Displaying items by tag: Plant

PPC revealed plans this week to build a new cement plant in the Western Cape region of South Africa. It has entered into a “strategic cooperation agreement” with Sinoma Overseas Development Company to put together a 1.5Mt/yr integrated plant for around US$160m. It is hoped that construction will start in the second quarter of 2025 with commissioning scheduled by the end of 2026.

CEO Matías Cardarelli described more details about the project during a tie-in webcast on 16 January 2025. Specifically, the new unit will be built at the company’s integrated Riebeeck Plant site due to the quality of the local limestone and the greater reserves. In addition, all the key environmental approvals and mining rights have already been obtained. Both this plant, and the nearby De Hoek Plant, will continue to run throughout the construction and commissioning period. A decision will then be made about required staffing. PPC did not explicitly say whether the two old plants would be closed but the new plant will “replace and increase the existing capacity” at the other sites.

Points to note from the announcement start with the low cost for the clinker production line. PPC’s 1Mt/yr line at its Slurry plant cost around US$75m when it was commissioned in 2018. Sinoma also built that one. However, negative currency exchange effects make comparisons tricky. In 2015 PPC said that the cost of the Slurry line was around US$115/t. It pointed out that the price was low as it was a brownfield investment. This compares to US$107/t for the Western Cape project, another brownfield project. Other recent integrated plant projects in Sub-Saharan Africa to consider include Cemtech’s clinker plant in Sebit, Kenya (US$170/t) or West International Holding’s forthcoming plant in Buikwe District, Uganda (US$150/t). Plans for a new PPC plant in the Western Cape go back to at least 2017 when the then CEO Johan Claassen said it was preparing for a ‘mega plant.’ At the time it was hoping to replace its Riebeeck plant with a ‘semi-brownfield’ facility that would use around 25% of the current plant’s equipment. The scheme had actually been around longer but Claassen remarked that insufficient domestic demand had held it back.

The next detail to consider is that PPC is planning to build this new plant within 100km of the coast. This was addressed directly with PPC saying that the new plant would be “extremely competitive” against imports. They say it will be able to produce cement, at least, to a similar cost to imports from Vietnam. It was also remarked that only 10 - 15% of the 1Mt/yr of imports, mainly from Vietnam, go to the Western Cape with the rest heading to KwaZulu-Natal via the Port of Durban.

PPC’s plans in Riebeeck are part of its ‘Awaken the Giant’ development strategy. For its six month financial results statement to September 2024 it said that it had “early positive and encouraging signs in all lines of our business.” In South Africa its earnings were up despite lower sales volumes. Dangote Cement’s local subsidiary, Sephaku Holdings, reported a similar picture with a small bump in revenue and earnings back up after coal and fly ash supply constraints a year earlier. PPC isn’t the only cement company developing capacity. Huaxin Cement-owned Natal Portland Cement was reportedly investing US$65m in the autumn of 2024 towards expanding its Simuma Plant in KwaZulu-Natal.

The cement sector in South Africa had a couple of ownership changes in 2024. As mentioned above, China-based Huaxin Cement bought Natal Portland Cement from InterCement at the start of the year. Then, Afrimat received approval to buy Lafarge South Africa in April 2024. Both of these incomers have clear ambitions to expand in the industry. In this context PPC’s decision to finally revive its Western Cape plans, before whatever its new competitors devise, makes sense. Expect more talk of capacity upgrades in the future.

Türkiye: Two members of the cement sector have reportedly died in a fire at the Bolu Kartalkaya Ski Center. Aysemin Elif Dogan, Mehmet Cem Dogan and their daughter perished in the incident, according to posts by their employers on LinkedIn. 76 people have so far reported to have been killed.

Aysemin Elif Dogan was the R&D and Quality Director for Baştaş Çimento, a subsidiary of France-based Vicat.

Mehmet Cem Dogan had been the plant manager of OYAK Çimento’s Bolu plant in Caydurt since 2023. Prior to this he was the manager of a plant in Ankara. Dogan previously worked for Vicat’s subsidiary Baştaş Çimento and Cimpor in process engineering and production management roles.

