Displaying items by tag: grinding plant

Bangladesh: Premier Cement Mills has installed an 11,000t/day vertical roller mill (VRM) at its West Mukterpur grinding plant in Munshiganj. The producer said that the expansion will more than double the grinding plant’s capacity to 7Mt/yr.

Energy & Power News has reported that Premier Cement Mills took a loan worth US$32.4m for the construction of the new mill.

India: Sinoma subsidiary LNV Technology has won an engineering, procurement and construction (EPC) contract in India. Reuters News has reported that the contract is in the area of 'cement production.' Its value is US$53.8m.

LNV Technology is headquartered in Chennai, Tamil Nadu. It previously supplied grinding systems and other equipment for JK Lakshmi Group, Jaiprakash Associates (now part of Dalmia Bharat) and Holcim India (now part of Adani Group).

France: Ireland-based Ecocem has partnered with CB Green to launch a joint venture to scale up production of 70% reduced-CO₂ cement based on Ecocem's ACT technology. The technology combines widely available alternative raw materials into a product with enhanced strength and durability compared with ordinary Portland cement (OPC). The new joint venture will build a grinding plant in Dunkirk, Nord Department. The plant will produce 600,000t/yr of limestone filler for use in alternative cement production with ACT technology. The partners expect to invest Euro60m in the plant's construction, with commissioning scheduled for mid-2025.

Ecocem managing director Donal O’Riain said “This long-term cooperation agreement with CB Green marks a major milestone in our work to scale ACT, our low carbon cement technology, and deliver on our commitment to help the cement industry cost-effectively decarbonise by 50% by 2030. It secures production of fillers and access to high quality limestone, and is an important next step to ensuring that our ACT technology can be distributed at scale and start delivering on its potential to reduce CO₂ emissions by up to 70%. Technology is no longer the issue, scale and speed are what matters now."

Mining and materials company Afrimat said it was buying Lafarge South Africa this week. The assets it is acquiring include aggregate quarries, ready mix concrete (RMX) batching plants, one integrated cement plant, two cement grinding plants, cement terminals and fly-ash sources. The means of purchase is somewhat unusual, as Afrimat is paying around US$6m but it also appears to be taking responsibility for around US$50m of outstanding debt that Lafarge South Africa owes its parent company, Holcim. In a statement Afrimat’s chief executive officer (CEO) Andries van Heerden talked up the benefits for his company in terms of the boost to its aggregates and concrete businesses.

This is quite the change from 2012 when India-based Aditya Birla Group was reportedly looking into buying Lafarge South Africa. At this time the value for the business for a similar mix of assets, including 55 RMX plants and 20 quarries, was said to be to US$900m. Prior to this, Lafarge South Africa spent around US$170m in the late 2000s on increasing the production capacity at its integrated Lichtenburg plant and building its Randfontein grinding plant. Then in 2014, when the merger between Lafarge and Holcim was announced, Lafarge consolidated its Nigeria-based and South Africa-based operations as Lafarge Africa. It later decided to move the South African business to another Holcim subsidiary, Caricement, in 2019 to keep the business in Nigeria more profitable by reducing its debts. This transaction was valued at US$317m. At the time chair Mobolaji Balogun said that Lafarge South Africa’s operations had faced a challenging market in South Africa, with shrinking demand in an aggressively competitive sector. Afrimat is now buying Lafarge South Africa and its subsidiaries from Caricement.

Holcim isn’t alone in making an effort to sell up in South Africa. In April 2023 the Valor Econômico newspaper reported that Brazil-based InterCement was receiving offers for its remaining African-based assets in Mozambique and South Africa with a potential deal valued at around US$300m. InterCement runs Natal Portland Cement in South Africa, which operates one integrated plant and two grinding units. This follows the sale of its Egypt-based assets in January 2023 to an unnamed buyer.

PPC, the country’s largest cement producer, is staying put. However, it issued a mixed trading update this week ahead of the formal release of its annual results to 31 March 2023. Trading conditions in the interior of South Africa and Botswana were described as being ‘difficult,’ with cement sales volumes down by nearly 6% year-on-year and earnings before interest, taxation, depreciation and amortisation (EBITDA) down by 26%. Yet the group says it was able to grow its revenue. PPC’s CEO Roland van Wijnen added, “We therefore remain hopeful that the South African government will roll out its infrastructure development plans and protect the local cement market through the introduction of import tariffs to create a level playing field for domestic producers.” Dangote Cement subsidiary Sephaku Cement was more circumspect in its recent trading update but it too warned that, “deteriorating economic conditions and persistent challenges in the cement industry impacted Sephaku Cement’s financial performance to break-even levels.”

