Displaying items by tag: Plant

Adani Group’s latest target for acquisition in the cement sector was revealed this week to be Heidelberg Materials’ India-based business. The Economic Times newspaper reported that talks have started between the companies with a tentative value of US$1.2bn. As might be expected, Adani Group is said to be keen to close the deal down quickly. It wants to avoid an auction situation where it might face competitors. However, there may be some disagreement about the actual production capacity of Heidelberg Materials’ companies in India. If a deal were finalised, it might be completed by early 2027.

Heidelberg Materials’ capacity in India was listed as 14Mt/yr by the press but this could include the company’s grinding plants as well as its integrated ones. Heidelberg Materials, itself, says it has a capacity of 12.1Mt/yr from three integrated cement plants, four grinding plants and a terminal across 12 states. Data from the Global Cement Directory 2024 suggests that this refers to the group’s integrated cement capacity. The plants are roughly split equally between subsidiaries Heidelberg Materials India and Zuari Cement. Heidelberg Materials entered the Indian market in 2006 when it acquired Mysore Cement, Cochin Cement and established a joint-venture with Indorama Cement. It later added Zuari Cement to its portfolio when it bought Italcementi in 2016. The group used to run four integrated plants in India until in May 2024, when it shut down clinker production at its Ammasandra plant in Karnataka, although grinding activity has continued at the site.

Back in 2021 Heidelberg Materials’ CEO Dominik von Achten said that the group had considered selling anything following a business review. "There are no sacred cows. Everything was on the table." Indonesia was generally perceived by analysts as a likely sale target in the developing markets but nothing happened in the end. India wasn’t mentioned at this time, although no doubt it was being considered. Yet Holcim divested its businesses there in 2022. These were picked up by Adani Group for US$6.4bn. This, in turn, kicked off the rivalry in the Indian cement sector between market leader UltraTech Cement and Adani Group. Both companies are now in a race to build production capacity through expansion, new plants and acquisitions.

One reason why Heidelberg Materials may have decided now in particular to talk to Adani Group can be seen in its recent financial reports. In 2023 it said that its “cement and clinker deliveries increased moderately, as massive excess capacities persist in our core markets.” It then followed this up in 2024 by noting that deliveries were slightly down year-on-year in the first half of the year. It blamed this on excess capacity in South India. The subsidiary reported a net loss of €6.3m in 2023. An article by Holtec Consulting in the October 2023 issue of Global Cement Magazine implied that capacity utilisation was 56% in 2023, the lowest of the country’s regions. This is a particular problem for the company given that Zuari Cement is based in the south.

Funnily enough, a sale of 12.1Mt/yr capacity for US$1.2bn suggests a price of US$99/t, a similar figure to what Adani Group paid to buy Holcim’s assets in India in 2022. This may explain why Adani Group is trying to avoid an open sale for the Heidelberg Materials assets. Then again, maybe the market in southern India really is suffering. By comparison, when Adani Group concluded a deal to buy Penna Cements in August 2024 it paid US$1.2bn for an integrated capacity of about 7Mt/yr or around US$170/t. Factor in the low capacity utilisation rate in south India and this potential Adani-Heidelberg Materials deal ends up at roughly the same price.

Something that may help Adani Group reach its goal might be a formal merger between its two main cement companies, Ambuja Cements and ACC. The Mint newspaper reported on it this week, saying that Jefferies and Axis Capital has been hired as an advisor. This certainly makes sense in synergy savings but moving all the mining and leasing rights around might prove cumbersome. Regardless, Adani Group is on an expansion drive, with a capacity of 140Mt/yr targeted by 2028. All the smaller cement companies in the country are potentially targets.

Zimbabwe: Bulawayo City Council has granted approval for China-based Labenmon Investments to establish a grinding plant, expected to employ over 500 people, at Umvumila Industrial Park. Once operational, the facility will produce 900,000t/yr of cement, and plans to export to regional markets including Zambia, Botswana, and Mozambique. The grinding plant was previously planned for Cowdray Park, also in Bulawayo, but the application was rejected in July 2024.

The council report reads “The establishment of a cement mixing plant is expected to benefit Bulawayo Metropolitan Province and other provinces in many ways, such as increased supply of cement, employment for more than 500 local people, increased export earnings for the province, enhanced technology and better equipment for the domestic cement industry in Zimbabwe.”  

Energy has been the theme for a couple of cement news stories of note from Egypt this week. The first concerns the government’s impending plan to centralise distribution of mazut (heavy fuel oil) to cement plants to help them cope with ongoing power shortages. Earlier in the week Cemex signed a deal with the Assiut Governorate to operate a second municipal solid refuse processing unit in the country. The company’s first Regenera facility, in Mahala, started operations in May 2024. Another story from mid-September 2024, along the same theme, covered the inauguration of an 18MW waste heat recovery (WHR) unit at Heidelberg Materials Egypt's Helwan Cement plant.

