Displaying items by tag: VICAT

France: Vicat has joined US-based Schlumberger New Energy, clean energy specialist CEA, Vinci Construction and the Occitan Regional Agency of Energy and Climate (AREC) in a hydrogen production technology joint venture called Genvia. The partnership will establish a ‘gigafactory’ at which to develop high-temperature reversible solid oxide electrolyser technology. The gigafactory will be situated in Béziers, Occitan. Deployment will take place via CEA’s Grenoble, Auvergne-Rhône-Alpes site.

“We are very pleased to be working alongside such experienced and strong partners as we strive to develop technologies that enable decarbonisation,” said François Jacq, chairman of the CEA. “Together, building on a set of technologies developed by the CEA over the last decade, we have ambitious growth plans for a technology that we expect to be a game-changer in the production of clean hydrogen. This initiative demonstrates an alignment of environmental and economic growth ambitions that is important for France and Europe in support of the government's and the commission's recovery plan.”

The technology Genvia plans to use is intended to achieve a high system efficiency, resulting in less electricity use per kg of hydrogen produced. The venture says that the technology is the first of its kind that is fully reversible, giving it the flexibility to switch between electrolysis and fuel cell functions.

France: Vicat started using a CO₂ntainer system supplied by UK-based Carbon8 Systems at its Montalieu-Vercieu cement plant in November 2020. It uses captured CO₂ from the unit’s flue gas emissions to carbonate cement-plant dust and produce aggregate, which can then be used to make products such as concrete. The system has particular relevance for a plant burning alternative fuels due to the additional chlorinated dust created compared to the use of conventional fossil fuels. The company says it is the first European cement producer to use the process at an industrial scale. Previously, Carbon8 Systems said that its CO₂ntainer would process and convert up to 12,000t of cement bypass dust in its first phase of operation.

Vicat Group scientific director Laury Barnes-Davin said, “We were drawn to Carbon8 Systems’ two-part technology: capturing the CO₂ that Montalieu emits, and using it to produce an aggregate that can be marketed in the construction industry. It opens up great potential for our operations not just in France but also in all the countries where we work across the globe.” The group hopes to reach a 100% alternative fuel substitution rate in France by 2024.

There were mixed feelings evoked by HeidelbergCement’s good news last week that its French subsidiary Ciments Calcia is to set to spend Euro400m on a modernisation project. Sadly, this came with the bad news that the integrated plants at Gargenville and Cruas will be downgraded into a grinding plant and a terminal respectively, and there will be a review of the company’s headquarters in Guerville. All of this will cut 160 jobs but create 20 new ones.

Make no mistake, this is serious money to invest. Euro300m alone will go towards an upgrade of the integrated Airvault cement plant in the former Poitou-Charentes administrative region. HeidelbergCement didn’t say it in its press release but French press reported that the pyroprocessing line at Airvault will be rebuilt starting in 2022 with commissioning scheduled for 2025. If correct then this certainly suits an investment on this scale for a single plant. Smaller investments in the region of Euro25 – 50m were also said be earmarked for the integrated plants at Bussac-Forêt, Beaucaire and Couvrot. These are serious commitments to HeidelbergCement’s production base in France.

Generally speaking, the French cement and construction market has done as well as expected for a country forced to implement two coronavirus lockdowns so far in 2020. Half-way through the year the major cement producers were reporting sales declines of around 10% year-on-year with business picking up again over the summer. Vicat, for example, reported a 9% fall in sales volumes in the first half followed by ‘solid business growth’ in June 2020. LafargeHolcim, CRH and HeidelbergCement all reported a similar situation for their local subsidiaries.

Looking at the wider construction industry, in October 2020 analyst company GlobalData stuck by its forecast of a contraction of construction output by 11.6% in France in 2020. It noted a 35.5% quarter-on-quarter rebound in the third quarter, although it reckoned output was still down by around 5% in the quarter year-on-year, using French National Institute of Statistics and Economic Studies (INSEE) data. With a second national lockdown initiated in late October 2020, it said that INSEE expected a contraction in the fourth quarter of 2020 even with construction sites being allowed to stay open. This follows a peak of cement production above 20Mt in the late 2000s before hitting a low of around 15.5Mt in 2015 and a gradual recovery since then, according to data from the French cement industry union (SFIC).

Ciments Calcia’s upgrade at Airvault is noteworthy for the whole of Europe because it is one of only a few new pyroprocessing line projects in the last decade. The last major one was the new 4000t/day line at HeidelbergCement’s Burglengenfeld plant in Germany that was commissioned in 2018. The trend since then has generally been one of integrated plants slowly closing as markets shrank following the 2008 financial crisis, international clinker levels boomed and environmental measures tightened. Dominik von Achten, chairman of the managing board of HeidelbergCement, addressed this last point directly with the announcement of the Airvault project when he said, “This is why we focus our initiatives on the main CO₂-emitting plants in France.” The competitors to the larger established cement producers in France are certainly thinking about CO₂. Alongside the general European trend of fewer new clinker production lines has been rise in France of the smaller cement producers with grinding and/or reduced-clinker factor models like Cem’In’Eu, Hoffmann Green Cement Technologies and Ecocem. Anyone spending Euro300m on a clinker kiln spewing out CO₂ would do well to consider how much the CO₂ price might be in fifty years time.