Much of the above makes for gloomy reading. As the local trade association Cement and Concrete South Africa (CCSA) has laid out to local media, the market faces the problem of having 20Mt/yr of production capacity, 12Mt/yr of demand and over 1Mt/yr of imports compounding the problem. Lobbying by local producers against imports has been a feature of the market since the early 2010s and this work continues through the efforts of the CCSA and others. However, the plea by PPC for government infrastructure spending suggests that the market faces more systemic problems. As a consequence some cement producers are trying to leave the market, while others are attempting to tough it out.

Benin: Société Des Ciments du Bénin (SCB) plans to build a new grinding plant in the industrial zone of Sèmè-Kpodji in Ouémé Department. 24 Heures au Bénin News has reported that the new plant will create jobs for local people in the production of cement for the Benin market from imported clinker.

Cement producers in Bangladesh received a surprise at the start of June 2023 when the government budget proposed increasing the duty on imported clinker. The Bangladesh Cement Manufacturers Association (BCMA) reacted this week by calling for the duty on clinker to be reduced, while also calling for the same for a non-adjustable advance income tax (AIT) applied to associated imports and sales.

During a press conference, reported upon by the Financial Express newspaper and other media, BCMA president Alamgir Kabir said that the customs duty on key raw materials for the sector had previously been around 5% of the import value. However, he argued that the new suggested increased tariff was “disproportionate” because it placed the burden at 12 - 13%. He urged the government to treat the cement sector as a "priority sector" given that it was facing higher prices generally due to the aftermath of the Covid-19 pandemic, the energy shocks from the Russian invasion of Ukraine and negative currency exchange effects.

The BCMA’s latest lobbying call may sound familiar because it follows a similar battle against import charges from late 2022. A supplementary duty was introduced in November 2022 when the National Board of Revenue (NBR) changed the way limestone was coded in response to a significant increase in imports from 2020. At the time, the price of limestone imports reportedly nearly doubled. The BCMA may have won this battle because in March 2023 the NBR withdrew its supplementary duty. It did require that importers submit to further scrutiny including an updated Import Registration Certificate and various tax related requirements.

The timing of the NBR’s decision to relax the limestone duty is telling given that the previous month or so six of the country’s seven publicly listed cement producers reported either falling profits or losses for the second half of 2022 or the year as a whole. Only LafargeHolcim Bangladesh bucked the trend with an increase year-on-year in its annual profit after tax in 2022, although it attributed this to 95% volume growth in its aggregates business.

As discussed previously a characteristic of the cement sector in Bangladesh is that the country has no domestic limestone reserves. It all has to be imported. Arusha Ahmed Khan, Shun Shing Group presented a summary of the national industry at the Global Slag Conference that took place in early June 2023 in Düsseldorf. The country has two integrated cement plants and 36 grinding mills operated by 31 companies with a total capacity of 84Mt/yr. At present around 14Mt/yr of new cement grinding production capacity is planned by UK Bangla Cement, MI Cement, Confidence Cement and Dubai Bangla with commissioning dates expected from mid-2023 to mid-2025. Khan revealed that the government switched from British to European standards in the early 2000s leading to a high level (95%) of blended cements on the market. Use of slag cements has grown as more producers commission vertical roller mills and more uptake of slag and other blended cements using secondary cementitious materials (SCM) is expected in the future.

A key vulnerability for a grinding-heavy cement sector, like the one in Bangladesh, is any burden on imports such as logistic costs, currency exchange effects and government tariffs. Sure enough each of these examples has been reported locally. The government says that its proposed higher import tariff on clinker is the first such change in a decade. Cement producers have reacted, predictably, in a negative manner. Whether the authorities go ahead with the planned increase and how well the cement sector could absorb it remains to be seen. There may never be a good time for a tax rise but the BCMA has been able to present the current period as being especially bad.

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Colombia: Cemex says that its Santa Rosa cement grinding plant is the first unit in its South, Central America and the Caribbean (SCAC) region to attain water self-sufficiency. The plant independently meets its water requirements using a 9000m³ reservoir, constantly replenished thanks to rainwater, runoff, and water circulation devices. The move aligns with the company's Water Management Roadmap, part of its Future in Action program. The achievement takes Cemex closer to its 2030 target of reducing freshwater consumption in its cement operations by 20%.

French Guiana: 27 of 30 workers at Ciments Guyainais’ Rémire-Montjoly grinding plant in Cayenne went on strike on 12 June 2023. The strikers advised management that they launched strike action because the current direction of the company is ‘disastrous.’ They have requested that senior representatives of parent company Grupo Argos attend a meeting with them.

