Displaying items by tag: Plant

Brazil: Votorantim Cimentos plans to invest US$1bn in expanding its Brazilian operations in the period up to the end of 2028. US$304m-worth of the investments are already underway at the start of 2024. Reuters has reported that the investments include cement plant projects to raise Votorantim Cimentos’ Brazilian cement production capacity by 8.8% to 37Mt/yr. These include a US$162m investment in a 20% capacity expansion to its Votorantim cement plant and a US$60.8m, 1Mt/yr expansion to its Salto de Pirapora plant. Further aims are to ensure structural competitiveness, raise energy efficiency and digitise operations, including applying artificial intelligence (AI) to freight. The producer expects its earnings before interest, taxation, depreciation, and amortization (EBITDA) to eventually rise by US$263/yr between 2023 and 2028 as a result.

It has been a busy week for carbon capture in the cement sector with Global Cement covering five stories. However, increasingly, the topic has become a regular feature in the press as the industry bends to the demands of the carbon agenda. This week’s selection is notable because three of the stories cover North America.

Holcim US announced that it is working with Ohio State University and GTI Energy to design, build and test engineering-scale membrane carbon capture technology at the Holly Hill cement plant in South Carolina. The information builds on an earlier release from the US Department of Energy’s (DOE) Office of Fossil Energy and Carbon Management (FECM) in late December 2023 about the project. It has a total budget of US$9m, with US$7m supplied by the DOE. It plans to build a 3t/day CO₂ capture unit that uses a method intended to retain 95 - 99% of CO₂ from cement kiln gas with a purity exceeding 95%. The new information at this stage is that GTI Energy is involved. Specifically, it will support the development of the pilot skid for site deployment.

The other two stories from North America are worth noting because they both concern commercial equipment or technology suppliers joining up to work together. First, 10 companies - Biomason, Blue Planet Systems, Brimstone, CarbonBuilt, Chement, Fortera, Minus Materials, Queens Carbon, Sublime Systems, and Terra CO₂ - announced they were launching the Decarbonized Cement and Concrete Alliance (DC2). The group’s principal aim is to lobby the US government toward using new low-carbon cement and concrete products in public infrastructure. It also intends to look at advocacy and public sector engagement including expanded tax credits, development of standards for novel cements, consistent ecolabeling and accounting, and customer demand support. DC2 was formally launched in January 2024 but it follows previous work by the companies in the area. The other related story was a memorandum of understanding that Aker Carbon Capture and MAN Energy Solutions have also signed this week to jointly pursue opportunities related to carbon capture, utilisation and storage (CCUS) and CO₂ compression in the North American market. These two companies have worked on the full-scale CCUS unit at Norcem’s Brevik cement plant, which is due to be commissioned later in 2024. They are likely intending to capitalise on the publicity that is likely to be generated once it officially starts up.

Back in North America the DC2 Alliance noted in its press release the DOE’s release of its Pathways to Commercial Liftoff: Low-Carbon Cement report in September 2023. Although it is similar to many other varied sector roadmaps, including the Portland Cement Association’s Road to Net Zero that was released in 2021, this document is well worth reading due to its details and local market context. The headline figure, for example, is that following a set of pathways to fully decarbonise the US cement industry would cost US$60 - 120bn by 2050. Doing so would involve reducing the clinker factor, improving energy efficiency, increased use of alternative fuels, using CCUS, using alternative feedstocks and adopting alternatives to traditional cement production methods.

Graph 1: US active cement kilns by capacity and age. Source: PCA survey data used in Department of Energy Pathways to Commercial Liftoff: Low-Carbon Cement report.

One other interesting tidbit to consider from the report is an analysis of the age of the US cement sector’s kilns versus their production capacity as shown in Graph 1 above. The largest 10 kilns in the country account for 22% of the country’s total capacity and these were all built after 2000. Then, the next 44% of the national capacity comes from 38 kilns out of a total of 120 kilns at 98 cement plants. The report itself does not make this assertion but the implication is that retrofitting CCUS units at one third of the country’s clinker lines would capture the CO2 being emitted from two-thirds of the sector’s production capacity. This is not to say that this could actually work technically, logistically or economically. Yet seeing the scale of the challenge presented in this way is fascinating and one starts to have thoughts about how a retrofit roll-out of CCUS units might actually be approached.

