flora installed in 2017 and 2018.

Cemex’s Lyons cement plant in Colorado won the Outreach award for volunteering work by its staff at the Rocky Mountain National Park in Boulder, Colorado, performing campground improvement activities at Glacier Basin Campground by moving rocks and fallen timber and clearing existing fire pits of ash deposits. The plant then introduced a new community outreach initiative by hosting a Manufacturing Day event, providing local students tours of the quarry and plant to increase youth interest in pursuing a vocation in skilled trades. Additionally, the plant teamed up with the Celestial Seasonings B Strong Ride for cancer care and research for an event aimed at increasing safety awareness while fundraising for two local organizations and their efforts to fight cancer.

US: The Portland Cement Association (PCA) forecasts that cement consumption will grow by 2.3% year-on-year in 2019. It is a slight drop from the rate of 2.6% it previously forecast in November 2018.

“While there are several phenomena that confront the economy in the next two years, the PCA believes the economy is strong,” said Ed Sullivan, PCA Senior Vice President and Chief Economist. He added that rising interest rates are expected to drag on economic growth, leading to a slowdown in private construction. Cement consumption is expected to slow as a result.

The PCA also said in its Spring Forecast that rising state deficits had forced many states to adjust budgets, reduce costs, and re-prioritise spending. Infrastructure spending had been falling in priority as a consequence. In the medium term the PCA expects cement consumption growth to soften until 2021. It then thinks that President Donald Trump’s supplemental infrastructure initiative will arrive in 2022 leading back to increased cement consumption.

US: The Portland Cement Association (PCA) has elected Tom Beck, president of Continental Cement Company, as the chairman of the PCA board of directors in 2019. Ron Henley, president of GCC of America, was elected vice chairman at a PCA board meeting in late October 2018. Beck takes over the PCA board chairmanship role from Allen Hamblen, president and chief executive officer (CEO) of CalPortland Company.

A past chairman of the American Concrete Pavement Association, Beck served as Senior Vice President at Continental Cement from 1996 to 2013, and held a variety of positions with Holnam from 1987 to 1996. Prior to joining GCC of America, Henley was President of Boral Construction Materials. He is also a board member of the Denver Scholarship Fund.

A couple of long-running news stories popped up this week, led by the Portland Cement Association’s (PCA) latest forecast for the US market. Chief economist Ed Sullivan and the Market Intelligence Group predict slowing cement consumption growth to 2020 as the recovery period ends following the financial crash in 2008. The background to this is an expected rise in interest rates dragging on the construction market, a limited boost from the Trump administration’s tax cuts and rising debt levels hitting federal infrastructure spending.

This marks an abrupt turnaround from the PCA’s April 2018 forecast in which potential federal infrastructure spending was anticipated to kick in towards the end of 2019 creating 4% growth in 2020. To give the PCA credit, it did say at the time that this was contingent on a couple of key steps, including passage of an infrastructure bill, federal and state paperwork, bid letting and review and finally, contract awards leading to construction. Following the US mid-term elections in early November 2018 the prospect of an infrastructure bills seems remoter than before given the political differences between the US House of Representatives and the Senate. This may have been the final straw for the PCA and it adapted its forecast accordingly.

Graph 1: Cement shipments in the US, January – August 2013 - January – August 2018. Source: Portland Cement Association (PCA).

It is also worth reflecting on the third quarter financial results of the multinational cement producers over the last few weeks. CRH may have been crowing this week about how its US performance was driving its business in the wake of its acquisition of Ash Grove Cement and other assets, but many of the other multinational cement producers weren’t. HeidelbergCement, Buzzi Unicem and Titan all blamed the weather in the US for dragging on their results. LafargeHolcim said it suffered less with a ‘soft’ first quarter in 2018 followed by recovery.

The other story this week with relevance to the US was the continued speculation in the Canadian press about the future of the McInnis Cement plant in Quebec. The latest update is that the plant’s shareholders have asked the provincial government if they can swap the debt the province holds in the venture for equity. This has been seen as a potential bid to keep the company operational while it continues to hunt for a buyer. Rumours of a sale have swirled around since the start of 2018, with the Global and Mail newspaper naming HeidelbergCement as being potentially interested. Three bids have been reportedly made by unnamed parties but they were rejected for being too low. A slowing US cement market is particularly bad news for McInnis Cement. The plant is situated on the Atlantic Coast of Canada and exports to the US have been seen as a major part of its business. To this end it officially opened its marine terminal in the Bronx, New York in October 2018.

The main US market needs to find an alternative to the ‘fabled’ infrastructure bill if it wants better growth. Yet, reduced US cement consumption growth won’t help McInnis’ shareholders recoup the money they have sunk in the project. Somebody seems certain to lose in this situation and, with a protectionist incumbent in the White House, it seems likely to be somebody north of the border.

US: Staff members from Ash Grove Cement, Argos USA and Lehigh Hanson have won awards at the Portland Cement Association’s (PCA) 2018 John P Gleason, Jr Leadership Awards. The awards recognise PCA members who have exhibited leadership in advancing industry programs and initiatives. The scheme is named after John ’Jay’ Gleason who served as PCA president from 1986 until his retirement in 2007.

Steve Minshall, Corporate Director, Safety and Health at Ash Grove Cement won the Business Continuity award. He has served on the PCA Occupational Health and Safety (OHS) Committee for two decades, where the PCA say he has proven to be a strong safety leader in implementing many programs and initiatives to reduce workplace injuries. He has led efforts to better partnership with regulatory agencies in pursuit of the common goal of safety. Finalists in this category were Brett Lindsay, Environmental & Energy Manager at Salt River Materials Group, and Steve Wilcox, Cement Technical Director at Argos USA.