Portail des Outre-mer News has reported that Ciments Guyainais holds a 100% market share in French Guiana. It supplied 107,000t of cement to customers in 2022, up by 8.6% year-on-year from 98,500t in 2021.

Heidelberg Materials North America held an official opening ceremony this week for its upgraded slag cement plant and terminal at Cape Canaveral in Florida. The US$24m project added a new roller press to the unit to increase its production capacity. In a statement Chris Ward, the president and chief executive officer of the company, said that it had made the investment to meet sustainability and resilient construction goals. Industrial Accessories Company (IAC) said in mid-2021 that it had been named as the engineering, procurement, and construction (EPC) contractor for the project. It planned to install a hydraulic roller press supplied by FLSmidth. IAC also said it was providing instrumentation equipment, hoppers, bins, belt conveyors, bucket elevators and dust collectors amongst other kit and services.

Other recent US slag cement-related news stories have concerned terminals. In late August 2022 Royal White Cement said it had leased a site on the Houston Ship Channel in Houston, Texas to handle and store approximately 100,000t of multiple cementitous products such as slag, ordinary Portland cement and white Cement. In May 2022 Titan America announced plans to spend US$37m on an upgrade to its Norfolk terminal in Chesapeake, Virginia. The major improvement was to add a 70,000t storage dome, with enlarged truck and railway capacity, to allow the site to import and distribute raw materials such as fly ash, slag and aggregates. Completion on this one was scheduled for some point in 2023. Titan added that the project was similar to the addition of a 70,000t dome under construction at the time at Titan's import terminal in Tampa, Florida.

The United States Geological Survey (USGS) estimates that domestic sales of iron and steel (ferrous) slags in the US amounted to 15Mt in 2022. Sales were around 20Mt in the 2000s but this fell to current levels in the 2010s as blast furnaces closed. In 2022 the USGS noted that, “domestic ground granulated blast furnace slag (GGBFS) remained in limited supply because granulation cooling was known to be available at only two active US blast furnaces while, elsewhere, only one domestic plant produced pelletised slag in limited supply.” It added that the grinding of granulated blast furnace slag was only being carried out domestically by cement companies. Imports of slag were 2Mt in 2022. This is a decline from a peak of 2.6Mt in 2018 but higher than the period 2000 – 2015. The price of slag, meanwhile, hit a high of US$53/t in 2022. This is the highest price recorded by the USGS since at least 2000. It is double that of 2017.

Charles Zeynel of ZAG International noted in the June 2023 issue of Global Cement Magazine that cement producers in Florida, California, Texas, Georgia and the Carolinas are far from steel mills, so they import granulated blast furnace slag (GBFS) and other secondary cementitious materials (SCM). This certainly fits with Heidelberg Materials’ plan to upgrade its slag cement plant and terminal at Cape Canaveral. Also on the US market, Zeynel added that due to rising global demand for SCMs more of the available share of GBFS was being purchased by ‘richer’ markets such as Europe, North America and Australia. He continued that GBFS and GGBFS producers had also started increasing the price of their wares internationally. This too is apparent in the prices published by the USGS.

One final story with links to slag to note this week concerns the launch of the Alliance for Low-Carbon Cement & Concrete (ALCC) in Europe. The group brings together companies producing products or services intended to decarbonise the cement and concrete sectors. Two of the members – Ecocem and Hoffman Green Cement Technologies – are Europe-based slag cement producers. Two other members – Fortera and TerraCO₂ – are companies based in North America that are marketing and selling low-carbon SCMs.

Various start-up companies have been emerging on a regular basis in both North America and Europe with the aim of decarbonising cement and concrete in various different ways. The formation of the ALCC can be seen as part of this trend as the more successful non-traditional cement-concrete-aggregate companies establish themselves. One point that cement producers in North America are likely to be well aware of is that concrete is becoming less linked to clinker as the cost of carbon mounts and the clinker factor of cement lowers. Slag supplies may be finite but Heidelberg Materials North America’s latest investment in Florida is further acceptance that one doesn’t just need clinker to make concrete.

Read Charles Zeynel’s interview on SCM Trends in 2023 in the June 2023 issue of Global Cement Magazine

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Peru: Invercem has successfully commissioned its new 220,000t/yr Pisco grinding plant in Ica Department. Management News has reported that the plant cost US$30m to build. Cemex Peru will supply clinker for use in cement production at the plant. Invercem plans to supply cement produced at the plant to the Cusco market under the Patrón brand. The company says that the facility has the potential to further expand up to a capacity of 330,000t/yr. In the longer term, Invercem aims to establish an integrated cement plant and limestone mine.