Displaying items by tag: Plant

France: Patrick Debavelaere has been appointed as the director of LafargeHoclim’s Val d'Azergues cement plant near Lyon. He suceeds Thomas de Charrette who has been in post for six years, according to Le Pays Roannais newspaper. Debavelaere, aged 43 years, had been working as an industrial director for Lafarge France’s aggregate business. Prior to this he was the production manager at the Martres cement plant.

Namibia/China: Sinoma Energy Conservation has signed a contract with China’s Asia-Africa Business Management (AABM) to build a 4.5MW waste heat power plant. The power unit will support a 2500t/day cement production plant that AABM and local company Whale Rock Cement plan to build as a joint venture. The cement plant project was first announced in 2015.

Slovenia: LafargeHolcim has lost a legal battle for an environmental permit at its Trbovlje cement plant. The cement producer appealed against a decision by the Environment Agency to decline to issue its consent to the company in May 2016, according to the Slovenian Press Agency. The company has been attempting to increase its cement production capacity to 1250t/day by using petcoke as a fuel.

Cambodia: Chip Mong Insee Cement has started production at its new plant in the Tuok Meas district in Kampot province. The unit had a soft launch with a visit from Suy Sem, the minister of mines and energy, according to the Phnom Penh Post newspaper. The US$262m plant will have a cement production capacity of 2Mt/yr when it is fully operational.

Nepal: Investment Board Nepal (IBN) and Huaxin Cement have signed a Project Investment Agreement (PIA) for the Chinese company to build a cement plant. The agreement follows the Department of Mines and Geology’s decision to award a limestone mine in Dhading district to the Chinese cement producer, according to the Xinhua news agency. Huaxin Cement plans to spend US$140m towards building a plant with a cement production capacity of 3000t/day. The deal follows an agreement between the IBN and Hongshi Cement finalised in September 2017 to build a new plant for around US$360m.

China: China Resources Cement has started a production line at a subsidiary in Hepu County in the Guangxi Zhuang Autonomous Region. The new line has a clinker production capacity of 1.6Mt/yr and a cement production capacity of 2Mt/yr. At present the company has a clinker and cement production capacity of 26.6Mt/yr and 33.2Mt/yr respectively in the region.

Colombia: Organizacion Corona has announced that its President Carlos Enrique Moreno will be replaced by Jaime Alberto Angel from October 2017 as head of the Corona Industrial division. Angel will oversee the construction of a US$400m cement plant in the Sonson Municipality of Antioquia, which the group is building as a joint venture project with Spain’s Cementos Molins. The 1.35Mt/yr plant is expected to come online in early 2019.

Moreno said that the decision to split the company’s management was due to the construction of the cement plant. Angel will also look after Corona’s bathrooms and kitchens, materials and paints, energy and industrial supplies and tableware divisions.

The old joke about buses only coming along in pairs might just apply to Angolan cement plants this week with the inauguration of Nova Cimangola’s new 2.4Mt/yr cement plant in Luanda. It follows the announcement of the start of an upgrade project to build a clinker kiln at Cimenfort’s grinding plant in Benguela. In cement industry terms for a country with a production capacity below 10Mt/yr these projects are right on top of each other!

Nova Cimangola’s new plant has been a well-publicised project internationally. Sinoma International Engineering coordinated the line for US$400m in 21 months using components from well-known suppliers. Loesche provided a number of raw material, cement and coal mills for the project, including the country’s first vertical roller mill, as well as other components and parts. Loesche’s Austrian subsidiary A Tec also got involved as an EPCM (Engineering, Procurement & Construction Management) partner.

Cimenfort’s clinker kiln project is the third phase of a process to turn its grinding plant at Catumbela in Benguela into a fully integrated unit since it opened in 2012. Earlier phases saw the grinding plant’s capacity increase to 1.4Mt/yr from 0.7Mt/yr by using a new roller press. Work on the kiln is now scheduled to start in January 2018 with completion scheduled for 2020.

