Spain: Acciona and Enagás-led consortium Power to Green Hydrogen Mallorca has begun the construction of one of two planned solar power plants at Cemex España’s Lloseta plant in Majorca. The first, 13,500MWh/yr, plant will consist of 16,600 solar panels. A second, 10,800MWh/yr plant consisting of 12,700 panels will subsequently bring the total power capacity to 24,300MWh/yr. This is enough to produce 300t/yr of green hydrogen for the Lloseta cement plant’s operations.

The project to develop a ‘renewable hydrogen ecosystem’ in Majorca currently has Euro10.0m-worth of funding. The consortium has agreed with local to sheep farmers to allow the latter to use the solar power plant sites for grazing after construction is finished.

India: The board of directors of Prism Johnson has approved plans for the company to raise funds through unsecured non-convertible debentures. The total value raised will be US$12.8m. The producer will issue the debentures on a private basis.

North America: US-based CalPortland has become a corporate member of the Wildlife Habitat Council. The council manages habitats to support sustainable ecosystems and the communities surrounding them. The Japan-based Taiheiyo Cement subsidiary says that the move formalises its commitment to integrating biodiversity and conservation action into its sustainability efforts.

President and chief executive officer Allen Hamblen said "Our membership with the Wildlife Habitat Council provides a unique opportunity to take corporate sustainability goals and objectives and translate them into tangible, on-the-ground actions which ensure a sustainable environment for the next generation."

India: Three construction workers have died after scaffolding collapsed inside the chimney of Saurashtra Cement’s Porbandar cement plant in Gujarat. India Today Online News has reported that a team of ten builders was performing repair work before the accident occurred. Four of the seven survivors remain trapped. District officials have established contact with them via a drone.

Argentina: Loma Negra recorded first-half 2021 consolidated sales of US$290m, up by 44% year-on-year from US$201m. It increased its earnings before interest, taxation, depreciation and amortisation (EBITDA) by 64% to US$100m from US$61.0m. Its net profit was US$86.0m, compared to US$12m in the first half of 2020. The company sold 2.79Mt of cement in the period, up by 39% from 2.01Mt.

Chief executive officer Sergio Faifman said “We are pleased to announce another quarter with an excellent performance. Demand continues with a strong momentum, and after several quarters of recovery is now exceeding pre-pandemic levels.” He continued “For the second half, we expect strong recovery to continue and an expansion vis-à-vis pre-pandemic levels, as seasonality and public works should begin to contribute positively. Nonetheless, we remain cautious, as the macroeconomic context may affect the recovery and some degree of uncertainty remains in relation to the pandemic.”

Denmark: FLSmidth recorded consolidated sales of Euro1.05bn in the first half of 2021, down by 7.0% year-on-year from Euro1.13bn. Its cement business’ sales fell by 17% to Euro346m from Euro419m. The supplier recorded earnings before interest, taxation, depreciation and amortisation (EBITDA) of Euro76.9m, up by 6.0% from Euro72.9m. Its total order backlog grew by 10% to US$2.24bn from US$2.05bn. It expects the majority of this to be converted into revenue in 2021. During the second quarter of the year, the company took in an order for Europe’s first full-scale clay calcination installation.

Chief executive officer Thomas Schulz said “Our second quarter showed positive progress across the board: A strong order intake, higher revenue from both service and capital businesses, 50% higher earnings before interest, taxation and amortisation (EBITA), further reduction in net working capital and a strong free cash flow.”

Canada: Giatec has launched Roxi, an AI testing programme designed to reduce cement use in ready-mix concrete production. The programme combines with Giatec’s proprietary sensing technology. The supplier has received funding from Sustainable Development Technology Canada (SDTC) for Roxi’s development and industrial roll-out.

CEO Pouria Ghods said “Based on two case studies, we estimate that up to 20% reduction in cement usage can be achieved using our technology. With this funding, Giatec will provide a solution that will bring not only economic, but also environmental benefits, by reducing CO2 emissions, air pollution, and water use in the construction industry.”

India: Germany-based HeidelbergCement subsidiary HeidelbergCement India has secured 22GWh-worth of power from Lalganj Power. The energy company will source the electricity from its solar power plants. The deal is expected to reduce the company’s CO₂ emissions by 0.4Mt over the life of the contract.

Spain: Cemex España has inaugurated its refurbished central laboratory at Buñol, Valencia. The Valencia Plaza newspaper has reported that the laboratory is equipped with new analytical equipment. It will introduce several new techniques for testing cement to the company’s existing procedures.

Quality Director Jesús De la Calle said "The company's strategy is currently focused on decarbonising all of its products and processes and developing specific low-carbon products for specific needs, and the central laboratory is key in the achievement of these objectives." The facility is one of the company’s three central laboratories. The others are situated in Monterrey, Mexico, and Tampa, US. The Buñol laboratory will be closely involved in the conversion of Cemex España’s Alicante cement plant to a ‘benchmark, pioneer’ low-CO2 cement plant.

Dalmia Bharat managing director Puneet Dalmia characterised India’s cement industry as one of ‘many regions and many players’ in an interview on 10 August 2021. It is equally an industry of many plants – which are seemingly larger and more numerous by the week.