Brazil: thyssenkrupp Polysius has secured a front-end engineering design contract from Circlua for the construction of the world’s largest activated clay plant, with a capacity of 0.96Mt/yr (3000t/day). The plant will be largely powered by renewable electricity, and will be located in Pará, utilising clay sourced from the Carajás iron ore complex. The clay contains up to 80% kaolinite content, and will be upcycled as supplementary cementitious material.

thyssenkrupp Polysius CEO Christian Myland said “We are honoured to partner on this landmark project. Leveraging high-quality local clay and our advanced activated clay technology, this plant will set a new benchmark for carbon-conscious cement production.”

South Africa: PPC has partnered with Sinoma Overseas Development to build a US$159m, 1.5Mt/yr cement plant at an existing site in Western Cape. The plant will supply customers in Western Cape, Eastern Cape, and Northern Cape. This comes after PPC and Sinoma signed a 'strategic co-operation agreement' in July 2024 that would see them partner with each other to identify new projects and opportunities to improve the efficiency of PPC's operations.

Equipped with solar power and ‘the latest’ technology, the facility will reportedly improve energy efficiency, reduce coal consumption and lower emissions per tonne of cement produced, contributing to reduced production costs.

Over the next three months, the parties will finalise the scope and final assessment of the new plant, as well as the associated turn-key engineering, procurement and construction agreements. Construction of the new plant is expected to begin in the second quarter of 2025, with the plant commissioned by the end of 2026.

PPC CEO Matias Cardarelli said "With this new and most advanced energy and environmentally efficient plant in the country, we will be able to supply our customers with lower-carbon cement at a more competitive cost.”

US: Oakland, California-based cleantech startup Brimstone has received a US Department of Energy grant worth up to US$189m to establish a plant with a capacity of 80,000t/yr of ‘green’ cement and 20,000t/yr of smelter-grade alumina, according to the San Francisco Business Times. The grant will be paid out in instalments and requires matching funds from new investments, loans and other sources.

The US$378m facility, which is still in the site selection phase, will be located near an existing quarry in order to mine calcium silicate rocks.

CEO Cody Finke said “We’re exclusively looking at brownfield sites. The goal is to build our own plant while utilising existing quarries to ensure a sustainable and economically viable operation.”

Brimstone plans to begin pilot operations in 2025 and aims to have the plant fully operational by the end of the decade. The company is currently testing its decarbonised cement with potential customers from its Oakland research and development facility.

Iraq: Iraq’s largest cement plant in Kirkuk has resumed operations after a shutdown in November 2024 due to environmental non-compliance and an issued fine of US$343,000. Upgrades include a new dust control system and pollution monitoring equipment. Residents of nearby Lailan have previously protested against the plant, stating that the pollution caused adverse health effects and poisoned local crops, according to Intellinews. Following inspections, the factory now reportedly meets relevant pollutant standards.

Nigeria: The Bauchi State government has approved a US$7.9m road project to support the development of the Gwana cement plant in Alkaleri. 10,000 people will be employed in the construction of the plant before it commences production in the next two years, according to Leadership News. Feasibility studies for the plant have reached an advanced stage for the location of the plant by Resident Cement Company.

The plant will generate 100MW of electricity for the plant from coal, with surplus power supplied to nearby communities.

Consolidation in the Indian cement sector continued through December 2024. UltraTech Cement completed its acquisition of a larger stake in The India Cements late in the month. Then, this week, Nuvoco Vistas said that it was preparing to buy Vadraj Cement. Along similar lines, JK Lakshmi Cement also confirmed that it was moving ahead with the merger of its cement-related subsidiaries.

The UltraTech Cement deal was approved by its board of directors in July 2024 but it took until 24 December 2024 before it formally completed the purchase of an additional 33% stake in The India Cements. The deal was valued at around US$460m in mid-2024 by local press. UltraTech Cement now owns just under a 55% stake in the company and is its majority shareholder. Back in July 2024 UltraTech Cement said that The India Cements had a total production capacity of around 14.5Mt/yr of ordinary Portland cement (OPC). Just under 13Mt/yr of this is based in the south of the country, mostly in Tamil Nadu, and 1.5Mt/yr is in Rajasthan.

