Global Cement Newsletter

Issue: GCW407 / 29 May 2019

Headlines


There were two main takeaways from the Global Future Cement Conference that took place in Brussels last week. Firstly, there are not any obvious alternatives to using cement and concrete. Secondly, serious at-scale commercial investment on capturing CO2 process emissions from clinker production is still waiting for the right economic conditions.

Graph 1: Embodied energy versus embodied CO2 of building materials. Source: Hammond & Jones, University of Bath, UK. 

Graph 1: Embodied energy versus embodied CO2 of building materials. Source: Hammond & Jones, University of Bath, UK.

Although the conference was heavily focused on Europe, the graph above explains why the cement and concrete industries are sitting pretty right now in the face of mounting environmental activism. The sector may be responsible for 5 - 10% of annual CO2 emissions but, put bluntly, there is simply no alternative. As Karen Scrivner from the Ecole Polytechnique Fédérale de Lausanne (EPFL) explained during her presentation, concrete uses some of the most abundant minerals present on earth, notably silicon and calcium. Alternative chemistries are simply not backed up by available materials. The cement and concrete associations have strongly promoted the unique position by focusing on the whole lifecycle of building materials.

The energy and emissions research needs to be scrutinised much more closely but, if it’s correct, there is no way to maintain modern standards of living without concrete. And, judging from the response by the French public to a badly handled meagre carbon tax on diesel by the so-called Yellow Vest movement, whacking up the price of housing or infrastructure might go down badly, especially in developing countries.

Two immediate ‘outs’ presents themselves. Cement doesn't necessarily have to be made from clinker as Robert McCaffrey’s presentation reinforced (also given at the IEEE/IAS-PCA Cement Conference this year). Future research may find alternatives to clinker and wipe out the cement business in the process. Also, the graph above is based on per kilogramme amounts of each building material. It doesn’t indicate how much of each material is required to build things. Even if clinker-based building materials are irreplaceable, there is no reason why their market share might not decrease. This could have large consequences in a market already burdened by over-capacity.

Graph 2: Comparison of cost of carbon capture technology for the cement industry. Source: European Cement Research Academy (ECRA). 

Graph 2: Comparison of cost of carbon capture technology for the cement industry. Source: European Cement Research Academy (ECRA).

Solid research into carbon capture technology is proceeding apace, from the LEILAC project at HeidelbergCement’s Lixhe plant, to oxyfuel kiln development and other methods, as Jan Theulen from HeidelbergCement demonstrated in his presentation. Off-the-shelf technologies from other industries also exist ready to be used. Today, for example, Inventys has announced plans to test its own CO2 capture technology with Lafarge Canada. Yet there are no commercial-scale installations in Europe. most likely due to the price burden it would place on the end product.

With the European Union (EU) Emissions Trading Scheme (ETS) entering its fourth phase and the carbon price holding above Euro20/t the question is: when will the serious investment begin in Europe? Notably, more than a few major European cement equipment manufacturers attended the Global Future Cement Conference, yet none are offering mature products to capture CO2 emissions. Most or all have projects up their sleeves ready to be developed and sold but orders aren’t being received. The carbon price in Europe is the problem here. If it's too low then nothing happens outside of government subsidy. Too high and cement plants start being shut down because they become too expensive to run. To be fair to the cement sector other carbon emission mitigation strategies are being employed from alternative fuels usage to lowering the clinker factor and other methods but the endgame is based on reducing process emissions.

The challenge for the cement and concrete industry is to show legislators that their materials are essential and irreplaceable. They are doing this. The legislators then need to concoct ways of encouraging mass scale rollout of carbon emissions abatement technology without destroying the cement industry. This is far from certain right now. If nothing else it’s in governments’ interest to get this right because, as the Yellow Vest protests show, if they get it wrong their voters become angry. All of this is happening against the clock as CCU/S is required to get the cement industry past the 2050 2°C maximum warming target set by the Paris Agreement. In the meantime the cement industry is essentially in a holding position on the more far-reaching aspects of CO2 emissions mitigation. Its products are likely irreplaceable but its carbon capture technology has to be encouraged by governments. This means that, for most cement producers, waiting to see what happens next is the way forward.

