Displaying items by tag: Upgrade

Switzerland: Holcim Schweiz has replaced the kiln stack at its Eclépens cement plant. Deputy plant manager Christian Petit said that the previous stack had been in place since 1971. He thanked the team which installed the new 100m-high stack on 22 October 2021.

Cameroon: Cimenteries du Cameroun has begun building a new US$88.4m 0.5Mt/yr line at its 0.15Mt/yr Figuil cement plant. Agence Ecofin News has reported that the line is scheduled for commissioning in October 2023. It will have an additional clinker capacity of 0.1Mt/yr. When commissioned, the expanded plant will serve northern Cameroon, Chad and the Central African Republic, and bring the company's total cement capacity to 2.5Mt/yr.The LafargeHolcim Maroc Afrique subsidiary, in which the Cameroon National Investment Company (SNI) holds a minority stake, aims to compete with market leader Dangote Cement in Cameroon.

China: Anhui Panjing Cement has ordered an upgrade to its production line from KHD and AVIC. The project includes: installing new triple cyclones in conjunction with existing preheater top stage twin cyclones; a partial modification of downcomer duct; installing a new preheater fan; adding optimised and larger dip tubes for the existing cyclones; installing a new Pyrobox type calciner firing system; adding new raw meal pipes for the two lowest cyclone stages; making calciner modification within the existing preheater building; and installing a new kiln drive system. Where possible the project plans to use reuse existing equipment. It is scheduled for completion by January 2022. It follows a previous upgrade at the plant in 2020 – 2021.

Other recent orders that KHD has announced with China-based cement companies include an upgrade to a production line at Hongshi Group’s Lanzhou plant in Gansu province and the installation of NOx-reducing modifications on a 5000t/day clinker production line operated by China United Cement Baoding.

India: Penna Cement has received clearance for a US$207m initial public offering (IPO). The company will offer a US$33.3m stake for sale along with the fresh issue of US$173m. The Times of India newspaper has reported that the company plans to use US$73.3m of the fresh capital to settle its debts and to invest US$14m in the construction of second line at its Krishnapatnam grinding plant Andhra Pradesh. It will invest a further US$10.7m in an upgrade to raw material and clinker grinding mills at its Talaricheruvu cement plant, also in Andhra Pradesh.

Australia: Cockburn Cement has begun a US$152m upgrade of its Kwinana grinding plant. Business News has reported that the project will consolidate the company’s Kwinana and Munster grinding operations at a single 1.5Mt/yr plant. The company says that this will increase its production capacity by 36% and reduce its cement’s CO₂ emissions by 20%.

The company will manage operations at the plant directly. Managing director Nick Miller said "We've all seen through the Covid-19 outbreak that domestic manufacture of essential products such as cement and industrial lime becomes critically important. Reliability of supply has become a very important driver for decision makers." He added "We have turned away from a turnkey contract to a self-delivery model. Part of the self-delivery model is to access small to medium sub-contractors in the market, where we have seen better value in what is a very heated market."

Russia: Krasnoyarsk Cement has installed a continuous monitoring system for emission control at its Krasnoyarsk cement plant. It carried out the upgrade under the government’s national Ecology project. The system will transmit daily average emissions data to the Krasnoyarsk Territory Ministry of Ecology and Nature Management. Members of the public will be able to access the submissions on the ministry’s website.

Managing Director Dmitry Kireev said “According to the current legislation, the installation was supposed to start working before 31 December 2028. However, due to the fact that the enterprise is located within the city, we voluntarily assumed increased obligations and launched online monitoring of emissions ahead of schedule."

US: Cemex USA has upgraded two Florida cement terminals, the Pensacola and Palm Beach terminals, at a cost of US$8m. The upgraded terminals will serve to increase Cemex USA’s cement supply to the region through marine shipments from its global operations. The Palm Beach terminal is also involved in the distribution of assorted cementitious materials including granulated blast furnace slag (GBFS) and fly ash for cement production.

USA executive vice president Matthew Wild said “Florida is growing rapidly, and Cemex’s strong network makes our company well-positioned to implement supply chain and operational enhancements to meet the high demand for building materials in Florida and beyond.” He added “On the cement side, increased demand has outpaced supply at times, and we expect our supply chain enhancements to help alleviate that issue.”

US: The US Department of Energy has selected Central Plains Cement to receive US$5m-worth of funding to realise its plans for a cryogenic carbon capture (CCC) installation at its Sugar Creek, Missouri, cement plant. Contify Energy News has reported that the system will initially have a capacity of 30t/day of CO₂, with a view to eventually capturing 95% of the plant’s flue gas’ CO₂ content. The Eagle Materials subsidiary will receive US$5m in funding from the US Department of Energy for the project. The sum is part of a raft of a total US$45m-worth of grants to help towards decarbonising heavy industry and natural gas power. Chart Industries will carry out the work.

Chart Industries CEO and President Jill Evanko said that the company’s CCC model increases cement production costs by just 24%, compared to 38% - 130% for other types of system. She added “We are delighted that public and private entities recognise Chart as a leader in carbon capture technologies and products; we view this award as well as our third quarter 2021 commercial activity as meaningful steps and accelerators toward capturing - pun intended - a significant share of our anticipated US$6bn total addressable market for carbon and direct air capture in 2030.”

