Displaying items by tag: Plant

India: Ramco Cements has commissioned its new US$366m Kolumigundla cement plant in Andhra Pradesh’s Kurnool District. The Hindu Business Line News has reported that the plant has a clinker capacity of 2.25Mt/yr. It will be equipped with a 12.2MW waste heat recovery plant, 6MW-worth of which will be commissioned in October 2022, with the remainder to follow in 2023. A dedicated fossil fuel-fired power plant and 35km-long railway siding will follow some time in the 2024 financial year.

Nigerian billionaire Aliko Dangote was spotted attending the inauguration ceremony of Kenyan President William Ruto earlier in September 2022. This is relevant because Dangote’s cement company previously announced plans in 2016 to build two 1.5Mt/yr plants in Kenya, near Nairobi and Mombasa respectively. They were intended to become operational by 2021. Unfortunately, Dangote himself allegedly described Kenya as being more corrupt than Nigeria to Kenyan broadcast journalist Jeff Koinange a few years later and nothing more happened. Back in 2014 Ruto visited Dangote Cement’s Obajana plant in Kogi state in Nigeria when the politician was the Deputy President of Kenya. Dangote’s attendance at the presidential inauguration this month suggests at the very least that his relationship with Ruto remains active. Maybe more news on those planned plants will follow.

Graph 1: Cement in Kenya, 2018 – June 2022. Source: Kenya National Bureau of Statistics (KNBS).

The reason why the owner of Africa’s largest cement company might be interested in the Kenyan market can be seen in its latest cement production figures. Data from the Kenya National Bureau of Statistics (KNBS) shows that production for the first half of 2022 grew by 20% year-on-year to 4.95Mt in the first half of 2022, from 4.12Mt in the same period in 2021. Cement production was broadly similar in 2018 and 2019 at around 6Mt. It then increased by 25% to 9.25Mt in 2021 from 7.41Mt in 2020. On a rolling annual basis, production picked up at the start of 2020 and has risen consistently since then each month, peaking at over 10Mt in May 2022.

However, the elections in August 2022 probably slowed this growth trend, despite being much more peaceful than those in 2007, although the KNBS is yet to release the data. Bamburi Cement said in its outlook for the second half of 2022 that it expected markets to recover after the ballot. The subsidiary of Holcim reported increasing turnover in the first half of 2022, due to mounting sales volumes and price rises, but its profit fell sharply. It blamed this on fuel and logistics inflation, growing clinker import costs as well as negative currency exchange effects.

That last point about imported clinker is worth noting given that a government report in late 2021 found that the country had a clinker shortage of up to 3.3Mt/yr. Yet, the KNBS data in recent years shows that cement production and consumption are broadly similar, suggesting that the shortfall in clinker is being imported. The report added that 59% of the imported clinker originated from Egypt, tariff free, due to a free trade agreement. Local producers were reported to have been operating at a 65% capacity utilisation rate. Egypt and the UAE accounted for most of the imported clinker followed by Saudi Arabia. An interview in the Standard newspaper at this time with Bamburi Cement’s managing director Seddiq Hassani revealed that, despite locally produced clinker being cheaper than imported clinker, some producers were reluctant to hand control of a key input material over to their local competitors. Other producers, predictably, were trying to persuade the government to raise the duty on imports of clinker from 10% to 25%. Tariff discussions have continued in 2022.

So far in 2022 the other big stories in the sector have included Bamburi Cement’s plans to build two solar power plants and a major repair to the kiln shell at East Africa Portland Cement’s (EAPCC) Athi River cement plant. The solar plants will be built next to Bamburi Cement’s integrated Mombasa plant and its Nairobi grinding plant. Once operational in 2023 they are anticipated to supply up to 40% of the cement producer’s total power supply. Devki Group, the owner of National Cement, also announced plans in August 2022 to set up a wind farm near Mombasa. However, this seems more like an attempt to diversify the group into electricity production rather than to supply its own plant near Nairobi. EAPCC’s upgrade project has completed this week after about a month and half of work. It is intended to increase the plant’s cement production by 50%.

Cement production started in rise in 2020 but the Covid-19 pandemic may have constrained this. Production (and consumption) then jumped up in 2021 and looks set to do similar in 2022 bar a possible blip from the elections in August 2022. This is despite the global market issues arising from the end of Covid-19 and the war in Ukraine. These may be uncertain times but the fundamentals for the Kenyan cement market look positive despite rising end prices. Unsurprisingly, it looks likely that Dangote Cement remains keen to extend its business to Kenya.

