Displaying items by tag: Plant

Canada: Holcim subsidiary Lafarge Canada has successfully transitioned its Richmond cement plant to exclusively producing ECOPlanet reduced-CO2 cement. The company says that cement produced at the plant in British Columbia will offer at least 30% reduced CO2 emissions compared with ordinary Portland cement (OPC).

Lafarge Canada West president and chief executive officer Brad Kohl said “This is a proud moment for our organisation. This conversion in Lafarge’s Western Canada division highlights our strong commitment to accelerating green growth."

India: Police are investigating an incident in which a construction worker died and two others were injured at My Home Industries’ Huzurnagar cement plant in the Suryapet District of Telangana. Workers were laying concrete for a new medium-rise building on the site on 25 July 2023, when a pipe conveying concrete became congested. Three workers succeeded in clearing the blockage, however this caused a powerful burst of concrete, knocking them into a lift, which fell to the ground floor. The Indian Express newspaper has reported that 32 year-old Arvind Singh died, while his colleague Raja Singh is receiving treatment for a head injury in Hyderabad. The third worker, Hassan Jamal, has since been discharged from hospital.

Police have reportedly filed charges of negligence against the contractor responsible for the site.

New Zealand: Neocrete has launched an investment round to raise over US$1.86m in funding. The start-up will use the funds to build an industrial-scale plant for its Neocrete activator for pozzolan-based concrete. The use of Neocrete's activator can eliminate up to 50% of cement in concrete. Neocrete aims to ultimately displace 100% of concrete's cement content. The Hawke's Bay Today newspaper has reported that pozzolan-based concrete made using Neocrete's additive offers resilience benefits compared to conventional ordinary Portland cement (OPC)-based concrete. It is especially suited construction in seawater-exposed settings.

Brazil: Votorantim Cimentos has secured a US$150m loan from the International Finance Corporation for an upgrade to its Salto de Pirapora cement plant in São Paulo. The producer aims to increase the alternative fuel (AF) substitution rate at the 4.8Mt/yr plant, and reduce its CO₂ emissions. It says that the loan is tied to sustainability performance indicators (SPIs), based on the reduction in the plant’s Scope 1 CO₂ emissions.

The government in Indonesia made building new cement capacity harder this week. The new rules are intended to strengthen the local sector in the face of a utilisation rate of only 53%. A moratorium policy and/or new investment arrangements have been placed on new cement plant projects. Instead, companies have been asked to focus on the regions of Papua, West Papua, Maluku and North Maluku instead, where demand for cement is higher than what the local production base can produce. Ignatius Warsito, the Director General of the Chemical, Pharmaceutical and Textile Industry at the Ministry of Industry, said that the new rules would be reconsidered once the capacity utilisation rate reaches 85%.

Other measures the government is also looking at include increasing exports of cement, changing regulations related to the coal Public Service Agency (BLU) and improving overland transport. On that last point the authorities and the cement producers are looking at how logistics costs can avoid rising in the face of the impending Zero Over Dimension Over Load (ODOL) policy. Proposals the sector has submitted include implementing a multi-axle policy for trucks and improving the quality of certain roads to allow for higher capacity vehicles.

As one of the government’s focus areas - coal - suggests, fuel prices have been a headache for the cement sector in recent years. Warsito noted that international coal prices started to rise in late 2020. This was likely due to the logistical mess that the coronavirus pandemic caused to the global economy. Higher coal prices caused a “significant” effect on the cement industry through both higher production costs and restrictions on supplies. One irony to note here is that Indonesia is one of the world’s leading coal producers. Donny Arsal, the head of Semen Indonesia, told the government in 2022 that the war in Ukraine had enticed local coal companies to export more coal due to the rising international price. At this time he lobbied the administration to use its local domestic market obligation (DMO) subsidy to better serve the cement sector by giving it more coal at a fixed price.

Graph 1: Cement demand and capacity in Indonesia. Source: Semen Indonesia and Indonesia Cement Association.