The St Louis Post newspaper has reported that Holcim US’s Ste-Genevieve, Missouri, cement plant is also among facilities chosen to receive funding for carbon capture and storage (CCS) installations.

Oman: Oman Cement Company will spend US$300m on the new 10,000t/day Line 4 as part of the upcoming upgrade and expansion of its Rusayl cement plant in Muscat governorate. The Oman Observer newspaper has reported that Switzerland-based PEG Resources will carry out the work. Oman Cement Company CEO Salem bin Abdullah al Hajri said that the new line will help Oman to achieve cement self-sufficiency by 2024.

The company said “The new 10,000t/day production line will be the largest in Oman and will have more cost-effective production, for the company to sustain its success and competitiveness in the local and international cement markets in a long run.” It added “The company will focus on utilising state-of-the-art production technology resulting in lower power consumption, potential for waste heat recovery (WHR), higher fuel efficiency, realisable use of alternative fuels (AF), improved productivity and the best environmental standards.”

Oman Cement Company is also expanding the Rusayl plant’s Line 3 by 25% to 5000t/day from 4000t/day, prior to decommissioning its other two lines.

There have been a couple of news stories worth noting in the Turkish market this week. First, it was revealed that Medcem had chosen Sintek Group to build a new production line at its integrated plant in Mersin. Second, Çimko Çimento agreed to buy two integrated plants and a grinding plant from Çimsa.

The Medcem upgrade project will see the subsidiary of Eren Holding add a second production line, with a clinker capacity of 9000t/day. Sintek Group reportedly has agreed to do this for US$128m. This follows an announcement from Medcem in late May 2021 that it was intending to invest over US$200m towards increasing its plant’s overall production capacity to 6.5Mt/yr from 3.5Mt/yr. The plan at this point was to start construction work in August 2021 with eventual commissioning of the second line in the first quarter of 2023. In addition the cement producer said at the time that it was going to open a new terminal in the US shortly. This was intended to join the company’s existing grinding plants in Cameroon and Tunisia and terminals in Russia and Northern Cyprus. On a side note, Medcem likes to point out that the 11,500t/day clinker production capacity on its existing line at its plant is the biggest in Turkey and Europe.

The Çimko Çimento deal with Çimsa was for US$127m. It includes the Nigde Kayseri integrated plants, the Ankara grinding plant and seven ready-mix concrete plants. As would be expected, the transaction is subject to the approval of the local competition authority.

Graph 1: Domestic and export cement sales in Turkey, January – June 2017 – 2021. Source: Türk Çimento.

Graph 1 above gives an idea why some cement producers might have decided that it’s time to expand either through upgrades or acquisitions. The general Turkish economy suffered a jolt in mid-2018 when the value of the Turkish Lira dropped and interest rates rose. The coronavirus pandemic hit in 2020 but after a slowdown at the start of that year the economy managed to grow. The growth has continued so far in 2021 but inflation rates have also soared. In the cement sector, annual domestic sales fell consecutively from 2017 to 2019. They started to recover in 2020 and so far in 2021 it looks like they are continuing to grow. As domestic sales fell the sector focused on exports and they have grown steadily on an annual and half-year basis since 2018. Annual exports hit a high of 16Mt in 2020 or 23% of total sales.

Despite this, in June 2021 the Turkish Cement Manufacturers' Association, Türk Çimento, was warning that input costs were mounting, particularly in the last year. It reported that the price of petcoke had nearly tripled in this period. It also warned of mounting production overcapacity, estimated at over 20Mt/yr in 2019 although down to 7Mt/yr in 2020. Coupled with a fall in annual domestic sales from 2017 to 2019, in its words, “The contraction in domestic consumption during that period steered our companies toward exports.” Some of the larger cement producers, including Oyak, Akçansa and Çimsa all reported healthy rises year-on-year in revenue and operating profit in the first half of 2021. They also reported mounting costs which have risen by 35 – 80%.

The other recent stories from Turkey to note are a two week strike organised by the Building Contractors Confederation (IMKON) in September 2021 due to high costs, particularly cement. The confederation claimed that the price of cement had tripled over the last year. Earlier, in late April 2021, the Turkish competition authority Rekabat Kurumu launched a probe into alleged collusion by nine cement producers including Oyak, Çimsa and Limak. We are not saying these two stories are connected. The current state of the Turkish economy is more than enough to cause input costs for cement producers to spike. Yet headlines like this cannot be reassuring to builders wondering why the cost of cement is going up.

In summary, it’s an uncertain time for the Turkish cement industry. Sales are recovering but this has been achieved by pushing exports more than a rally at home. Alongside this, currency instability and high inflation rates are raising costs for cement producers and end-users. This hasn’t been enough though to stop growth activity from a couple of producers in the last week.

For more on the Turkish cement sector read ‘Cement in Turkey’ in the October 2021 issue of Global Cement Magazine