The 3rd Future Cement Conference and Exhibition is scheduled to take place in Vienna, Austria in 2021


France: Bertrand Collomb, the former president of Lafarge, has died at the age of 76 years. He was the chief executive officer (CEO) of the building materials company from 1989 to 2003 and was later its president until 2007.

Collomb joined Lafarge in 1975 after various roles in government. He became the CEO of its North American subsidiary in 1985 before leading the company as a whole. Notable achievements during his tenure included the acquisition of the UK’s Redland and Blue Circle. Lafarge also set up a Chinese joint-venture in 1994 before many of its Western competitors.


Kenya: East Africa Portland Cement has appointed Stephen Nthei as its acting managing director. He succeeds Simon Peter Ole Nkeri, who was relieved of the role by the company’s board, according to the Standard newspaper. Nthei joined the company in 2007 and has held various roles, including Head of Internal Audit and Head of Financial Management. He is a Certified Public Accountant with experience working for bodies including Ernst & Young, the Central Bank of Kenya and Kenya Petroleum Refineries.


UK: Breedon Group has appointed Amit Bhatia as its non-executive chairman with immediate effect. He has served as deputy chairman since April 2018 and he succeeds Peter Tom, who has retired. Bhatia created Hope Construction Materials and served as its executive chairman for over three years until it was acquired by Breedon in mid-2016, at which point he joined the board of Breedon.


Canada: Lafarge Canada plans to develop and demonstrate a full-cycle solution to capture and reuse CO2 from a cement plant. Project CO2MENT will demonstrate and evaluate Inventys' CO2 capture system and a selection of CO2 utilisation technologies at Lafarge's Richmond cement plant in British Colombia over the next four years. This project is being led by Inventys in partnership with Lafarge Canada and Total. It also received financial support from CCP (CO2 Capture Project), the Province of British Colombia and Canada's federal government through the National Research Council of Canada Industrial Research Assistance Program (NRC IRAP).

"At Inventys, we see a real opportunity to build a CO2 marketplace where tonnes of CO2 are traded between emitters and users," said Inventys president and chief executive officer (CEO) Claude Letourneau.

Phase I of Project CO2MENT, the Contaminant Program, will attempt to reduce harmful organic and inorganic substances, such as sulphur dioxide, dust and soot, as well as nitrogen oxides, from cement flue gas. Phase II, the CO2 Capture Program, will separate the CO2 from flue gas using a customised-for-cement version of Inventys' carbon capture technology at pilot scale. Phase III, the CO2 Reuse Program, will prepare post-combustion CO2 for reuse and support the economical assessment and demonstration of CO2 conversion technologies onsite, such as CO2-injected concrete and fly ash.

Funding for the first two phases is complete and development of Phase I is underway. Phase I will begin operation in 2019 followed by Phase II and III in 2020.


Malaysia: Hong Leong Group has offered to buy out the minority shareholders in Tasek. The offer values the cement producer at around US$160m, according to the Star newspaper. Hong Leong Group is controlled by Quek Leng Chan who owns an 80% stake in Tasek through Hong Leong Asia. If the minority shareholders accept the offer the the cement producer could become a private company. Tasek operates a 2.3Mt/yr integrated plant in Perak state.


Kenya: Bamburi Cement has paid a US$3m settlement to the Kenya Revenue Authority in a long-running dispute. The figure is significantly less than the US$38.5m the tax authority originally demanded in 2012, according to the Business Daily newspaper. However, the cement producer still owes US$2.8m in penalties, although it has applied to have this waived.