Overcapacity has been a recurring feature of the Indonesian cement market since at least the 1990s as the demand and capacity have grown sometimes out of step. The capacity utilisation rate reached 90% in the early 1990s only to fall to 50% by the end of that decade due to the Asian financial crisis. More recently Holcim left the market in 2019 when it sold its business to the Semen Indonesia. The state-owned company consolidated more than half of the country’s cement production capacity at the time. According to its data for the first quarter of 2023 it has a 51% market share and a 46% production capacity share. It also said that 92% of local demand was catered for from four of the country’s 14 producers, namely: Semen Indonesia; Indocement; Conch; and Merah Putih.

A recent study by the Jakarta Post newspaper suggested that after a poor first half in 2023, cement demand was expected to rebound and create modest overall annual growth by the end of the year. The key reasons for this outlook are increased government infrastructure spending, ongoing work on the new capital city Nusantara and anticipated price stability. The new city project, for example, is expected to require 1.6Mt of cement in the 2022 - 2024 period. Risk factors, of course, abound such as a global economic slowdown, financial problems at some of the government-owned construction companies like Waskita Karya and new capacity. A new 8Mt/yr (!) plant owned by local company Kobexindo and China-based Honshi Cement, for instance, is scheduled to start operation in the second half of 2023 in East Kalimantan. Even though the government says that the new unit will export 90% of its production, it will place pressure on other existing sites hoping to increase exports.

The country’s largest cement producer being majority owned by the government is a pertinent feature here given that the same government has also effectively banned new capacity. Semen Indonesia’s earnings before interest, taxation, depreciation and amortisation (EBITDA) have fallen each year consecutively since 2020. As mentioned above overcapacity has long been present in the local sector and recent events have made it worse. Yet, the companies that are likely to benefit the most from a block on newer, competitive cement plants are likely to be the established players. That said, though, with the utilisation just above 50% and new projects like the Kobexindo-Honshi plant on the way, the government likely feels it has to take some form of action. Other tools at its disposal include a national carbon exchange set to launch in September 2023. Power companies will participate from the start with cement producers anticipated to follow at a later stage. Despite the uncertain short-to-medium term outlook the cement sector in Indonesia remains one of the largest in the world with plenty of business to be done. Denmark-based FLSmidth was clearly mindful of this when it opened a new office in Jakarta in April 2023.

India: Ramco Cements plans to invest a total of US$91.3m towards growing its capacity during the 2024 financial year, which ends on 31 March 2024. Its planned investments consist of US$15.8m in an expansion to its Haridaspur grinding plant in Odisha and US$75.5m in the acquisition of land in Bommanalli, Karnataka, on which to establish a limestone mine.

During the previous financial year, which ended on 31 March 2023, Ramco Cements invested US$215m in capital expenditure.

India: Three workers died after an oxygen cylinder exploded at UltraTech Cement’s Hirmi cement plant in Chhattisgarh on 18 July 2023. The Indian Express newspaper has reported that the workers were subcontractors hired to carry out repairs at the 1.9Mt/yr integrated cement plant. They reportedly brought the cylinder with them to the site before it exploded for unknown reasons. Police are investigating the event, and have named the victims as Lakesh Kumar Gayakwad, Shatruhan Lal Verma and Umesh Kumar Verma. The men were aged between 21 and 27.

Tajikistan: The government ordered the immediate shutdown of Tajikcement’s Dushanbe cement plant ‘due to serious air pollution’ on 18 July 2023. Asia-PLUS News has reported that the suspension will likely last until the end of 2023. The government has indicated that an upgrade to the plant’s equipment would be necessary for it to be able to reopen. It previously stated that the plant would have to shut down altogether and relocate to a new site, to be replaced by a confectionary factory.

India: UltraTech Cement has announced the inauguration of its expanded Sonar Bangla II cement plant. Reuters has reported that the expansion has more than doubled the plant's capacity to 1.3Mt/yr. It increases UltraTech Cement's total installed capacity by 0.5% to 131Mt/yr.

Vietnam: The People’s Committee of Hoa Binh Province authorised Xuan Khiem Group to begin building its Xuan Son cement plant earlier in July 2023. Việt Nam News has reported that the upcoming plant will commence operations in late 2024, and will have a capacity of 2.3Mt/yr.