Displaying items by tag: Plant

Germany: Heidelberg Materials has started the Front-End Engineering Design (FEED) Study phase on the GeZero project at its Milke plant in Geseke. The technical planning phase is being conducted by Fluor Corporation. It will focus on the design and integration of the various systems into the overall technical concept, which also includes a CO₂ transport solution. The technical planning is expected to be completed in mid-2025 with construction scheduled to start in 2026.

Christian Knell, CEO of Heidelberg Materials Germany, said “With GeZero, Heidelberg Materials will rely on CO₂ capture using state-of-the-art oxyfuel technology in combination with a CO₂ cleaning and liquefaction plant. To pave the way for domestic CCS plants, a CO₂ transport solution by rail is part of the planning until the necessary pipeline infrastructure is available. In addition, a local CO2 storage hub is to be created as interim storage. The electrical energy requirement for the operation of the plant is to be covered exclusively by renewable energies. A new photovoltaic system in the vicinity of the factory premises will help to meet the needs.”

The GeZero project is preparing to build a carbon capture and sequestration (CCS) value chain for the Geseke cement plant, North Rhine-Westphalia, in inland Germany. It aims to capture 0.7Mt/yr of CO₂ starting from 2029. The project is supported by the European Union Innovation Fund.

Kenya: East African Portland Cement (EAPC) has contracted a technical audit from Denmark-based FLSmidth Cement with a value of just under US$70m. EAPC’s acting managing director Mohamed Osman said the findings would guide a pending plant upgrade, to be funded by some of the proceeds from the land sale, according to the Star newspaper. It hopes to double capacity at the unit by the late 2020s without incurring debt. The cement producer is also considering its options to use alternative fuels such as macadamia husks and other agricultural biomass. The 10-week audit process is expected to end in early December 2024.

Osman said “We have tapped FLSmidth to undertake a comprehensive technical audit of the plant, which will assess how to maximise the capacity and inform the design and cost of a new one,'' Osman said. “The audit by FLSmidth will also look at the reserves of raw materials that it has and inform whether it needs to acquire more land that has adequate reserves.”

Italy: Cementir Holding has blamed a fall in earnings in the first nine months of 2024 on “lower results achieved in all geographical areas except Egypt.” It added that sales had fallen due to a decrease in volumes in some places and negative currency effects in Türkiye and Egypt. The group’s revenue fell by 5% year-on-year to €1.24bn in the first nine months of 2024, from €1.30bn in the same period in 2023. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) dropped by 9% to €296m from €326m. Sales volumes of cement and clinker remained stable at 7.98Mt. It noted that volumes increases were reported in Türkiye and, to a lesser extent, in Malaysia and the US. However, volumes of ready-mixed concrete rose by 5% to 3.33Mm³ from 3.18Mm³.

Francesco Caltagirone Jr, chair and CEO, said “The results for the first nine months of 2024 are in line with our expectations and, after several quarters of contraction, signs of a market turnaround in some geographies are emerging in the third quarter of 2024. We are strengthening our competitive position through initiatives such as: the investment on Kiln 4 in Belgium, the restart of the second line in Egypt, the acquisition in concrete in Nordic & Baltic, a new limestone quarry in Malaysia, and the repurchase of a large part of the minority interest in our Egyptian subsidiary, to prepare ourselves for any upcoming market opportunities”.

Türkiye: The Ministry of Environment, Urbanisation and Climate Change has initiated a new process for the ‘Integrated Cement Factory and Raw Material Quarries Project’ in Muğla, which had previously been halted due to local opposition and judicial rulings. A meeting of the Investigation and Evaluation Commission (IAC) is scheduled for 28 November 2024, according to the Ministry's announcement on 6 November 2024.

According to Railly News, the project ran into difficulties when construction by local company Muğla Cement Industry and Trade began in 2021. Following environmental concerns, the Muğla 2nd Administrative Court cancelled the construction permit and the environmental impact assessment (EIA) 'positive' decision, citing non-compliance with the law. A request to appeal was denied.

In response to these developments, local environmental groups and residents have continued their legal efforts, most recently challenging the designation of the plant area as an 'Industrial Area' in the regional development plan. The case remains pending.

When we think about ‘up and coming’ regions for the global cement sector, Africa is high on many people’s lists. This is unsurprising given that Africa is the youngest continent on Earth, with a population set to boom to 2.5 billion by 2050 – or 1 in 4 of the global population for that year, according to the UN. This population, 1 billion higher than today, will drive rapid urbanisation. Cement capacities, currently around 350Mt/yr across the continent, will have to rise substantially to meet demand.

Filling part of this rise will be Amsons Group. This week it announced plans for a US$320m investment in a 1.6Mt/yr greenfield cement plant in Tanzania. It also promised a whopping US$400m to revamp Bamburi Cement in Kenya, should its existing US$180m bid for the Holcim subsidiary be accepted. Based on the numbers for Tanzania, this investment might be enough to take Bamburi Cement from 1.1Mt/yr to around 3Mt/yr, assuming similar project scope and equipment suppliers.