Whether the cement sector adopts CCUS at scale remains to be seen but demonstration projects are definitely coming in both Europe and North America. The DOE report from September 2023 suggests that decarbonisation will cost a lot of money. No surprises there and, as ever, there is rather less detail on who will actually pay for this. One thing that might help here, that the DOE report mentions frequently, is the 45Q carbon capture tax credit scheme, which was introduced by the Trump administration in 2020. Regardless of the potential bill for consumers of cement though, the suppliers are clearly taking note of the investment potential as evidenced by all the non-cement plant CCUS news stories this week.

The 1st Global CemCCUS Conference will take place 13 - 15 May 2024 in Norway and it will include a plant tour of the Norcem Brevik cement plant and CCS project

Saudi Arabia: Sinoma Overseas Development has reported the successful construction of the first steel column for the kiln inlet of the new Line 3 at Yamama Cement’s Al Kharj cement plant in Northern Halal. The China-based supplier used a crawler crane to position the structural element, which is painted in its characteristic blue. In a post to LinkedIn, it said that the development ‘kicks off the steel construction and installation’ of the upcoming 12,500t/day (4.6Mt/yr) line.

Sinoma Overseas Development said “Meticulous preparations were made for the successful completion of the first installation as a landmark task in the project’s construction: civil engineers re-measured pre-embedded bolts multiple times, cleared pathways, and set the area ready for operation. Seamless coordination between commanders and operators, combined with whole-process supervision of managers, made the successful installation of the first steel column possible.” Looking forwards, it said “The project team, greatly inspired by the successful installation, will continue to face challenges head-on, chase for high quality while ensuring safety and make sure tasks are completed in due time for the safe and smooth operation of subsequent construction.”

North America: Aker Carbon Capture and MAN Energy Solutions have signed a Memorandum of Understanding (MoU) to explore carbon capture, utilisation and storage (CCUS) and CO₂ compression opportunities in North America. The collaboration will combine Aker Carbon Capture's amine capture technology with MAN Energy Solutions’ compressor technology to provide standardised and modularised solutions, with optimised energy consumption and delivery time. Both parties are currently participating in the Brevik capture and storage project with Heidelberg Materials Northern Europe in Norway. Rystad Energy has forecast potential capture capacity across North American industries of 200Mt/yr by 2030.

Aker Carbon Capture head of North America Jonah Margulis said "This agreement will strengthen our position to remove and reduce carbon emissions from industries and energy solutions, which is supported by strong incentives from the US government."

MAN Energy Solutions head of sales and project management, carbon capture and storage, Marco Ernst said "We are delighted to work with Aker Carbon Capture, which appreciates our comprehensive expertise in compressor solutions in general and in the area of CO₂ compression in particular. We feel encouraged by the high level of interest in our technical solution concepts that we are on the right path towards sustainable decarbonisation of the industries that have previously had particularly high emissions."

India: Adani Group has announced plans to build a new cement plant, possibly at Godda, in Jharkhand’s Santhal Pargana Division. The Times of India newspaper has reported that producer recently established a 1.6GW power plant in Godda.

The group said “In keeping with our group’s expansion plans, we are conducting a feasibility study to set up a cement factory, most probably in Godda. A proposal will be sent to government soon. The proposed plant will further boost the economy of Godda and Santhal Pargana. The proposed plant will utilise fly ash from our existing power plant here as raw material. At present, the fly ash is being sent to the ACC cement plants in Jhikpani and Sindri.”

India: Shree Cement’s Nawalgarh cement plant has entered production, Dow Jones Newswires has reported. The plant has an integrated cement capacity of 4.2Mt/yr.

Saudi Arabia: Yamama Cement has hired China National Building Material subsidiary Sinoma Overseas Development to upgrade a production line it is moving from its old plant site south of Riyadh to its new site at Northern Halal in Al-Kharj governorate. The 10,000t/day line will be enhanced to a 12,500t/day line as part of the project. Sinoma Overseas Development general manager Yang Lei re-emphasised the company’s commitment to leveraging its technical strengths in both of its on-going projects with Yamama Cement.

The cement company commissioned two production lines supplied by Germany-based ThyssenKrupp with a total production capacity of 20,000t/day in late 2022 at its new plant location to the east of Riyadh. Once the production line from the older Riyadh plant has been moved and upgraded, the Northern Halal plant is expected to have a production capacity of 32,500t/day. Yamama Cement previously shut down five of its older production lines at the Riyadh site in 2017 before saying it was going to sell them in 2019.

Egypt: Arabian Cement Company is replacing electrostatic precipitators at its Ain Sokhna cement plant with bag filters. Arab Finance News has reported that the project will commence in two phases. Arabian Cement Company will first install the filters in Line 1 of the plant, before subsequently installing them in Line 2. Italy-based air pollution control specialist Redecam Group will execute the upgrades.