Belarus/Moldova/Russia/Ukraine: Tariffs on on imported building materials from Belarus, Moldova and Russia imposed by the Ukrainian government will start on 26 June 2019, according to Interfax. The interdepartmental commission for international trade has set duties of 115% for goods originating in Russia, 57% for goods from Belarus and 94% for goods from Moldova.


Germany: Pollrich has acquired the fan product range and trademark of Rußwurm Ventilatoren. The latter company registered as insolvent in late 2018.

Following the takeover, Pollrich says it has become a leading supplier of heavy-duty industrial fans and has consolidated knowledge in the field. Customers will be able to continue to buy fans and spare parts for Ruwu and Meissner+Wurst products. Former company director Hans Jörg Rußwurm will remain the lead contact for queries regarding the takeover and the product range at a new sales office at Meitingen, Bavaria.


Australia: ThyssenKrupp Industrial Solutions has opened a new service centre in Brisbane. The US$0.7m centre will be used to support customers in the mining, cement and chemical industries. It includes office, warehouse and workshop space.

“This new facility enables us to co-locate our engineering and project staff with our service personnel. For our clients in the mining, cement and chemical industries this means they benefit from an integrated project life-cycle approach, incorporating the latest products and technologies. After having worked successfully with our customers in Australia for many years, this investment was a logical consequence”, says Andrew Howie, chief executive officer (CEO) of ThyssenKrupp Industrial Solutions Australia.


Canada: Sean Monkman, Senior Vice President of Technology Development at CarbonCure Technologies, has been named as Canada’s inaugural Mission Innovation Champion at the fourth annual Mission Innovation Summit (MI4) and 10th annual Clean Energy Ministerial (CEM10) summit hosted by Canada in Vancouver, British Colombia in late May 2019.

Mission Innovation, a global initiative involving 22 countries and the European Commission, has identified carbon capture utilisation and storage (CCUS) as one of eight Innovation Challenges that are key to achieving substantial emissions reductions. Mission Innovation Champions were selected from member countries to celebrate individuals with a track record of progressing creative new ideas that drive the pace and scale of the clean energy revolution.


Indonesia: Semen Indonesia’s cement sales volumes grew by 19% year-on-year to 8.89Mt in the first three months of 2019 from 7.45Mt in the same period in 2018. The company’s acquisition of Holcim Indonesia in February 2019 drove the growth. The cement producer’s domestic sales fell by 3.5% to 5.98Mt although export sales grew significantly. Both domestic and export sales from its Vietnamese TLCC subsidiary fell by 32% to 0.41Mt. Overall national cement sales volumes increased by 3.2% to 17Mt in the reporting period.


Tajikistan: The Ministry of Industry and New Technologies says that Mohir Cement plans to build a new 0.6Mt/yr cement plant in the Jaloliddini Balkhi district of Khatlon province. The project has a budget of US$30m, according to Asia Plus. As part of the agreement with the government, the cement producer has been granted a range of tax breaks on foreign workers and the import of equipment and materials required to build the plant. Mohir Cement currently operates a 1.2Mt/yr plant with Chinese investors known as Chzhungtsai Mohir Cement.


Mexico: Cemex has adopted the United Nations (UN) Sustainable Development Goals (SDG). It has prioritised five goals from the charter that connect with the company’s business and represent an opportunity to contribute to the UN 2030 Agenda. These five goals are focused on the promotion of decent employment and economic growth (SDG 8), innovation and infrastructure development (SDG 9), climate change mitigation (SDG 13), environmental and ecosystem conservation (SDG 15) and the advancement of sustainable cities and communities (SDG 11). Cemex plans to continue embedding the UN SDGs into its business processes to create systemic change, increase engagement, promote a sense of purpose and raise awareness among its stakeholders.


Philippines: Cement producers say that if the government does not implement a permanent safeguard duty on cement imports they may reconsider investment plans to upgrade their plants. Representatives of Taiheyo Cement, Republic Cement, Holcim and Cemex made the comments at public hearings by the Tariff Commission, according to the Philippine Star newspaper. The commission is conducting an investigation to determine whether the provisional safeguard duty imposed by the Department of Trade and Industry (DTI) on cement imports should be kept.