Germany: The Catch4Climate project has moved into the planning stage of its oxyfuel pilot plant at the Mergelstetten cement plant. The group, comprising Buzzi Unicem’s subsidiary Dyckerhoff, HeidelbergCement, Schwenk Zement and Vicat, signed a letter of intent with the state’s prime minister and transport minister in Stuttgart in mid-November 2020.

The consortium intends to build and operate its own demonstration plant on a semi-industrial scale, to use the oxyfuel process to capture CO₂. In the future, the captured CO₂ will be used to produce so-called ‘reFuels’, climate-neutral synthetic fuels such as kerosene for air traffic, with the help of renewable electrical energy.

The cement producers formed CI4C – Cement Innovation for Climate in late 2019. The aim of the Catch4Climate project is to create the basis for a large-scale application of CO₂ capture technologies in cement plants enabling the later use of CO₂ as a raw material in other processes such as a carbon capture and utilisation/storage.

France: Vicat recorded net sales of Euro2.07bn in the first nine months of 2020, up slightly from Euro2.06bn in the first nine months of 2019. Sales rose in Africa by 23% to Euro198m from Euro161m, in Europe (excluding France) by 8% to Euro317m from Euro294m and in the Americas by 7% to Euro471m from Euro442m.

Cement sales constituted 51% of sales at Euro1.05bn, up by 5% from Euro991m. Cement volumes rose by 8% to 18.0Mt from 16.7Mt, while concrete volumes fell by 2% to 6.65Mt from 6.78Mt.

Chair and chief executive officer (CEO) Guy Sidos said, “The impact of the Covid-19 outbreak on the group's operating profit was eliminated by the end of July 2020. The good momentum observed since then, particularly in the group's most recent operations in India and Brazil, leads us to envisage that operating profit may increase significantly at constant scope and exchange rates in 2020. Nevertheless, the group is continuing its efforts to reduce structural costs, signified by the relocation on 1 October 2020 of its head office to l’Isle d'Abeau in Isère.”

France: Falls in sales in India, France and Italy since the end of the first quarter of 2020 have negatively affected Vicat’s half year results. However, it noted a rebound at the end of the period, particularly in France, and reported earnings growth in the US and Brazil. Its consolidated sales fell by 2.7% year-on-year to Euro1.30bn in the first half of 2020 from Euro1.34bn in the same period in 2019. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) decreased by 6.7% to Euro213mm.

“We kept our production activities running at almost all our sites to keep pace with market trends and seize any commercial opportunities by remaining close to our customers, which has helped to mitigate the impact of the crisis,” said Guy Sidos, the group’s chairman and chief executive officer (CEO). He added that, “In this unprecedented environment, visibility on our full-year performance remains limited.”

France: UK-based Carbon8 Systems has announced plans for the commercial implementation of its carbon capture and use (CCU) system at Vicat’s Montalieu integrated cement plant in France. It follows successful demonstration projects at cement plants in the UK and Canada.

The company’s CO₂ntainer product will be deployed directly onsite at the plant and integrated into Vicat's existing industrial processes. It will capture CO₂ directly from the plant's flue gas emissions and use this as part of its Accelerated Carbonisation Technology (ACT) process. This accelerates the carbonation of cement bypass dust into lightweight aggregates. In its first phase of operation it will process and convert up to 12,000t of cement bypass dust.

US: Vicat subsidiary National Cement has received a fine of US$148,000 from the Alabama Department of Environmental Management (ADEM) for exceeding mercury emissions regulations over a 123-day period between May 2019 and February 2020 at its integrated Ragland plant in Alabama. The Daily Home newspaper has reported that unexpectedly high mercury levels in coal and other raw materials burned as fuel during that time caused the breach, which the company immediately reported to ADEM.

National Cement president Spencer Weitman said, “The issue took several months to fix.” Multiple upgrades and operational changes solved the issue, including installation of a US$400,000 mercury absorption carbon injection system. ADEM said, “National Cement did not economically benefit from the emissions violations.”

In January 2020 National Cement began work on construction of a new US$250m kiln line, due for completion in 2022.

France: Vicat says that group business activity increased month-on-month between April and May 2020. In a special update on business in the context of the coronavirus, the company said that the outbreak’s impacts varied across the 12 countries in which it operates, all of which locked down due to the pandemic.