If Cimenfort makes it to clinker production they will join the country’s three main producers: Nova Cimangola, Fabrica de Cimento do Kwanza Sul (FCKS) and the China International Fund. Getting that far is by no means certain as the Palanca Cement plant project demonstrates. That scheme was backed by Brazil’s Camargo Corrêa, the owners of InterCement, and local business group Gema. However, the regulators bailed out Portugal’s Banco Espírito Santo, the financial backer of the project, in 2014 effectively killing it. Another project that has gone on the back burner is Portugal’s Secil’s plan to build a second plant next to its grinding plant in Lobito. Originally approved by the Angolan government in 2007 the project has been kicked around since then through various revisions to the local investment body. It was last reported as being under consideration by the president’s office of Angola in 2016.

Ministry of Industry figures place cement production capacity at 8.3Mt/yr compared to a consumption of 6Mt/yr. In contrast to this Secil’s parent company Semapa reported that the Angolan cement market contracted in 2016 by 25% to 3.9Mt in line with the poor state of the general economy, pushed down by poor oil prices. It blamed the decrease in cement consumption on a halt in public infrastructure spending and the negative effect that local currency devaluations had on clinker imports and other incoming raw materials. With the International Monetary Fund (IMF) forecasting economic growth to pick up for Angola in 2017, improvements in the construction and cement sector are expected by Semapa but they hadn’t been seen so far during the first quarter of the year.

The government’s keenness to describe its cement industry as ‘self-sufficient in cement’ mimics calls from other African countries like Nigeria. The Angolan government banned cement imports in 2015, with the exception of certain border provinces, and this has continued into 2017. However, the ban hasn’t stopped the country exporting cement to its neighbours. Earlier this year the head of Cimenterie de Lukala in the Democratic Republic of Congo blamed the closure of his company’s integrated plant on imports from Angola.

All of this leaves an enlarged local cement industry waiting for the good times to come again. In the meantime, exporting cement and clinker no doubt seems like a promising proposition. In the middle of this are projects like those from Cimenfort and Secil that are looking decidedly dicey in the current economic environment. These companies may have just missed the bus to make their upgrades happen. Still, if they wait around long enough, their chance may come again when the market revives.

Sad news this week from the Talcahuano cement plant in Chile that is to stop producing clinker. Local media reports that the Cementos Bío Bío unit has decided to import clinker from Asia instead, which will reduce its production costs. At the same time it has laid off a third of its workforce. The plant has been producing cement since 1961.

The decision carries echoes of Holcim New Zealand’s closure of its Westport cement plant in 2016, another unit in a country on the Pacific Rim. However, in that country LafargeHolcim has purposely moved towards becoming a distribution company by opening import terminals and depots. Plus the local subsidiary benefits from the cement-trading arm of a multinational company. By contrast, local producer Cementos Bío Bío still retains two integrated plants and a grinding plant in Chile. Following the closure its production share from integrated plants will drop to 2.4Mt/yr (39%) from 3.2Mt/yr (45%). The country will retain a total production capacity of 6.2Mt/yr from its clinker producing plants.

The timing of Cementos Bío Bío’s decision is also interesting given that the Chilean competition authority (TDLC) approved Hurtado Vicuña Group to buy a controlling stake in Cemento Polpaico from LafargeHolcim in early July 2017. The deal was originally announced in October 2016 to sell LafargeHolcim’s 54.3% stake in Cemento Polpaico for US$225m. The sale includes one integrated plant with a cement production capacity of 2.3Mt/yr and two grinding plants. Hurtado Vicuña has not been required by the regulator to sell any of its cement units but it has been asked to sell parts of its concrete business and to abide to a ban on repurchasing the assets within 10 years. Hurtado Vicuña owns Cementos BSA, a subsidiary that runs the El Bosque cement grinding plant in Santiago and it has just started-up production at a new 0.95Mt/yr grinding plant at Quilicura, also near the capital.

