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Displaying items by tag: Plant
Lemi cement plant in Ethiopia set to launch
03 June 2024Ethiopia: The Lemi National Cement Factory is preparing to begin production within two months. Located in Amhara Regional State, 130km north of Addis Ababa, the plant will produce 6.4Mt/yr of cement, nearly doubling the nation's current production capacity. The plant represents a joint investment between Ethiopian and Chinese investors and according to 2Merkato News, is expected to become the largest cement plant in Africa.
Update on Spain, May 2024
29 May 2024Cemex announced last week that it will stop producing clinker at its Lloseta plant in Mallorca. Grinding activity at the site will continue, along with the shipment of bagged and bulk cement products. The company has framed the closure as part of its decarbonisation plans. The dismantling of the two preheater towers at the plant is scheduled to take place by the end of 2030. Cemex said that it will take this long to allow the cement plant to continue operating, as well as a neighbouring hydrogen unit and other nearby industrial units. The status of the Lloseta plant has been in question before. It was closed in early 2019 due to reduced cement demand and mounting European CO2 emissions regulations. However, it reopened in 2021.
Readers may recall that Cemex España participated in the Power to Green Hydrogen Mallorca project. Land by the Lloseta cement plant was used to hold solar panels and a solar-powered hydrogen unit. Other partners in the project included energy suppliers Enagás and Redexis and renewable power and infrastructure company Acciona, among others. When the unit was commissioned in early 2022, it said it was the first solar power-to-green hydrogen plant in Spain. The link between Cemex and hydrogen is noteworthy given the cement company’s adoption of hydrogen injection as part of its alternative fuels strategy. Interestingly, Acciona planned to use a blockchain method to certify that hydrogen produced at the site was made using renewable energy sources. Heidelberg Materials also plans to use the same process to verify its evoZero brand of net-zero cement products in 2025. Another recent sustainability sector news story in Spain is the commissioning by Çimsa of a 7.2MW solar plant supporting its Buñol white cement plant in Valencia. The new installation is expected to supply about 18% of the plant’s energy needs.
On the corporate side of things, FCC revealed in mid-May 2024 that it was preparing to spin-off its cement and real estate subsidiaries into a new company called Inmocemento. The cement part of this is Spain-based Cementos Portland Valderrivas. The move is intended to bolster the values of the different parts of the business. The proposal will be put to FCC’s shareholders in late June 2024, with any resulting action taking place by the end of the year. The decision to separate FCC’s cement assets is reminiscent of the financial engineering Holcim has proposed with its US business. However, in this case the driver does not appear to be the disparity between the European and US stock markets.
Graph 1: Domestic consumption and exports of cement in Spain, 2013 - 2023. Source: Oficemen.
Market data was also out this week from Oficemen, the Spanish cement association. Domestic cement consumption grew year-on-year in April 2024 but the year so far is looking weaker with consumption from January to April 2024 down by 4.5% year-on-year to 4.65Mt. This is below Oficemen’s forecast for 2024 where it expected a stagnant situation. However, there are eight more months to go. In 2023 cement consumption fell by 3% to 14.5Mt and exports declined by 7.5% to 5.2Mt. The association blamed continued underinvestment in both the public and private sectors due to economic instability since the Covid-19 pandemic. Graph 1 above shows the wider situation in the Spanish cement market over the last decade. The share of exports has declined and local consumption rebounded after 2020 but has declined since then.
These news stories provide a snapshot of what’s been happening in Spain recently in the cement sector. Oficemen’s prediction for 2024 is gloomy but local consumption has risen over the past 10 years. Exports have fallen but the cement association has started to spin the country’s decarbonsiation drive as a potential positive for the industry’s competitiveness generally. It’s hard to discern right now but there might be an advantage for an export-focused country that conforms to European standards in the future if it can hold onto its capacity. Admittedly, that’s a big if. This thinking along sustainability lines could be seen earlier in May 2024 when Cementos Molins Group rebranded itself as Molins. It described the rebranding as a bid to represent the wider range of construction products it manufactures and sells beyond cement. Oficemen has also pointed out that the local market has room for development given the relatively low cement consumption per capita in Spain compared to its peers. So, whatever happens next, there is likely to be room for improvement in the cement market.