In France, the level of business is “slightly lower” than in May 2019 following a steady recovery from a “strong slowdown in mid-March 2020.” Macroeconomic and competition issues continue in Egypt and Turkey, not however due to the coronavirus outbreak, while volumes and prices have generally increased in Switzerland, the US, Brazil and Western Africa, except in Senegal, where the government has cancelled infrastructure projects. Following the pan-Indian lockdown between 24 March 2020 and 17 April 2020, business in India has resumed, albeit at a “level significantly below that of the same period of 2019.”

The group says that it is planning cost-cutting measures and has postponed a planned US price rise to late 2020.

Many of the first quarter financial results are in from the multinational cement producers and a few points are worth discussing. As usual a few caveats are worth mentioning such as seasonal and geographical variations between companies, such as producers in the northern hemisphere experiencing a generally slower period. It’s also worth noting that this is a selective look at some of the larger cement producers as not all of them release detailed figures at this stage and others have been delayed. However, the economic effects of the coronavirus lockdowns are clearly showing an effect in a kind of wave as the pandemic has spread.

Graph 1: Sales revenues in the first quarter of 2020 from selected cement producers. Source: Company financial reports.

Graph 1 above shows the effects of the earlier lockdown in China upon the results of the Chinese producers like CNBM, Anhui Conch and China Resources Cement (CRC). What’s interesting with these companies is that they have all suffered revenue hits of 20 – 25%. Huaxin Cement, a producer based in Hubei province near Wuhan where the Chinese lockdown was strictest, is not shown in Graph 1 but its revenue fell by 35% in the first quarter. See GCW452 for more on coronavirus effects on the Chinese cement industry.

Looking more widely, both LafargeHolcim and HeidelbergCement suffered declines of around 10%. This is somewhat misleading as both companies are constantly selling assets making the like-for-like results not quite as bad, particularly in the case of LafargeHolcim with its South-East Asian divestments. Although note this week that LafargeHolcim’s deal to sell its majority stake in Holcim Philippines lapsed this week due to the local competition regulator not granting permission in time. Yet, they are also beneficiaries and victims to an extent of their wide geographical spread with worse performance in Asia and better results in North America. For a fuller look at LafargeHolcim’s first quarter results see last week’s column. The rest of the producers featured generally reflect their tighter market spread with Buzzi Unicem particularly benefiting from the relatively untouched market in the US. Shree Cement, an Indian producer, escaped relatively unscathed, possibly as the Indian lockdown only started in late March 2020. All eyes will be on the results of UltraTech Cement, the largest producer in India, when they finally emerge.

Graph 2: Cement sales volumes in the first quarter of 2020 from selected cement producers. Source: Company financial reports.

Cement sales volumes tell a similar story, although a few different companies are featured in Graph 2. Note CRC’s year-on-year fall of 26% to 11.2Mt in the first quarter. It’s the only larger Chinese cement producer that we’ve found so far that has released sales volumes. Semen Indonesia is interesting too because its figures jumped in January 2020 as its acquisition of Holcim Indonesia only went on the books in February 2019. It’s February and March sales volumes have each been 4 - 5% down year-on-year but it’s far from clear whether this is due to general production overcapacity in the country or from the global health crisis. Despite this, its export volumes from both the mainland and its TLCC subsidiary in Vietnam have held up well. Unfortunately though, its performance in Vietnam may be an outlier if data from the General Department of Vietnam Customs is to be believed this week. It indicated that overall cement exports from the country fell by 9.7% year-on-year to 7.73Mt in the first quarter of 2020. Cementos Argos is also worth looking at as it suffered from the government lockdown in Colombia despite having an international presence in the Caribbean and the US.

Most of the world’s largest cement producers are preparing for the economic shockwaves from lockdowns to hit balance sheets in the second quarter of 2020. Many have said exactly this and have paraded their liquidity levels in preparation. Alongside this the results of the Chinese producers in the next quarter may offer some light on what kind of recovery is possible from easing lockdown measures. Yet the risk of second waves of infections from coronavirus potentially jeopardises any kind of fast or easy recovery without a vaccine. Today’s news that Cemex is considering mothballing its integrated plant at South Ferriby in the UK has been blamed on an analysis of the company’s European cement supply chain. The company says it is not related to coronoavirus but it does suggest the company is making savings.

This week has seen international press coverage return to Wuhan, China and South Korea where small numbers of infections have started to build despite being thought mostly eradicated. No one wants the so-called ‘W’ economic recovery with its rollercoaster ride of crests and dips or indeed the ‘L’ with its slow tail of recovery. Yet, for better or for worse, some form of normality has to return after the lockdowns end. The UK, for example, the country with the worst death rate from coronanvirus in Europe, has allowed its construction workers to pick up tools this week. If and when they can do so in the UK and everywhere else without causing the basic reproduction number (R₀) to rise then the future starts to look a little brighter.