Displaying items by tag: grinding plant
India: The Odisha State Level Single Window Clearance Authority (SLSWCA) has approved two cement and slag grinding plant projects in Odisha. It has granted JSW Cement permission for an upgrade to its upcoming 1.2Mt/yr Kalinga Nagar, Odisha slag cement grinding plant that will increase the finished plant’s capacity to 2.4Mt/yr at an additional investment cost of US$359,000. JSW Cement restarted work on the facility, which will grind Ordinary Portland Cement (OPC) and granulated blast furnace slag (GGBS), in September 2018 after suspending the project due to leasing issues in 2016.
Sagar Cements subsidiary Jajpur Cements has also received clearance from the SLSWCA for the construction of a 1.5Mt/yr grinding plant on the site of the existing 0.5Mt/yr Jajpur Cements grinding plant in the Kalinga Nagar Industrial Complex in Jajpur District, Odisha. The project, valued by the company at US$44m, is scheduled for completion in March 2021. Sagar Cements acquired Jajpur Cements on 7 May 2019 for US$16m.
GM Iron & Steel Company reveals 0.4Mt/yr Dhenkanal slag cement grinding plant plans
03 September 2020India: GM Iron & Steel Company Limited has published plans for the construction of a 0.4Mt/yr slag cement grinding plant in Dhenkanal, Odisha. United News of India has reported that the plant is part of an upcoming construction materials complex, including a 46MW captive power plant, that will cost US$82.7m, according to the company.
Prime Cement inaugurates grinding plant in Rwanda
02 September 2020Rwanda: Prime Cement has inaugurated its new 0.6Mt/yr grinding plant in Rwanda in Musanze, Northern Province. It also announced the start of commercial production at the US$40m unit, according to the Rwanda New Times newspaper. It plans to ramp up production to 1.2Mt/yr by mid-2022. Germany-based Loesche installed a Loesche Jumbo CCG (Compact Cement Grinding plant) with type LM 30.2 mill at the site.
The cement plant is owned by Milbridge Holding, a group of companies involved in manufacturing and distribution of construction materials in Angola, the UAE, Rwanda and South Africa. It employs 110 workers directly.
NTPC Limited dispatches first rail load of fly ash from new depot to ACC Cement’s Tikaria grinding plant
17 August 2020India: State-owned energy supplier NTPC Limited has announced the shipment of 3450t of fly ash from its 3.0GW Rihand power station in Uttar Pradesh to Switzerland-based LafargeHolcim subsidiary ACC Cement’s 3.0Mt/yr Tikaria grinding plant, also in Uttar Pradesh. The Orissa Diary newspaper has reported that the shipment – the first from a new purpose-built rail depot – over 458km is part of NTPC Limited’s commitment to 100% total fly ash utilisation, up from 73% in the 2020 financial year, ended 31 March 2020. ACC supply chain head Suresh Rathi said, “This will pave the way for efficient and safe transportation of all fly ash from power plants to cement production units located at a distance in larger quantity.”
NTPC Limited generates some 60.5Mt/yr of fly ash alongside 62.9GW of power.
Birla Corporation plans Durgapur grinding plant upgrade
10 August 2020India: Birla Corporation has shared details of its plans for a US$9.68m upgrade to its 1.3Mt/yr Durgapur, West Bengal grinding plant to expand the plant’s capacity to 1.5Mt/yr. The Times of India newspaper has reported that the company is planning to install a 0.2Mt/yr capacity vertical roller mill at the plant in response to “expected robust demand for premium slag-based cement in the eastern region.”
Birla Corporations recorded a profit of US$8.77m in the three months ended 31 June 2020, the first quarter of the Indian fiscal year, down by 53% year-on-year from US$18.8m in the corresponding period of 2019. Sales fell by 35% to US$163m from US$252m due to subdued demand during the coronavirus lockdown.
Dalmia Bharat cuts costs to build profits despite lockdown
07 August 2020India: Dalmia Bharat says that price rises and cost cutting helped it to improve its profits in the first quarter of the Indian financial year. Its income from operations fell by 22% year-on-year to US$263m in the quarter to 30 June 2020 from US$338m in the same period in 2019. Its cement sales volumes dropped by 20% to 3.66Mt from 4.55Mt. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) decreased by 8% to US$81.9m from US$88.9m. However, its profit after tax grew by 24% to US$25.1m from US$20.3m.
The group said that, once the coronavirus-related lockdown in April 2020 ended, cement demand picked up due to infrastructure projects and the residential sector, especially in east India, with an emphasis on rural markets. It also reported that the ongoing upgrade to grinding plants has been delayed by the health situation with completion rescheduled to December 2020.
Australia: Adelaide Brighton says its sites in Victoria can continue to operate during coronavirus-related lockdown measures that have been implemented until mid-September 2020. It said it would work with its customers, “to assess their requirements for construction materials and modify production levels in response to demand.” The company operates a jointly-owned cement grinding plant in Melbourne as well as concrete and aggregate units in the state.