In its 2016 annual report LafargeHolcim reported that cement sales volumes of cement fell in Chile due to a fall in the residential construction market in the second half of the year. However it did manage to raise its operating earnings before interest, taxation, depreciation and amortisation (EBTIDA) off the back of higher prices and lower production costs compared to the previous year. Cementos Bío Bío concurred with this assessment of the market in its 2016 report, lamenting the country’s poor economic growth since 2015 and declines in the mining and construction sectors. Despite this its cement despatches rose very slightly to 1.56Mt in 2016. The big drop in its sales occurred in 2014 when its sales fell by 10% year-on-year to 1.51Mt. More recently, Bío Bío noted a 37% decrease in its operating profit for its cement, concrete and lime division for the first quarter of 2017 due to falling sales volumes and margins in cement and lime. However, it did benefit from falling costs for energy and petcoke inputs. The group also announced plans to sell a minority stake in itself in February 2017.

These stories show another country that is realigning its cement industry to a clinker-rich world market. Chile appears to retain a ‘big three’ group of local clinker producers that has shifted with the rise of Cementos BSA and the departure of LafargeHolcim. However, the market share in the cement grinding business has changed significantly as Cementos BSA has gained both an integrated plant and a more national profile, away from the capital, with its grinding plants. Once the local market picks up it will be interesting to see whether this trend towards clinker import and local grinding continues.

Congratulations are due to India’s UltraTech Cement this week for finally completing its US$2.5bn asset purchase from Jaiprakash Associates. The deal has been around in some form or another since at least 2014 when UltraTech arranged to buy two cement plants in Madhya Pradesh for around US$750m. That deal, publicly at least, became a victim of the 2015 amendment to India’s Mines and Minerals (Development and Regulation) (MMDR) Act. The Bombay High Court eventually rejected it in early 2016 after a period of delays. However, the deal bounced back in a much larger form around the same time and since then everything has gone relatively smoothly.

As chairman Kumar Mangalam Birla put it in his letter to shareholders in the company’s 2016 – 2017 annual report the, “move is essentially for geographic market expansion.” He then went on to mention all the usual keywords like ‘synergy’ and ‘economies of scale’ that you expect from an acquisition. Quite rightly he finished with, “It is with great pride that I record, that UltraTech is the largest cement player in India and the fifth largest on the world stage.” On that last point he meant outside of China but UltraTech does have a small number of assets outside of India, notably in the UAE, Bahrain, Oman and Bangladesh, hinting at an international future for the cement producer.

Map 1: UltraTech Cement’s plants in India. Source: UltraTech Cement Corporate Dossier, January 2017.

To give a scale of the deal, UltraTech has increased its number of integrated cement plants in India to 18 from 12 and its cement grinding plants to 21 from 16. Its overall cement production capacity will increase by nearly 40% to 91.4Mt/yr from 66.3Mt/yr. The new assets are in Himachal Pradesh, Uttar Pradesh, Uttarakhand, Madhya Pradesh and Andhra Pradesh. The main regions that will benefit are the North, Central and South zones. In particular the Central Zone will see its capacity jump to 21.1Mt/yr from 6.2Mt/yr. This area also includes a new 3.5Mt/yr plant at Dhar in Madhya Pradesh that is scheduled for commercial production in late 2019.

The completion of the Jaiprakash Associates deal was followed by the introduction at the start of July 2017 of the Goods and Services Tax (GST), a rationalisation of some of the country’s central and state taxes. UltraTech promptly said it had reduced its product prices by 2 – 3% in light of tax reductions under the new regime. Some producers were warning of a rise in cement prices in the run-up to the introduction of the GST and the Cement Manufactures’ Association said that the new tax rate was insufficient. However, UltraTech said that the new tax rate of 28% was better than 30 – 31% previously. Other Indian producers also reduced their prices this week following the introduction of the GST.

UltraTech’s expansion and the start of the new tax scheme auger well for the Indian cement industry in 2017. Demonetisation knocked cement production at the start of the year and it may have lowered UltraTech’s capacity utilisation rate as well as reducing domestic sales by cutting housing demand. However, sector rationalisation and a simpler tax approach should help to remedy this. Not all government interaction has been helpful to the cement industry in recent years as the MMDR amendment and demonetisation show but the signs are promising.
Roll on the next set of financial reports.