So, what is Amsons Group? Founded in 2000, Amsons is a Tanzania-based conglomerate with interests in construction, transport, flour, container depots, cement and concrete. It already operates Camel Cement, a grinding plant, in the Mbagala suburb of Dar es Salaam and it owns a 65% stake in the 1.1Mt/yr integrated Mbeya Cement plant, which it bought from Holcim in September 2023. The group’s website states that it emphasises local production of materials to reduce the nation’s reliance on imports. A greenfield cement plant fits right into that philosophy.

Looking at recent market trends, we see some positive news for Amsons. In Tanzania, cement production rose by 6.2% to 8Mt in 2023, according to the country’s Ministry of Industry. This followed a 9.7% rise in the prior year. Data is so far lacking for 2024. To the north, cement consumption ramped up strongly in Kenya in the second half of 2023, following a less than stellar start to the year. Thanks to a particularly strong June to September period, consumption finally ended 2023 around 0.8% higher than the previous year, at 9.6Mt. However, consumption tailed off in the final quarter. Worse, the first four months of 2024 - the most recent data available from the Kenya National Bureau of Statistics - saw a 10% decline in cement consumption relative to the same period of 2023, falling to 2.6Mt/yr.

As Africa lacks cement capacity compared to other regions, it is important to highlight that Amsons’ new plants will have to take on not just existing capacity in East Africa, but countries that export to the continent too. Indeed, this week Pakistan, a long-time agitator of South African cement producers, reported a year-on-year rise in exports for October 2024. Exports rose to 4.36Mt, a 9% increase compared to 4Mt in October 2023. This news comes amid precipitously falling domestic demand within Pakistan, with September 2024 shipments down by 22% year-on-year. It is also worth noting that Tanzania itself exported around 1.1Mt of cement to Rwanda, Burundi, Malawi, the DRC and Zambia in 2023. This figure will likely be higher in 2024, given the February 2024 launch of Huaxin Cement Tanzania Maweni Company’s 1.3Mt/yr plant in Mavini, which has a focus on exports.

This apparent abundance of existing capacity, plus exposure to imports, would appear to give an investor like Amsons Group pause for thought. However, it has committed to a total investment of US$900m. This is not small change. If we add in the money it paid for Mbeya Cement in September 2023 – the amount was not disclosed – Amsons will likely shell out more than US$1bn in just a few years. It is going ‘all in’ to become, in the words of its Managing Director Edha Nahdi, “one of the largest cement manufacturers in Kenya and Tanzania by 2030.” It will be very interesting to follow it on its journey.

Kazakhstan: Aktobecem will build a cement plant in the Aktobe region with a production capacity of 2Mt/yr. The company intends to invest US$143m in the facility, which will create over 500 jobs, according to Trend. Construction is set to begin in spring 2025, with operations commencing in 2026. The construction of the new plant will reportedly supply 80% of the cement needs of the region and reduce logistics costs.

Tanzania/Kenya: Amsons Group will build a US$320m cement plant in northern Tanzania's Tanga area with a production capacity of 5,000t/day, Bloomberg reports. The company also plans to implement a major upgrade at the recently acquired Mbeya Cement in Tanzania, including a new grinding mill, according to Capital News Kenya. Additionally, Amsons plans to invest US$400m in Holcim’s Kenyan subsidiary Bamburi Cement, contingent on its successful US$180m bid.

Edha Nahdi, managing director at Amsons Group, said "Thanks to the support of the Tanzanian and Kenyan governments, our regional expansion plans are now firmly on course. We plan to be one of the largest cement manufacturers in Kenya and Tanzania by 2030."

Zimbabwe: Representatives from the Magunje community appeared before the Parliamentary Portfolio Committee on Lands, Agriculture Mechanisation and Irrigation, voicing concerns over Labenmon Investments Pvt’s noncompliance with legal procedures in establishing a cement production plant near Kemureza Dam and Magunje Growth Point. Led by Zimbabwe National Organisation of Associations of Residents Trust (ZNOART), the community alleged that their views were ignored in the environmental impact assessment process for the plant, which will occupy 135 hectares. The Parliament Committee plans to visit the site soon to gather information from residents. The project is expected to employ over 1500 people and boost the local economy.

Thomas Chidzomba, representative for Hong Kong-based Labenmon Investments Pvt, said "Our project is clear and will follow all the country's laws. In addition, the plant is going to use state-of-the-art technology which ‘minimises or eradicates’ air pollution. We will also not pollute the Kemureza Dam as we will not draw water from it for our operations."

Afghanistan: The Ministry of Mines and Petroleum has signed a US$163m contract for the construction of a cement plant in northern Jawzjan province. The plant will produce 3000t/day of cement under a 30-year contract and is expected to employ about 1200 local people.

In an attempt to become self-sufficient in its cement production, the Ministry has also recently signed contracts worth US$476m with domestic and international companies across Parwan, Kandahar and Herat provinces.

India: Adani Group has entered talks with the Odisha government to construct its first greenfield cement plant. Ambuja Cements, a subsidiary of the Adani group, is likely to build the 4Mt/yr unit for US$357 – 416m. The plant is expected to be operational by the 2028 financial year, according to the Hindustan Times. This follows Adani's recent announcement of a new clinker grinding unit in Bihar for US$190 – 238m. Funding for the plant will reportedly come from internal accruals.