The wider story is that the country has faced so-called load shedding, or power rationing, since mid-2023 due to falling gas production, rising energy demand and negative currency exchange effects making it harder to buy fuel imports. The power cuts were extended in duration in July 2024 due to a heat wave. The government then said in late September 2024 that it is making investments to prevent domestic power cuts in 2025.

The cement stories mentioned above show some of the ways cement companies cut their energy costs. Two potential ways of doing this are to increase the use of alternative fuels (AF), such as municipal solid waste, or to install a WHR unit. Titan Cement, for example, reported AF thermal substitution rates of above 40% in Alexandria and above 30% in Beni Suef in the first half of 2024. The local press hasn’t reported power shortages amongst the country’s cement producers, but the plans to control the distribution of mazut suggest that either ‘something’ has happened or the government is trying to avoid ‘something.’ Readers may recall that producers have periodically faced step changes in power supplies over the years. In the mid-2010s, for example, lots of plants switched from heavy fuel oil and gas to coal. The energy price fluctuations following the start of the Russia - Ukraine war in 2022 then saw the price of coal rise.

However, what the foreign-owned producers have complained about in the first half of 2024 is the declining exchange rate of the Egyptian Pound. Cementir, Cemex and Titan Cement all noted this. However, Titan reckoned that International Monetary Fund and European Union investment had actually eased the economic situation in the first half of the year leading to an increase in the number of large construction projects.

One effect of the currency problems upon the cement market has been a focus on exports. At the start of September 2024 the Federation of Egyptian Industries said that national cement consumption in 2024 was expected to drop by 4% year-on-year to 45Mt. However, exports were projected to rise to 15Mt. The first and second most popular destinations so far in 2024 have been the Ivory Coast and Ghana. Yet, exports to Libya, the third biggest external market, may have had the biggest effect. These have been blamed for creating a shortage of trucks that was causing delays to the local construction sector. The round-journey from Egypt to Libya can take up to 12 days. This has left building sites bereft of raw material deliveries because all the trucks are elsewhere! Vicat acknowledged the growing importance of imports for its business in Egypt in its half-year report for 2024. It said that ‘sluggish’ domestic market conditions “were more than offset by growth in cement and clinker volumes for export to the Mediterranean and Africa regions.”

The wider picture of the cement sector in Egypt remains one of overcapacity with integrated capacity estimated above 70Mt/yr. The government introduced cement production quotas in mid-2021 and this stabilised prices (and profits). The recent state of the local economy may have strained this, but the latest round of external investment appears to have buoyed things for now. Although the effects of the Israeli military action in Lebanon may have unforeseen consequences upon neighbouring markets. In the meantime, cutting energy costs and growing exports offer two ways for producers to raise their profits.

Saudi Arabia: Turboden, a subsidiary of Mitsubishi Heavy Industries, has announced its first project in Saudi Arabia — a 13MW organic rankine cycle (ORC) power plant at Riyadh Cement Company. This marks the first ORC plant in the Kingdom and the largest globally.

The plant will capture residual heat from the cement plant's clinker coolers and pre-heaters (2 kilns of 5000t/day each), offering high energy efficiency and eliminating water consumption. Sinoma Energy Conservation serves as the project's engineering, procurement and construction contractor.

General manager Andrea La Gioia said "Turboden is honoured to spearhead this groundbreaking project in collaboration with Riyadh Cement Company. With around 460 ORC plants in 52 countries, 50 in ‘waste’ heat recovery application, our ORC technology represents a game-changer in the global energy landscape, and we are proud to support the Kingdom of Saudi Arabia in its transition towards cleaner, more sustainable energy sources."

Ethiopia: Prime Minister Abiy Ahmed has inaugurated the Lemi National Cement Factory, built by a joint venture between West International Holding, the African arm of West China Cement, and East African Holding Company. With a production capacity of 15,000t/day, this facility is now reportedly the largest in Ethiopia, according to Xinhua news. Located 150km north of the capital city of Addis Ababa in the Lemi Building Materials Industrial Park, the project cost US$600m.

Prime Minister Abiy Ahmed said "The project exemplifies the swift and efficient delivery of crucial infrastructure. Congratulations to all those involved in realising this important project, which now produces 50% of the cement made by plants across the country."

India: Ambuja Cement has proposed the establishment of a cement plant at Ramannapet, eliciting concerns from local residents over potential environmental impacts. The proposed plant is intended to be built on 70 acres initially designated for a dry port, and involves an investment of US$167m, according to the Deccan Chronicle. The River Musi, located 14km from the proposed plant, is expected to be at risk, as well as local residents living near the site. The Pollution Control Board is scheduled for a public hearing on 23 October 2024 regarding this matter.

Rythu Sangam district president Meka Ashok Reddy highlighted the community's concerns, noting that fertile agricultural fields within a 14km radius could be turned into ‘wastelands’, and crop yields along the River Musi might drop by 30% due to water contamination. He said that 10 villages around Ramannapet would be affected by pollution from the proposed plant.