Lori Tiefenthaler, Senior Director of Marketing at Lehigh Hanson won the Market Development award. As chair of the American Concrete Pavement Association (ACPA) in 2017, Tiefenthaler led efforts to better align the missions of allied cement and concrete associations, including an effort to launch PavementDesigner.org, which is a joint project between PCA, ACPA and National Ready Mixed Concrete Association. She has served on the executive board for the National Concrete Consortium, through which she has helped improve connections and outcomes for the cement and concrete industries with federal and state departments of transportation and academia. Finalists in this category were Bill Asselstine, Vice President Sustainability at St. Marys Cement/VCNA, and David Gray, Market Manager at GCC of America.

Gina Lotito, Vice President, Energy & Environmental, GCC of America won the Young Leaders award. She is an active member of the PCA Environment & Energy Committee, where she has been chair and vice chair of the Sustainable Manufacturing Subcommittee, and served on the Sustainable Development Committee. She has proven a leader in promoting the use of clean alternative fuels for cement production, and in federal advocacy efforts to lower regulatory barriers for using such fuels under the Non-Hazardous Secondary Materials Rule. Finalists in this category were Ed Griffith, Vice President Sales & Marketing, US at St. Marys Cement/VCNA and Adam Posly, Production Manager at LafargeHolcim US.

The Global Cement and Concrete Association (GCCA) announced this week that it intends to take over the work done by the Cement Sustainability Initiative (CSI). This marks a change in how the cement industry as a whole approaches sustainability and in the wider context how the sector manages itself on the world stage.

The CSI was set up in 1999 with the aim of advancing a sustainability agenda for the cement industry. It has done this by laying out strategy for the industry to follow in the form of technology roadmaps and publishing its ‘Getting the Numbers Right’ (GNR) data on CO₂ and energy performance information. By 2018 it had 24 cement company members composed of nine core members, 14 participating members and one affiliate member. It represents around 2.4Bnt/yr of global cement production capacity or over half of the world production, according to Global Cement Directory 2018 data.

The idea behind the membership was that the core members are all members of the World Business Council for Sustainable Development (WBCSD) and that the members would contribute ‘modest’ funds to run the organisation. That last point about WBCSD membership is worth noting because members need to stick to conditions such as publishing an annual sustainability report and agree to have the sustainability report reviewed and benchmarked by the WBCSD.

Figure 1: Outline of selected current global cement organisations with a sustainability remit. Source: Association websites, Global Cement Directory 2018.

The GCCA, which formed in early 2018, says it had formed a ‘strategic’ partnership with the WBCSD and that it will take over the work previously done by the CSI from the start of 2019. Although there’s no mention so far whether GCCA members have to actually become WBCSD members with all that this entails. At present the GCCA consists of nine major international cement producers, including over half of the world’s top 10 producers by production capacity, with a production base in every inhabited continent except Antarctica. Roughly speaking it represents just under 2Bnt/yr of global cement production capacity or about half of the world’s total.

Now where this starts to get confusing is that other cement associations exist with their own established advocacy roles and sustainability agendas. The established players include the various regional associations such as the Portland Cement Association in the US, Cembureau in Europe and so forth. The multinational ones also often represent national bodies.

Then there is the World Cement Association (WCA), which formed in 2016. This independent body is a private company run out of an office in London, UK with non-profit aims. It has 45 members but only three quarters are actual cement producers. Of these most are single-country cement manufacturers. The glaring standout is China National Building Material (CNBM) and its subsidiaries, representing over half of the association’s member’s cement production capacity. The production capacity of the WCA’s members is around 1Bnt/yr or a quarter of the global total. More than half of this comes from CNBM and its subsidiaries. Unsurprisingly then that Song Zhi Ping, the head of CNBM, is the president of the WCA. It too supports a sustainability agenda, saying that it, “seeks to co-operate with the WBCSD, CSI and regional and national Cement Associations.” What is noteworthy is how few of the current members of the WCA joined the CSI previously.

There is definitely a need for a global organisation advocating sustainability issues for the cement industry and by taking over the work of the CSI and the GCCA has cornered this part of what a global cement association might do. However, the GCCA represents less cement production capacity than the CSI did. The main omissions are the Indian producers, led by UltraTech Cement, as well as others. It seems likely that they will join the GCCA following the end of the CSI but there is no guarantee.

The other point arises when looking at these various cement associations is: who does what exactly? The CSI’s focus on sustainability gave it a purpose that it did well with a genuine appearance of independence. Its narrow focus also gave it a complimentary role to the existing national and regional associations. Global bodies like the GCCA and the WCA are clearly more into advocacy territory for their members. Also, a more general association approach like the GCCA and the WCA may clash with regional bodies like the PCA and Cembureau. Regional bodies seem better suited to the way governance works globally with regional groups such as the European Union (EU) or government departments in continental sized countries such as the US, China and India. However, a truly global cement body could respond better to coordinated environmental lobbying and fill in the gaps around the world in places with looser regional representation.

Sustainability is the immediate link between the CSI, the GCCA and the WCA. Indeed the WCA recently held a ‘Global Climate Change’ forum in Paris to discuss its own climate action plan. Yet, with the GCCA taking over the work the CSI does and the WCA saying it wants to cooperate with the CSI, the obvious outcome is that the GCCA will become the world’s apex cement association. It will represent the companies with the most cement production capacity, have a presence in every inhabited continent and take the lead on WBCSD issues. Beyond this though it will be interesting to see what, if anything else, the GCCA chooses to do.