Nigeria: BUA Cement has appointed Chikezie Ajaero as its acting chief financial officer. He succeeds Jacques Piekarski in the post, who resigned at the end of April 2024.
Ajaero is a fellow of the Institute of Chartered Accountants of Nigeria and has over 25 years of experience in financial reporting and control. He also holds a masters of business administration from the University of Lagos. He previously worked as the finance director for the company’s Obu cement plant since 2020.
Indonesia: PT Kobexindo Cement has entered an agreement to construct a new cement plant in South Aceh, despite a national moratorium on such developments. The project, under China-based Hongshi Holding Group subsidiary Zhejiang Hongshi Cement, plans a US$621m investment for a facility with a 6Mt/yr capacity, according to the Jakarta Post.
The Indonesian central government's moratorium, aimed at curbing oversupply in the cement market, prohibits new cement plants except in specified eastern regions. This edict arose as national cement production significantly exceeded demand, according to the Indonesia Cement Association (ASI).
ASI president Lilik Unggul Raharjo said that the move by South Aceh regency not only violated the ban but also threatened the viability of three state-owned cement companies in Sumatra. Raharjo said "These companies are guaranteed to go out of business. The Industry Ministry will conduct a technical verification of foreign direct investment in the cement industry before the permit is issued.”
Tanzania: Fortune Cement Co has initiated white cement production at its new plant in Mkuranga District, Coast Region, aiming to meet both domestic and international demand. The plant, which produces 200t/day of white cement, will bolster employment and increase revenue through exports under the African Continental Free Trade Area (AfCFTA).
Deputy Minister of Industry and Trade, Exaud Kigahe, said “The Ministry will collaborate to ensure that the products manufactured in this plant cross national borders and reach even the African free market.” He also noted that the new production capacity will reduce imports and create job opportunities for Tanzanian youth while enhancing foreign exchange earnings. Currently, over 50% of the raw materials for the plant are sourced locally, excluding white clinker, which is imported.
Delegates at the Global CemCCUS Conference last week applauded when Anders Petersen, the Senior Project Manager Brevik CCS, Heidelberg Materials said that the Brevik cement plant will be capturing CO2 and permanently storing it within the year. Rightly so. This moment will mark a historic milestone for the sector when it arrives. Net zero cement production is coming.
Last week’s event in Oslo delivered an overview of the current state of carbon capture in the cement and lime industries. It explored the practical challenges these industries face in capturing CO2 emissions and - crucially – then working out what to do with them afterwards. Incredibly, delegates were able to view the construction site of Heidelberg Materials’ forthcoming full-scale carbon capture unit at its Brevik plant in Norway. On the same day as the tour, Holcim broke ground on the Go4Zero carbon capture project at its Obourg plant in Belgium.
The key takeaway at the conference was that a (dusty) bulk solids sector is starting to work with handling (clean) gases in a way it hasn’t before. This recurred repeatedly throughout the conference. Petersen summarised it well when he described Brevik as a meeting pointing between the cement industry and the petrochemical one. It looks likely at present that there will not be a single predominant carbon capture technology that the majority of cement plants will deploy in the future. Similarly, CO2 storage infrastructure and sequestration sites differ. Utilisation plans are less developed but also offer various options. Yet, if carbon capture becomes common at cement and lime plants, then these companies will need to learn how to filter and handle gases regardless of the capture method and destination for the CO2. So presentations on filtration and compressors were a revelation at CemCCUS.
The key obstacle remains how to pay for it all. By necessity, most of the big early projects have received external funding, mostly from governments. Although, to be fair, the private companies involved are often investing considerable amounts of their own money and taking risks in the process too. In the European Union (EU) CO2 is being priced via the Emissions Trading Scheme and investments are being made via the EU Innovation Fund and other schemes. In the US the approach lies in tax breaks, on-shoring and investment in new sustainable technologies.