Italy: Italcementi and Calcestruzzi have supplied specialists and products, including 67,000m3 of concrete, for the Genoa-San Giorgio Bridge. The new structure has been built to replace the Morandi Bridge that collapsed in mid-2018. Products from the integrated Calusco d'Adda cement plant, the Novi Ligure grinding plant and Calcestruzzi’s concrete plants in Genoa supported the project.
Chadian president asks SONACIM to restart production
29 July 2020Chad: Idriss Déby, the president of Chad, has asked the Société Nationale de Ciment du Tchad (SONACIM) to restart production following reports of cement shortages and price rises. He made the announcement following a meeting with representatives of the local industry, according to the Journal du Tchad. SONACIM’s plant at Baore has reportedly been not operating recently due to long-running issues since its opening in 2012.
Update on Rwanda
22 July 2020Rwanda’s newest cement grinding plant is set to start commissioning at a great time. Last week Milbridge Group subsidiary Prime Cement said that its 0.6Mt/yr grinding plant in Musanze, Northern Province was preparing to start up in August 2020. This week the main local producer, Cimerwa, announced that it was setting standardised cement prices in an attempt to control speculation in the market following a shortage. According to local press, spikes in prices have been caused by an urgent supply tender from the Ministry of Education, which has started a large-scale project to build over 20,000 classrooms. Prime Cement is unlikely to make a difference to this particular shortage but its timing is spot on.
Graph 1: Cement production capacity/population of East African countries. Source: Global Cement Magazine & Global Cement Directory 2020.
Cement price surges in land-locked African countries crying out for construction materials are not new but it’s always illuminating to review how the situation is changing. Rwanda’s sole 0.6Mt/yr integrated plant is run by Cimerwa, a subsidiary of South Africa-based PPC, near Bugarama in the south-west of the country, close to the borders with Democratic Republic of the Congo (DRC) and Burundi. The new grinding plant is located in the north-west near the borders with DRC and Uganda. It will join another grinding plant run by Kenya’s ARM Cement at Kigali.
PPC’s operation in Rwanda has performed well in comparison to a poor market back home in South Africa. For its financial half year to September 2019 Cimerwa reported revenue growth of 28% year-on-year to US$31.2m due to a 20% increase in sales volumes. Earnings rose even more in percentage terms due to higher volumes and an improved cost per tonne performance, likely due to a debottlenecking project. More recently, PPC said that its operations in Rwanda were disrupted in April 2020 due to a coronavirus lockdown that started in late March 2020. It partially resumed operations in the second half of April 2020 with cement sales volumes for the month expected to be 15 - 20% of those in April 2019. The other point of note is that the Rwandan government was trying to sell its minority share in Cimerwa in mid-2019 but nothing has been publicly announced since then. However, Cimerwa was reported as being in the process of listing on the Rwanda Stock Exchange in May 2020.
Rwanda’s other grinding plant at Kigali has had problems with its parent company in Kenya. ARM Cement went into administration in mid-2018 and its assets have gradually been sold off since then amidst legal wrangling. It has also had ongoing operational issues with interrupted production due to clinker and coal shortages caused by import issues with Tanzania. An attempt to sell the 0.1Mt/yr grinding plant in September 2018 failed when an auction didn’t even reach one tenth of the estimated market value of US$1.4m. The plant was still reportedly on sale in May 2020.
The new Prime Cement grinding plant will have a production capacity of 0.6Mt/yr. It has been supplied by Germany-based Loesche, who installed a Loesche Jumbo CCG (Compact Cement Grinding plant) with mill type LM 30.2. The project has been reported to have a cost of around US$65m. A second phase was also mentioned at the time of the initial announcement that might include upgrading the grinding plant to a fully-integrated one at a later stage. Time will tell. In the meantime though it will be interesting to see whether the new plant has the same raw material issues that ARM’s Kigali Cement has had. One potential source of clinker is the integrated Hima Cement at Kasese in Uganda. Bamburi Cement reported in May 2020 that its Hima Cement subsidiary in Uganda was unable to ‘access’ the market in Rwanda in 2019 due to ongoing trade problems across the Rwanda-Uganda border.
Rwanda’s cement consumption has been reported to be 0.7Mt/yr so a new combined national production capacity of 1.4Mt/yr seems likely to create significant exports. Other countries in the region have also noticed what’s going on in Rwanda and want to do likewise. In June 2020 DRC’s Industry Minister Julien Paluku talked up plans of reviving the 0.3Mt/yr state-owned National Cement Plant (CINAT) in Kimpese. He noted that DRC has been partly reliant on cement produced by Cimerwa in Rwanda, which has been serving a combined demand of 900,000t/yr in DRC and Burundi.
A statistic that received a fresh airing this week was one from the World Bank in 2016 that worked out that the price of cement in Africa was on average 183% higher than the global average. It popped up in a news article about the expanding Nigerian cement industry but it applies to the whole continent. While it continues to hold true, exports will boom and plants will keep being built in the places that exports can’t reach.