During the hearings, Cirilo Pestaño II the executive director of the Cement Manufacturers Association of the Philippines (CEMAP), lobbied the government to impose a higher ‘definitive’ safeguard duty. He said that imports of cement rose by 64% year-on-year to 1.74Mt in the first quarter of 2019 from 1.06Mt in the same period in 2018 despite the provisional safeguard measure being in place.


India: The Builders Association of India (BAI) has called for the creation of a regulatory body to control the price of cement. Sachin Chandra, the president of BAI, called on the newly elected Indian government to set up the organisation, according to the Hindu newspaper. He alleged that the Monopolies and Restrictive Trade Practices (MRTP), the Competition Commission of India and the National Company Law Appellate Tribunal had ‘repeatedly’ found evidence of anti-competitive behaviour in the cement industry.


Moldova: Rybnitsky Cement plans to challenge the Ukrainian government’s tariffs on building materials from Russia, Belarus and Moldova. The producer recently started exporting cement to Ukraine, according to the Infotag News Agency. About 20% of its export sales go to Ukraine. A 94% duty on goods originating from Moldova has been imposed following an anti-dumping investigation by the Ukrainian interdepartmental commission for international trade. In 2018 the Rybnitsky Cement plant produced about 0.4Mt of cement.


Vietnam: Long Son Cement has launched the Vu Dinh 125, a 7000t cargo ship at the Hai Phong Pacific Shipyards. The vessel will be used to transport bulk cement to the central and southern domestic markets and for export to China, Taiwan, Japan and the Philippines.


Oman: Resolve Marine Group (RMG) says it has completed the wreck removal of the bulk cement carrier MV Raysut II. The ship was grounded on Fazayah Beach in May 2018 due to poor weather. The location is home to several endangered species of sea turtle which nest there and RMG worked to remove the ship without causing environmental damage.

At the time of its grounding the vessel held around 6750t of cement. After attempts to refloat the ship failed it was declared a constructive total loss. In November 2018 RMG was awarded the contract to remove the ship and its cargo. It was partially repaired and refloated with its cargo onboard in February 2019. It was then towed to the Port of Salalah where the cargo was discharged and the ship was recycled.


Cuba: The University ‘Marta Abreu’ of Las Villas (UCLV) has started operating a 7t/day limestone calcined clay cement plant. The unit will be run by the Geominera del Centro Company, according to the Cuban News Agency. Building materials produced at the plant will be used locally.

Fernando Martirena Hernández, director of the Centre for Research and Development of Structures and Materials (CIDEM), said it was the first plant producing low carbon cement in the world. The project is a collaboration between the university and the Swiss Agency for Development and Cooperation as part of the LC3 project. Similar plants are planned for 18 countries including India, China, Indonesia, Thailand, Guatemala, Mexico, Ecuador, Colombia, Peru, Ivory Coast, Cameroon and Senegal.


France/Serbia: Turkey’s Fons Technology International, part of Dal Engineering Group, has released information about recent projects for CRH. In France a replacement clinker cooler and roller crusher was commissioned at the Lumbres plant in February 2019. The project started in October 2018 and the upgrade has a capacity of 1500t/day. In Serbia a Fons Delta clinker cooler and three roller crushers were commissioned at Popvac plant in January 2019. This project started in September 2018 and it has a capacity of 2200t/day.


Qatar: Sika is starting operation at a new concrete admixture plant in Doha. The site will include production lines for concrete-admixture manufacturing as well as a main office and a central storage facility. The new plant follows the establishment of the national subsidiary in 2012.

"The optimisation of our supply chain will enable us to play an even greater role in major construction projects in Qatar. Having our own production capacities available locally makes it possible for us to lower transportation costs and enhance proximity to customers," said Ivo Schädler, EMEA Regional Manager for Sika.


