Displaying items by tag: Power Plant

India: Orient Cement says that it has 'mutually terminated' a memorandum of understanding with Adani Group subsidiary Adani Power Maharashtra for a sublease of land in Tiroda in Maharashtra. Orient Cement had planned to establish a grinding plant on the land. It is located at the site of Adani Power Maharashtra's Tiroda coal-fired power plant and belongs to the state-owned Maharashtra Industrial Development Corporation. The parties signed the agreement in September 2021. The reason for termination was the parties' failure to meet its conditions, even despite extensions beyond the stipulated 365-day period in which to do so.

Nigeria: GE Gas Power expects to commission a new 50MW power plant at a Dangote Cement site in early 2023. The supplier said that the new power plant will provide energy for Dangote Cement's cement production and refinery operations.

The This Day newspaper has reported that the new plant is part of a total 500MW-worth of new power infrastructure which GE Gas Power expects to commission in Nigeria before July 2023.

Japan: Mitsubishi Heavy Industries (MHI) has won an Award for Excellence at the 41st Nikkei Excellent Products and Services Awards for its carbon capture system. It was among eight industrial products to win the award for the year. The panel of judges selected MHI's system for its compact and versatile module configuration, which shortens installation and transport times.

MHI's model has been in industrial operation since June 2022, when MHI inaugurated its first system at Taihei Dengyo Kaisha's Seifu Shinto biomass power plant. The technology is now in operation or under implementation at cement plants in Japan and overseas. Most recently, MHI secured a carbon capture contract with a UK cement plant, Hanson's Padeswood plant, in mid-December 2022.

Austria: Lafarge Zement has successfully demolished the chimney of a former gas power plant at its Mannersdorf cement plant in Lower Austria. Hans Zöchling GmbH carried out the demolition work. Lafarge Zement plans to use the cleared space for a new solar power plant. Plant manager Helmut Reiterer said that further renewable power projects are also planned at the site.

Pakistan: National Transmission and Despatch Company (NTDC) has secured a US$46.6m loan from German state-owned bank KfW for construction of a new 500kV grid station in Chakwal, Punjab. The German government loaned NTDC a further US$2.55m for power capacity expansions. The investments will go towards increasing the availability of electricity in Chakwal, primarily for the benefit of the district's multiple cement plants.

Bestway Cement, DG Khan Cement and Gharibwal cement operate four cement plants with a total capacity of 8.5Mt/yr in Chakwal.

India: Dalmia Cement (Bharat) has concluded a contract for the acquisition of cement and other assets from Jaypee Group for US$684m. Mint News has reported that the deal will bring Dalmia Cement (Bharat) into control of an additional 9.4Mt/yr of cement production capacity, including 6.7Mt/yr of clinker production capacity, as well as 280MW-worth of fossil fuel-fired power capacity. All cement and grinding plants included under the deal belonged to Jaypee Group subsidiaries Jaiprakash Associates and Jaiprakash Power Ventures and are situated in Chhattisgarh, Madhya Pradesh and Uttar Pradesh.

Kenya: Savannah Cement has hired China-based Sinoma International Engineering for construction of its upcoming 2.92Mt/yr Kitui clinker plant in Eastern Province. The plant will additionally have a 900,000t/yr grinding unit, a 35MW fossil fuel-fired captive power plant and a 13MW waste heat recovery (WHR) system. Savannah Cement chair Benson Ndeta said that the plant will convert to 100% solar and WHR-powered production by the end of 2029.

Sinoma International Engineering plans to commence the project immediately, and to complete it in late 2024.

India: Birla Corporation plans to increase its cement production capacity to 30Mt/yr in 2030 from 20Mt/yr at present. It made the proclamation in its annual report for the 2021 – 2022 financial year. Recent developments include the inauguration of its 3.9Mt/yr integrated plant at Mukutban in Maharashtra, run under its RCCPL subsidiary. It is the group’s fourth integrated plant and is reportedly the largest single cement production line in the state. The unit also includes a 40MW captive power plant.

Other developments include plans to expand the capacity of its Kundanganj grinding plant in Uttar Pradesh to 3Mt/yr from 2Mt/yr and a plan to build a new 1.2Mt/yr grinding plant at Gaya in Bihar. The group is also increasing production from its captive coal mines. Output from the Sial Ghoghri coal mine has been increased by 20% above its rated capacity to 30,000t/month. Development of the Bikram coal mine has been advanced and production is expected to start in mid-2023. Finally, the group is adding 8MW of solar power capacity at its Chanderia, Satna and Kundanganj plants in the current financial year and a 10.6MW waste heat recovery (WHR) unit is planned for the Mukutban plant.