The Nuvoco Vistas announcement follows a bidding process to acquire Vadraj Cement through a corporate insolvency process. Key parts of the deal include taking control of Vadraj Cement’s 6Mt/yr grinding plant in Surat and its 3.5Mt/yr integrated plant in Kutch. Both plants are in Gujarat. The agreement also includes limestone mining rights in the state and a captive jetty near the Kutch plant. However, the expression of interest for the insolvency proceedings, published in March 2024, revealed that the company’s operations have been suspended for five years. The grinding plant and the jetty were described as ‘partially constructed.’ Nuvoco Vistas has not disclosed how much it had bid to pay for the company, although it was keener in its press release to state that the transaction would see it become the fifth largest cement producer in India. It says that its cement production capacity will rise to 31Mt/yr; 19Mt/yr of this in the east, 6Mt/yr in the north and 6Mt/yr in the west. Synergies are also hoped for when the new assets are combined with Nuvoco Vistas’ current plants at Nimbol and Chittorgarh in Rajasthan.

Compared to the previous two news stories, the JK Lakshmi Cement merger plan is on a smaller scale but it follows the same trend. The cement producer presented its corporate restructuring plan to its shareholders in July 2024. It wants to merge JK Lakshmi Cement, its main cement company, with Udaipur Cement, Hidrive and Hansdeep. JK Lakshmi Cement runs two integrated cement plants at Sirohi, Rajasthan, and Durg, Chattisgarh respectively. It also operates what it calls ‘split location grinding’ plants at Kalol and Surat in Gujarat, at Jhamri in Haryana and at Cuttack in Odisha. Udaipur Cement operates one integrated plant in Rajasthan, Hidrive owns land next to the group’s Surat unit and Hansdeep is a preferred bidder for limestone resources in Nagaur, Rajasthan. The group’s clinker and cement production capacities are 10Mt/yr and 16.4Mt/yr. Its rationale is to gain synergies from production, distribution and logistics, to simplify the corporate structure, to improve efficiency and to raise shareholder value. That last one might be particularly useful for a cement producer looking to expand or sell in the future.

Further mergers and acquisitions are expected to happen in 2025 but at a slower rate than in 2024. Part of the dynamic so far has been that the highest demand is in the east and the highest capacity is in the south. Many of the deals announced in 2024 focused on markets in the south of the country. By contrast, analysts quoted in the Economic Times at the start of 2025 anticipate that new transactions might start to move to other regions. Obvious potential targets include Jaiprakash Associates and Heidelberg Materials. The first company became insolvent in 2024 and is likely to be sold off. Rumours of a potential purchase of the second company by Adani Group in the autumn hit the local press in October 2024. Doubtless there are other less visible possibilities too if the price is right. Read Global Cement Weekly in 2025 to find out what happens.

Philippines: DMCI Holdings will postpone developing a cement plant on Semirara Island following its acquisition of almost 90% of Cemex Holdings Philippines (CHP). 

Herbert Consunji, chief finance officer of DMCI and president and CEO of CHP, said CHP's existing plants in Antipolo and Cebu better serve key markets in Luzon and Visayas, according to The Manila Bulletin. Transport costs from Semirara Island would result in an increase in cement prices.

The company will reconsider the project upon the renewal of its coal operating contract in July 2027.

Zimbabwe: PPC Zimbabwe says it is speeding up the construction of two solar power plants, with a combined capacity of 30MW, to enhance power supply to its cement plants. The company plans to start work on the solar units from the first quarter of 2025 with completion scheduled for the second half of 2026, according to the Herald Zimbabwe newspaper. Albert Sigei, Managing Director, said that the company was also continuing to work with the Zimbabwe Electricity Transmission and Distribution Company (ZETDC) to improve the electricity supply.