Displaying items by tag: Plant

Pakistan: Pioneer has announced the completion of a new 3.7Mt/yr integrated cement plant with a 12MW waste heat recovery (WHR) power plant and 24MW coal-fired power plant. It said that production and dispatch would start ‘in due course.’ It commenced construction of the facility in 2017.

Liberia: HeidelbergCement subsidiary Cemenco has commissioned a 0.3Mt/yr cement plant in Liberia following an investment of US$14m. The Daily Observer newspaper has reported that the plant is equipped with a 2000t silo, bulk truck unloading equipment and a bagging line, in addition to four Samson Eco Hoppers for dust-free delivery in the Port of Monrovia. Cemenco already operates a 0.8Mt/yr grinding plant on Bushroda Island in Monrovia.

Germany: A Zollernalb, Baden-Württemberg resident who mounted legal action against Tübingen Council in June 2019 over LafargeHolcim subsidiary Holcim Süddeutschland’s use of waste glass in cement production at its 1.1Mt/yr integrated Dotternhausen plant has submitted ‘extensive reasoning’ for the challenge. The Schwarzwälder Bote has reported that Holcim Süddeutschland allegedly did not complete the proper tests before introducing glass to cement production at Dotternhausen in late 2017. The claimant ‘noticed a rise in heavy metal levels.’

At a subsequent council meeting, a Holcim Süddeutschland employee bore witness to the presence of a defective bag filter. By receiving glass ground to grains of a certain fineness, the claimant alleges that Holcim Süddeutschland was able to bypass federal waste regulations necessitating contaminant checks. They said the company was ‘taking citizens for idiots.’

Uzbekistan: Chinese investors have announced the launch of a 0.9Mt/yr integrated cement plant in the Fergana region of Uzbekistan as a result of a total investment of US$113m. Trend News has reported that a second phase of work beginning in May 2020 will further increase the cement plant’s production capacity. This is one of five upcoming Chinese-owned integrated plants in Uzbekistan, with a shared capacity of 6.0Mt/yr.

Germany: Buzzi-Unicem subsidiary Dyckerhoff has paved the 3700m2 of road outside the limestone quarry at its 0.4Mt/yr integrated Geseke plant in North Rhine-Westphalia. It used a concrete blend containing PKZ Doppel N cement produced at the Geseke plant, which it applied to a thickness of 20cm over an asphalt base. Dyckerhoff made the decision to pave the road ‘to minimise dust emissions, especially in prolonged dry spells.’ It says the concrete’s low water content and good compression give the road a strength rating of 50N/mm2.

Last month Soyuzcement, the Union of Russian Cement Producers, reported that cement production was on course to grow by 8% year-on-year to 58Mt in 2019. This estimate was based on growth from January to October 2019 followed by a modest rise in November.

Graph 1: Cement production in Russia, 2010 – 2019. Source: CM Pro, Ernst & Young.

The pickup is significant because it’s the country’s first annual resumption of growth since 2014. At that time low commodity prices, a worsening economy and international sanctions broke a fairly steady growth cycle that had started in 2000. The only blip in that run was the global economic downturn around 2008. In the medium to long term Soyuzcement’s review pinpointed growth drivers as being government-backed residential housing schemes, integrated land development projects and an increase in the construction of concrete roads. This increase has been driven by consumption growth in most regions, led by a 12% rise in the Central Federal District although the Volga Federal District started to slow in the second half of 2019.

Figure 1: Russian Federal Districts by cement production in 2016. Source: Soyuzcement.ru.

Anecdotally, this change in the fortunes of the Russian cement industry can be seen in the volume of news coverage on the Global Cement website over the last few years. The mean number of news stories on the country in 2016 and 2017, increased by half in 2018 and then again in 2019. Partly this is down to our attempts to increase our coverage of the region but it also shows a general trend. In the news specifically there haven’t been many new plant projects domestically but there has been a steady stream of upgrades and maintenance related stories. For example, Eurocement subsidiary Kavkazcement reported in recent weeks that it had installed a replacement dry kiln. This has been part of a group of upgrades that Eurocement has started in 2019. On the supplier side both Germany’s Gebr. Pfeiffer and Italy’s Bedeschi opened subsidiaries in Russia in 2019.