On 9 August 2021, Orient Cement announced an investment of US$215m to increase its Devapur, Telangana, cement plant’s capacity by 53% to 11.5Mt/yr from 7.5Mt/yr. Another Southeast Indian producer, Ramco Cements, plans to invest a total of US$135m in upgrades in the 2022 financial year; it completed US$53.9m (40%) of the planned investments in the first quarter alone. NCL Industries is planning a US$13.5m expansion of its 2.7Mt/yr Mattapalli, Telangana, cement plant by 33% to 3.6Mt/yr and the establishment of a new 0.66Mt/yr grinding plant at nearby Anakapalle for US$26.9m by 2022. Thus, a single state has at least 5.56Mt/yr-worth of new capacity in the pipeline with US$337m-worth of pending investments. If the central government grants the Telangana government’s 6 August 2021 request to reopen Cement Corporation of India’s Adilabad cement plant in the state, this will be joined by a further 4.0Mt/yr of ‘old’ capacity.

Nationally, investments in on-going cement plant projects total US$1.81bn. What is remarkable here is the continued drive to expand despite existing overcapacity. Puneet Dalmia estimates that Indian capacity utilisation will be 70% in 2021. Despite this, his company plans to increase its installed capacity by 17% to 36.0Mt/yr in the (current) 2022 financial year and by 57% to 48.5Mt/yr with the realisation of all on-going projects by the 2024 financial year, from 30.8Mt in August 2021. By 2030, the group aims to more than triple its installed capacity to over 110Mt/yr. Dalmia says that, if it is to achieve this, it will be not as another South and East Indian regional company, but a ‘pan-India, pure play cement producer.’

Dalmia’s confidence is founded on the belief that overcapacity will abate. His assurance is more than just that of an investor: when, in July 2021, the Department for Promotion of Industry and Internal Trade established an advisory body, the Cement Industry Development Council (CIDC), to help tackle the oversupply issue, it appointed him as chair. Puneet Dalmia predicts that capacity utilisation will rise to 85% ‘within a few years’. Consolidation is key: over the same hazily defined time period, the top five producers’ 57% share of the cement market will rise to 65%, he believes. Rising fuel costs and restrictive limestone mining licencing will deter would-be cement plant start-ups; anticipated carbon costs should clear away a lot of old wood.

Demand is the other half of the coin in India’s attempt to pitch market forces against overcapacity. In the first quarter of the 2022 financial year, cement demand fell by an estimated 20% amid the Covid-19-led collapse of rural housing’s bagged cement uptake. This type of sales roughly accounts for a third of Indian cement consumption. Other construction segments have proved more resilient. Prime Minister Narendra Modi’s government, never infrastructure-shy, chose to resume national projects after India’s Covid-19 lockdown ended on 10 May 2020, keeping them running through subsequent waves of the pandemic. The National Highways Authority of India (NHAI) continued with 480 projects covering 25,000km of road. In Andhra Pradesh, the state government is building 122,000 new homes. Cement producers have been able to corner pent-up demand to shift their stock at a generous margin.

The Confederation of Real Estate Developers' Associations of India (CREDAI) claimed on 9 August 2021 that the price of cement is hampering the realisation of affordable housing targets, and lobbied the government to reduce the goods and services tax on cement to 18% from 28%. In parts of the country, state governments have taken the matter into their own hands. The Kerala government set out to take over 25% of the Keralan cement industry on 5 July 2021. Its plan: increasing cement production, a policy which it is already implementing via state-owned Malabar Cements and Travancore Cements.

Puneet Dalmia claimed on 10 August 2021 that India’s per-capita cement demand is 200kg/yr, corresponding to a total national demand of 276Mt/yr and 60% below the purported global average of 500kg/yr. Given India’s development trajectory, growth is nearly inevitable. Puneet Dalmia is unequivocal in his medium-term prediction: Indian cement revenues will rise at a rate of 9–10% per annum, outstripping forecast gross domestic product (GDP) growth by 2%.

Indian cement’s tale of rebound and growth is borne out in the latest financial reports. UltraTech Cement’s first-quarter sales in the 2021 financial year were US$1.59bn, up by 54% year-on-year from US$1.03bn in the first quarter of the 2020 financial year. Its cement sales rose by 47% in the period to 21.5Mt from 14.6Mt. In its 2021 first-half report, Ambuja Cements recorded year-on-year sales growth of 41%, to US$930m from US$659m, and cement sales growth of 36% to 13.5Mt from 9.95Mt. This is echoed both in the other Indian producers’ reports and internationally: France-based Vicat named India alongside its home country as an area of particular sales growth in the first half of 2021, especially in the second quarter.

The UN Intergovernmental Panel on Climate Change’s demonstration of the impacts of human activity on the climate in a report published on 9 August 2021 might lead an observer to ask “What’s the good?” in all this growth. In the face of the immense benefits cement offers to the lives of Indians, a more pertinent question would be “How best can growth happen?” Ambuja Cement’s aforementioned plan to grind clinker with fly ash is a step in the right direction. Another is Vedanta Aluminium’s proposed fly ash and bauxite residue supply deal, for which it is seeking a cement industry partner. The new Cement Industry Development Council’s remit extends to the coordination of the sector’s efforts towards maximising efficiency and eliminating waste. ACC and Ambuja Cements are participating in parent company Holcim’s Plants of Tomorrow programme, which aims to increase the efficiency of cement production through better plant optimisation, higher plant availability and a safer working environment. Dalmia Bharat has a goal of net zero CO2 cement production by 2040, and a plan for getting there.

Pan-Indian producers are on the rise. Big companies desperate to modernise and implement their models of sustainable growth are blazing a trail. The size gains will be a national marvel - if the promises of sustainability are realised. What will be lost is the Indian cement industry’s festival of local and regional producers. Though still an industry of many regions and many players, its regions are increasingly close together, its players increasingly few.