India: Birla Corporation plans to invest a total of US$1bn in realising its planned 50% cement capacity footprint expansion to 30Mt/yr by 2030. The producer is considering establishing 4Mt/yr-worth of new cement plants, possibly in the form of a new 4Mt/yr integrated cement plant in Chhattisgarh. It would also carry out 4Mt/yr-worth of upgrades and 2Mt/yr-worth of debottlenecking work.

The producer expects its newly commissioned Mukutban cement plant to contribute 600,000 - 700,000t of cement production during the remaining five months of the 2023 financial year, rising to 3Mt/yr by 2024.

During the 2022 financial year, Birla Corporation increased its cement sales volumes by 6% to 14Mt. The company said that it achieved 95% capacity utilisation throughout the year. It noted continuing cost pressures and slow demand growth so far in the 2023 financial year.

Chair Harsh Vardhan Lodha said "Things may not look up immediately, but post-Diwali we are hopeful of a robust turnaround."

India: Gensol has commissioned a 6.7MW captive solar power plant for Shree Cement’s Panipat plant in Haryana. The project is estimated to save over 9000t/yr of CO2 emissions. The cement producer acquired the 1.5Mt/yr cement grinding plant in 2015.

Pakistan: The Punjab Assembly has constituted a committee to review proposed plans for a new cement plant in Chakwal in the Province's Rawalpindi Division. Protestors have previously complained about plans to the Punjab Environment Protection Agency. The Dawn newspaper has reported that stated concerns include the threat to the local water supply, damage to future tourism promotion and possible harm to endangered species, including autochthonous wild sheep.

France: HeidelbergCement subsidiary Ciments Calcia plans to lay the first stone of a major upgrade project at its Airvault cement plant on 5 October 2022. The event will mark the start of the construction phase of a new 4000t/day clinker production line, according to La Nouvelle République newspaper. The Euro300m project will be built by Germany-based ThyssenKrupp.

Germany: Heidelberg Materials says it is considering shutting down plants in Germany due to the high cost of gas and electricity. In comments reported by Reuters chief executive officer Dominik von Achten said, "If power prices won't come down sustainably, we would have to take individual plants in Germany completely off the grid. That's what we have prepared for." He added that the company is shifting production to times and days when power prices are lower including at the weekend. However, changing staff shift patterns has required ongoing discussions with labour unions.

The building materials company expects its energy bill to rise by around half year-on-year to over Euro3bn in 2022. It has called on the German government to place a cap on energy prices despite measures the company has already taken to protect itself from soaring costs, such as using alternative fuels.

India: Ramco Cements plans to inaugurate its upcoming Nandyal cement plant in Kalvatala, Andhra Pradesh, on 28 September 2022. The Sakshi Post newspaper has reported that the plant will have a cement capacity of 2Mt/yr. Ramco Cements’ planned total capital expenditure (CAPEX) investments during the 2023 and 2024 financial years (1 April 2022 – 31 March 2024) are expected to reach US$154 – 167m.

Two West Bengali welders fell to their deaths at the site of the upcoming Nandyal cement plant on 25 September. The welders had been working on a conveyor system when it snapped. The Times of India newspaper has reported that both workers died immediately. Police have informed their relatives and are conducting post-mortems.

India: Dalmia Bharat has accelerated its commitment to net zero CO₂ cement production by 2040 with the launch of its newTransformative and Collaborative Strategy Roadmap. The roadmap provides a framework forinnovation, growth and sustainability initiatives through shared synergies with private and public entities, including Asian Development Bank and 50 local government authorities. Initiatives already underway include non-recyclable waste disposal partnerships with local administrations across India. Dalmia Bharat is supporting these initiatives with the installation of chlorine dust bypass systems at two of its cement plants, the first in India. The producer's cement operations are already 40% renewably powered and 13 times water positive.

Dalmia Bharat's environmental, social and governance (ESG) executive director and chief risk officer Arvind Bodhankar said “As a cement producer, we are attached to people’s happiness by gluing thousands of dreams into reality. We therefore strive to give our customers only the best building materials with the lowest environmental impact. In addition, we also intend to drive a net-zero emissions reality with a strategy that’s aligned with our business philosophy, Clean and Green is Profitable and Sustainable.”

Angola: Portugal-based IPIAC has won a contract to upgrade the Cimangola plant in Luanda region to use Limestone Calcined Clay (LC3). The project will be the first in the world to convert an existing clinker production line into a clay calciner. Switzerland-based Ecosolutions conducted a study of raw materials and sustainability issues prior to the signing of the contract. The project will be coordinated and supervised by Portugal-based Techbelt. Once completed the plant will produce 0.3Mt/yr of calcined clay, which can be used to manufacture up to 1Mt/yr of LC3 cement.