However, other countries have different priorities. Or as a South Asian contact told Global Cement Weekly at a different conference, “How can our government think about sustainability when it can’t feed everyone?” The world’s biggest cement producing countries are China and India, and then the EU and the US follow. Brazil, Türkiye and Vietnam are at similar levels or not far behind. The EU and the US represent about 9% of global cement production based on Cembureau figures for 2022. China and India cover 61% of production. Neither of these countries has announced a plan to encourage the widespread construction of carbon capture units. Once China ‘gets’ cement carbon capture though, it seems plausible that it will dominate it as it has in many other sectors such as solar panel production. Exporters such as Türkiye and Vietnam will have to adapt to the rules of their target markets.
The march by the cement and lime sectors towards carbon capture has been long, difficult and expensive. It also has a long, long way to go. Yet, the next decade promises to be exciting as new technologies are developed and tested, full-scale projects are commissioned and CO2 pipelines, sequestration sites and usage hubs come online. The next key milestones to look out for include the first full-scale installations using other capture methods (such as oxy-fuel kilns), the first CO2 pipeline network that hooks up to a cement plant, the first land-based sequestration site, the first industrial hub that uses CO2 at scale to manufacture a product, new government policies in China and India, and the first large unit that is funded entirely from private finance. To end on a positive note, a Cembureau representative at the Global CemCCUS Conference reckoned that Europe will be able to capture 12Mt/yr of CO2 by 2030. If it happens, this will be a major achievement and a serious statement of intent towards net zero for the sector.
The 2nd Global CemCCUS Conference will take place in Hamburg in May 2025
RDF plant construction begins in Jakarta
22 May 2024Indonesia: The Jakarta administration has commenced the construction of the Rorotan refuse derived fuel (RDF) plant on a 7.8-hectare site in North Jakarta, aiming to process 2,500t/day of waste. The US$75m project is funded from the 2024 regional budget and is expected to be completed by December 2024 and start operations in early 2025. The city of Jakarta produces nearly 8,000t/day of waste, the majority of which goes to the Bantar Gebang landfill in West Java. The facility will convert 35-40% of the waste processed into about 875t/day of alternative fuels.
The Rorotan facility is the second RDF plant initiated by the Jakarta administration, following the Bantar Gebang facility, which began operations in 2023. This new facility marks a shift from the planned waste-to-energy incinerator in Sunter, which was cancelled due to high costs and bureaucratic delays.
Acting Jakarta governor Heru Budi Hartono said "This technology is still a very small part of our larger efforts to address the city's waste problem."
Head of the Jakarta Environment Agency Asep Kuswanto said "The RDF can become another source of revenue for the city, as we can sell the alternative fuel from the facility to industry."
Zambia: Grizzly Mining has announced an investment of US$200m to establish a cement plant in Solwezi, Northwestern Province. The announcement was made by the company’s vice chairperson Abdoul Ba during an interview, according to the Times of Zambia.
Holcim breaks ground on Go4Zero at Obourg
17 May 2024Belgium: Holcim kicked-off its Go4Zero project at its Obourg plant on 16 May 2024 in an event attended by the Belgian Prime Minister Alexander De Croo and the European Commissioner for Climate Action Wopke Hoekstra. The €500m Go4Zero project, supported with €230m of funding from the European Union, will enable the integrated plant to reduce its CO2 emissions by 30% by 2027 and to produce 2Mt/yr of CO2-free cement by 2029. When fully operational, the Obourg plant will capture 1.2Mt/yr of CO2.
The Go4Zero project incorporates a number of approaches to achieve net-zero CO2 cement. The centrepiece is an oxy-fuel combustion process to generate an easy-to-handle exhaust gas with up to 80% CO2. This will be coupled to a cryogenic purification unit to generate a >99%-pure CO2 stream .The project will also make use of waste heat recovery (WHR), new exhaust filtration equipment and Europe’s largest floating solar panel farm.
Tunisia: Les Ciments de Bizerte has announced that it experienced financial difficulties during the first quarter of 2024. The company was unable to import petcoke due to a lack of cash and looming loan repayments, leading to the total suspension of clinker production. This left the company only able to grind existing clinker and operate its quay. As a result, the company’s total sales in the first quarter of 2024 fell by 53% year-on-year compared to the same period in 2023, falling from US$8.3m to US$3.9m.