India: Ambuja Cements has signed a memorandum of understanding (MoU) with the government of Telangana for the construction of a new cement facility in the state. The News Minute has reported that the producer plans to invest US$168m in the project. The MoU is part of an agreement between parent company Adani Group and the state of Telangana covering investments worth US$1.49bn. Other projects include an MoU with Adani Group’s renewables subsidiary Adani Green Energy for the construction of a total of 1350MW of energy storage capacity.

Eastern Province Cement said this week that it had awarded a new production line project to Sinoma CDI. The subsidiary of China-based CNBM Group and Sinoma International Engineering has picked up the contract to build a 10,000t/day plant from design to installation at the cement producer’s Al Khursaniyah plant. Word on project finance is to follow later and the contract should be signed by the end of March 2024. The cement company last mentioned the project to the Saudi Exchange back in March 2023, when it suggested that it was focusing on upgrading existing lines at its Al Khursaniyah plant rather than building a brand new clinker plant at Najibiyah. The plans for the latter project date back to 2015. Eastern Province Cement holds limestone extraction licences in both locations.

It is worth noting that the last couple of new conventional production line projects announced in Saudi Arabia have been picked up by Sinoma International Engineering and related companies. Sinoma International Engineering won an engineering, procurement and construction (EPC) contract to build Southern Province Cement's upcoming Jizan cement plant in May 2023. This followed the awarding of a new 10,000t/day line by Yamama Cement, also to Sinoma International Engineering, in November 2022. However, Germany-based IBAU Hamburg was confirmed by Hoffmann Green Cement Technologies (HGCT) in September 2023 as being the company that would build a ‘clinker-free’ cement plant in Saudi Arabia in 2024. This will be a copy of HGCT’s H2 plant in France, which uses a combination of activated clay, ground granulated blast furnace slag (GGBFS) and gypsum to manufacture its products. HGCT has signed a deal with Shurfah Group to build several Hoffman plants under a 22-year exclusive licensing agreement.

Arguably though, despite all these new plant news stories, the bigger issue so far this year was Saudi Aramco's decision to raise its feedstock and fuel prices from the start of 2024. Several Saudi cement producers released warnings in response that production costs would rise and earnings would fall. Al Jouf Cement, Arabian Cement, Qassim Cement, Saudi Cement, Yamama Cement and Yanbu Cement each made statements to shareholders on the issue, saying that they were working out the impact, would announce what this might be when known and that it was likely to make a difference from the first quarter results onwards.

The timing of Aramco's price hike is poor given that after a tough year, with falling sales for some producers, demand was expected to pick up somewhat. Aljazira Capital, for example, in a cement sector report released in late December 2023, forecast a 3% year-on-year increase in cement sales volumes in 2024 following an estimated fall of 8% in 2023. Its reasoning was that the domestic housing construction market had declined in 2023, leading to high levels of competition in the central region of the country caused by high levels of company inventory. Looking ahead, the competition was expected to ease as more projects were generated outside the central region and demand from the country’s various large-scale infrastructure plans took off. We will have to wait for Aljazira Capital’s next report to find out how they think the market will cope with higher fuel costs, but it seems likely that business may remain tougher than expected for the cement producers in the short term at least.

Finally, one more story to consider is that Al Jouf Cement signed a deal with Rabou’ Al-Taybeh Company this week to export cement and clinker to Jordan. The initial period covers six months with the option for renewal. Up until 2022, at least, clinker exports from Saudi Arabia were growing most years since the export rules were relaxed in 2017. With a difficult market reported domestically in 2023, the appetite to focus on exports may be growing and this could be a sign of that. Another example this week of Saudi-based cement companies looking outside the domestic market could be detected when Northern Region Cement said it had sold a 49% stake in its Iraq business to Al-Diyar Al-Iraqia for Investments Company. The cement company said that the new strategic partnership would help it to further expand its investments in the promising market. It will use the proceeds of the deal to repay loans and for ‘external investments.’ It valued the transaction at just under US$44m. For more on what Northern Region Cement and others have been up to in Iraq, see Global Cement Weekly’s analysis from November 2023.

The steady stream of new clinker production lines suggests confidence in the cement sector in Saudi Arabia in the medium to long term. It is also fascinating to witness a secondary cementitious material plant like the one HGCT is planning on the way too. Unfortunately though, the recent fuel price rise looks like it might ruin the party in the short term for those hoping for better things in 2024.

The 26th Arab International Cement & Building Materials Conference and Exhibition takes place in Cairo on 15 - 17 January 2024. Visit Global Cement at stand N3