Fuels procurement and costs have been weighing on the minds of Indian cement producers since the start of the Russian invasion of Ukraine in February 2022. Two news stories this week show some of this. The first concerns recent imports of petcoke from Venezuela. The second covers the closure of captive power plants due to domestic shortages of coal.

At the same time, as the financial results for cement companies for the first quarter of the Indian 2023 financial year have been released, one constant has been hefty hikes in power and fuel costs. Graph 1 below gives a rough idea of the jump in costs major producers have been contending with. One point to note is that, possibly, the larger cement companies may have been better at slowing down the cost inflation from fuel. However, the prevalence of waste heat recovery installations and alternative fuels usage may also be a factor here. Finally, the company approved to buy Ambuja Cement and ACC, Adani Group, also runs India’s biggest coal trader. It will be interesting to see in the medium term how this might affect the fuel costs for its new cement division.

Graph 1: Comparison of Power & Fuel costs for selected Indian cement producers in first quarter of 2022 and 2023 financial years. Source: Company financial reports.

The Venezuelan story demonstrates the greater lengths that Indian cement producers are now going to secure fuel supplies. Reuters reports that cement companies imported at least 160,000t of petcoke from the South American country between April and June 2022 and that more was on the way. JSW Cement, Ramco Cements and Orient Cement are among them. The Venezuelan oil industry has been under US economic sanctions since 2019 but byproducts such as petcoke are not covered by this. Its petcoke has apparently been discounted by 5 - 10% below the price of US alternatives.

Indian cement producers have been prepared to risk US sanctions further by importing coal from Russia. The Business Standard newspaper, using data from Coalmint, reported that Russia became India’s third largest source of coal imports, at 2.06Mt, in July 2022. Before the war it was the sixth-largest source of coal to the country. Again, Reuters covered how cement companies were doing this in July 2022, when it revealed that UltraTech Cement had used India-based HDFC Bank to purchase coal using Chinese Renminbi, not the US Dollar as is more common for international purchases of commodities. In a conference call for the release of its first quarter results, UltraTech Cement’s chief financial officer Atul Daga confirmed the purchase and described it as “opportunistic.” He added that, “If something more surfaces, we will pick it up.” As the data for July 2022 shows, it may or may not be UltraTech Cement that is buying Russian coal right now but other parties in India certainly are.

Some of the wider economic implications about India buying Russian coal in the face of US and European sanctions include whether any retaliation might be forthcoming and a general sign that the dominance of the US Dollar as the world’s reserve currency is not guaranteed. The former seems doubtful given the size of India’s markets. Yet if the sanctions against Russia drag on then a shift in the global economic status quo becomes more likely, especially if opportunistic purchases become regular ones.

The situation facing captive power plants illustrates one more turn of the screw on energy costs for industrial manufacturers. 30% of captive power plants in India are reportedly closed due to the high cost of coal or an inability to even import it. Although it is worth noting that it is unclear whether, proportionally, more or less of these are serving cement plants. As N Srinivasan, the vice-chairman and managing director of India Cements told the Business Standard newspaper, “Most of our plants have coal based captive power generation. The cost of captive generation is now more than the grid cost. Hence, we shut down all captive power units and resorted to grid power.”

The International Energy Agency (IEA) forecast in July 2022 that Indian coal demand would grow by 3% year-on-year to 1.16Bnt in 2023 due to expanded electrification and economic growth. In its view, global coal demand will be driven principally by China but also by India to a lesser extent. However, unhelpfully, it added that uncertainty was also rising with ongoing developments in the war in Ukraine having a prominent effect. This is unlikely to assist Indian cement producers and their fuel buyers who will be asking themselves: how long will the current situation last and can the prices be passed on to consumers? There is one small silver lining in the current group of economic storm clouds hanging over cement producers at least. The second quarter of the Indian financial year is monsoon season, when economic activity slows down. It won’t slow the trend down but it may reduce the fuel bill a little.

India: 30% of plants in India’s 78GW captive power plant network have temporarily closed due to high coal prices. 40GW-worth of capacity (55%) is coal-fired, with an annual consumption of 200Mt/yr. The Business Standard newspaper has reported that total Indian coal imports fell by 10% to 23.8Mt in July 2021 from 26.3Mt in June 2021. Deliveries of coal to non-power sector consumers fell by 33% year-on-year at the beginning of August 2021. The Indian Cement Manufacturers Association (CMA) and nine other national industry associations have contacted the government to urge the formation of policies for the equitable distribution of available coal.

India Cements has imported two shipments of Russian coal for use in cement production. The company’s power and fuel costs rose by 54% year-on-year in the first quarter of its 2023 financial year, which began on 1 April 2022. Its vice-chair and managing director Narayanaswami Srinivasan said “Most of our plants have coal-based captive power generation. The cost of captive generation is now more than the grid cost. Hence, we shut down all captive power units and resorted to grid power.”