One thing that didn’t seem to slow down the growth were mounting tariffs on Russian exports into Ukraine. Russia’s neighbour first blocked imports of cement from Russia in May 2019 due to, what it said was a Russian ban on imports. It then followed this with an antidumping rate of 115% for imported clinker and Ordinary Portland Cement (OPC) from Russia. It also penalised imports from Belarus and Moldova, although at lower rates. Russia’s cement export rates seemed untroubled by this, rising by 13.5% year-on-year to 0.8Mt in the first 10 months of 2019. Exports hit of high of just below 2Mt/yr in 2014 but have since stabilised at around 1Mt/yr. Imports reached around 5Mt/yr in the early 2010s and have been slowly declining since then, reaching 1.5Mt in 2018.

The lowered production rate that the Russian cement industry has faced over the last five years has been noteworthy given the apparent low capacity utilisation rate. The Global Cement Directory 2019 records the country as having a production capacity of 111Mt/yr. This gives Russia a capacity utilisation rate of 48% in 2018! Unlike, say, the countries in southern Europe that have had to rationalise their cement industries following the post-2008 decline, Russia may have structural aspects to the industry that have helped protect it from lower utilisation rates. These include relatively low export-import rates and the large size of the country with limited sea access to many regions. Most of its production capacity is located in the west but a sizable minority of plants are based further east across the Ural, Siberian and Far Eastern regions. Even under subdued economic conditions, plants in these places are likely to be less susceptible to foreign imports, for example.

Looking ahead, the question is whether the current growth that the cement industry is enjoying is viable once government spending slows down. Alongside this the industry could also focus on sustainability. As the government announced in early January 2020, the country expects to face both negative and positive effects from climate change. The cement industry could be at the front of this trend if it decides to clean up production and/or move into new markets as the Arctic region opens up.

UK: Cemex has entered a conditional agreement with Breedon Group for the divestment of certain UK assets, including 49 ready-mix plants, 28 aggregate quarries and a cement terminal for Euro211m including Breedon Group’s assumption of Euro27.3m lease liability. Cemex UK retains the 1.2Mt/yr Rugby cement plant in Warwickshire. Breedon Group CEO Pat Ward said, “We expect the deal to be accretive to both earnings and free cash flow in the first full year, with a positive ongoing impact on the cash generation of the enlarged Group.” Cemex CEO Fernando Gonzalez said that the transaction ‘further rebalances our portfolio into our core markets, enhances our profitability and enables us to continue to focus on deleveraging.’

The businesses being handed over also include concrete products operations, depots and asphalt plants and fall under all six of Breedon Group’s regional divisions. Ward has said the acquisitions will significantly enlarge the group’s footprint in underrepresented divisions, implying that the cement terminal in question may be the Leith terminal in Scotland or the Newport terminal in Wales, two regions in which the company currently has no terminals to receive cement produced at its 1.5Mt/yr integrated Hope cement plant in Derbyshire. Breedon Group will seek to hire employees working on the operations from Cemex and expects to bring its total UK personnel to 3600 people as a result. It says its mineral reserves will exceed 1.0Bt.

Cemex UK retains 259 concrete plants and 36 aggregates quarries and dredging operations. Cemex said it ‘will retain a substantial integrated business in the UK encompassing cement production.’

Austria: RHI Magnesita has published details of a planned raw materials plant in Austria. The company will spend Euro40m in the construction of the Dolomite Resource Centre Europe for the processing of raw local dolomite into sintered dolomite for use in refractory products at Hochfilz in the state of Tyrol. State Governor Günther Platter and French ambassador to Austria François Saint-Paul joined local folkloric figures Krampus and Saint Nikolas in breaking ground at the site of the future plant, which will be the source of dolomite for all RHI Magnesita European operations from 2021. The plant is part of a raft of projects totalling Euro300m in additional investments by the Austria-based refractory products manufacturer in 2020.

Bolivia: Empresa Minera Industrial’s 0.1Mt/yr integrated cement plant has resumed operations across both dry lines following a fuel shortage. Tinformas has reported that a natural gas shortage caused the suspension of operations in November 2019 following an attack on a pipeline.

Oman: Alsahawa Cement Company (ACC), the newly-founded Oman Cement Company (OCC) subsidiary, will operate the group’s upcoming Duqm cement plant, for which an engineering, procurement and construction (EPC) contract tender has been issued. Bidding is due to close on 27 February 2020.

The new facility will include a coal-fired power plant and waste heat recovery (WHR) power plant. OCC Chief Executive Officer Salim Abdullah Al Hajiri described the commissioning of the 1.7Mt/yr integrated plant as a ‘reverse integration’ process, whereby the plant will initially grind clinker produced at other OCC cement plants beginning in September 2021 before upgrading to fully integrated cement production in March 2022.