France: F Scott, a French group based in Switzerland, is set to construct a new grinding plant in Montoir-de-Bretagne, Loire-Atlantique, by 2027. The €55m investment is expected to create 50 jobs, according to API agency. The plant will import 300,000t/yr of blast furnace slag and a similar amount of clinker by ship, with plans to potentially switch to calcined clay for producing low-carbon cement. F Scott's proposal was approved in mid-late 2023 following a call for expressions of interest by the major maritime port of Nantes-Saint-Nazaire for a bulk products storage and industrial processing unit.

Montenegro: The government of Montenegro and the Ministry of Mining, Oil and Gas plan to construct a new cement plant in Pljevlja at the Jagnjilo site, known for its significant marl deposits. This initiative aims to replace an old landfill, contributing to environmental preservation and harnessing local raw materials for cement production, continuing a legacy that began with a plant operating from 1975 to 1988, according to a statement by the Ministry.

Latvia: Stiga RM is investing more than €32m in a new wood-wool cement board plant in Tukums, expected to complete construction by late 2024 and be operational by the end of 2025. Covering 15,000m², the plant will create almost 100 new jobs and focus on high-quality wood products, primarily for export markets in Europe, Scandinavia and North America. The plant has a capacity of 4.5Mm²/yr of acoustic wood-wool cement boards. The company has an agreement with SCM Group for the supply and installation of the production equipment at the plant.

Manager Sandis Fogelmanis said "We are pleased that the construction of the new plant is progressing according to plan and, at some stages, is even ahead of the original schedule."

One surprise at the end of August 2024 was that Türkiye-based Çimsa has agreed to buy a majority stake in Ireland-based Mannok. The subsidiary of Sabancı Holding signed a deal to acquire just under a 95% stake in Mannok Holdings based on an enterprise value of Euro330m for 100% of the shares. The final purchase price will be determined later in the process, as will a potential completion date subject to the usual regulatory approvals.

Çimsa has described the deal as its “third major global initiative in the past three years” following expansions in the US and Spain. Çimsa started production at its 0.3Mt/yr white cement grinding plant in Houston, Texas in 2019. It is currently planning to set-up a 0.6Mt/yr grey cement grinding plant, also in Houston, with operation expected to start by the end of 2024. Its Spain-based business received a boost in mid-2021 when it purchased the Buñol white cement plant in Valencia from Cemex. Outside of Türkiye the company also operates a few terminals in Germany and Italy. Of interest to this article it established a subsidiary for sales in the UK in mid-2023.

Mannok was previously known as Quinn Group before it was rebranded in 2020. In addition to cement the company sells a range of construction products including PIR (polyisocyanurate) insulation, aircrete thermal blocks, roof tiles and precast concrete. The company is headquartered at Derrylin in Fermanagh, Northern Ireland in the UK but it operates in both Ireland and the UK. It runs a 1.4Mt/yr integrated plant at Ballyconnell, County Cavan in Ireland, just across the border from Derrylin. With the 17th Global CemFuels Conference scheduled to take place next week in Dublin, it is worth noting that this cement plant had a recent upgrade of interest to the alternative fuels sector. In 2023 the company said that it had installed the world’s first FLSmidth Fuelflex Pyrolyzer at a cement plant following an earlier pilot of the system back in 2018. It is used to replace coal with solid recovered fuels (SRF) in the pre-calcination stage of cement production. Later in 2023 Mannok said that the equipment was reducing its CO₂ emissions by 58,000t/yr.

As reported in the October 2023 issue of Global Cement Magazine, cement from the Ballyconnell plant is sold in both Ireland and the UK. In 2022, 35% of its sales were in Ireland, 30% in Northern Ireland and the remaining 35% in the rest of the UK. The company uses a storage unit at Warrenport in Northern Ireland to despatch cement to a 8400t cement storage and distribution at Rochester in Southern England.

Çimsa said that the acquisition is intended to help it to increase the share of its revenue in foreign currencies to over 70%. It is not a revelation that Çimsa might want to do this given the parlous state of the economy in Türkiye since 2018. Interest rates are high and the Turkish Lira has lost value. Çimsa raised the issues this has caused in its 2023 annual report. These include higher costs for imported goods and services such as energy, equipment and engineering services. In 2023 the company reported that 57% of its sales consisted of foreign currency-based revenue. The same year exports represented just under 40% of the company’s total revenue. Overall, Çimsa’s revenue fell slightly year-on-year in 2023, in part due to the divestment of a cement plant and other assets, but earnings rose significantly.

Buying Mannok gives Çimsa another route into the European Union (EU), via Ireland, and the UK. Crucially, this gives its first integrated grey cement production site outside of Türkiye. Both of these things are especially useful for an export-focused company facing increasing hurdles to sales in the guise of the EU Emissions Trading Scheme. It also helps the business to further hedge against negative currency exchange effects back home in Türkiye. So ‘Sláinte’ to Çimsa and Mannok, and good luck.

The 17th Global CemFuels Conference & Exhibition takes place in Dublin, Ireland on 18 - 19 September 2024