India: India Cement net profit fell to US$2.74m in the year to 31 March 2019 from US$9.56m in the same period in 2018. It blamed competition in the south of the country and low prices in the first nine months of the year. Its power and fuel costs also rose during the period. Despite this its income grew by 6% year-on-year to US$836m from US$785m. Its cement sales volumes rose by 11% to 12.4Mt from 11.2Mt.


Iraq: Etihad Al Saqar has entered into a US$260m contract with China Machinery Engineering for a new cement plant. The unit will have a clinker production capacity of 6000t/day and will use a 52.2MW heavy fuel oil power plant, according to ET Net News. China Machinery Engineering, as the general contractor, will be responsible for the design, supply, civil engineering and construction, installation, training, commissioning, warranty and other works of the project. Construction is expected to last 30 months.


Philippines: Cemex Philippines has broken ground on the new US$235m production line at its Solid Cement plant at Antipolo in Rizal. The new production line will increase the plant’s production capacity to 3.4Mt/yr from 1.9Mt/yr, according to BusinessWorld magazine. The upgrade is intended to support the government’s ‘Build, Build, Build' infrastructure program.


Belarus: President Alyaksandr Lukashenka has issued an edict supporting loan deferments for the country’s three major cement producers. The total amount includes loans totalling about US$550m that were provided by China’s Eximbank in 2008 – 2009 for upgrades to the company’s plants, according to the Belapan news agency. The loans were repaid to the Chinese bank by the Belarusian government in the period from 2015 to 2019.

Under the edict, Belarusian Cement Plant should repay its debt to the government in the period from 2029 to 2038, Krasnaselskbudmateryyaly’s debt should be repaid in 2030 - 2037 and Krychawtsementnashyfer’s debt should be repaid in 2038 - 2049. The edict also sets out a repayment schedule for interest on the loans with a total of US$370m to the mid-2020s.

In addition, the energy ministry has been ordered to grant the cement companies a deferment until the end of 2019, followed by a repayment plan to 2023 for late natural gas bills.


Bhutan: Dungsam Cement has reduced its loss in 2018 by increasing its production volumes. It reported a loss of US$0.43m in 2018 from US$10.3m in 2017, according to the Bhutan Broadcasting Service. Its cement production volume more than tripled to 0.63Mt in 2018 from 0.2Mt in 2014.

The plant at Nganglam has commissioned in 2014 and it has reportedly been making a loss since then due to a loan. The cement producer has suffered from a low production capacity utilisation rate, as the plant has a production capacity of 1.3Mt/yr and it has had problems exporting cement to India. However, sales to hydroelectric projects in the country have been increasing.


Senegal: Falling export sales have reduced cement production. Exports dropped by 28% year-on-year to 0.14Mt in March 2019 from 0.2Mt in March 2018, according to the Agence de Presse Africaine. Cement production fell by 10% year-on-year to 0.59Mt in the first quarter of 2019 from 0.66Mt in the same period in 2018. Local sales remained stable in March 2019.


Philippines: Republic Cement has lunched its first Fast Laboratory On Wheels (FLOW), a mobile laboratory dedicated to providing technical support to construction and building industry players. The mini-truck, which has a pull-canopy converted into a laboratory, carries equipment and apparatus that can perform tests on concrete, aggregates and cement.

“The growing demand for quality construction solution is a primary motivation for Republic Cement’s move to establish its first mobile laboratory,” said Republic Cement president and chief executive officer (CEO) Nabil Francis. FLOW is intended to support the country’s rapid infrastructure development, under the government’s ‘Build, Build, Build’ program.

The mobile laboratory can be transformed into a demonstration area where technical training may be conducted. It can also be despatched quickly to a specific site to provide analysis within hours. FLOW will be deployed in the greater Metro Manila area and regions in Luzon such as Calabarzon and Central Luzon from June 2019.


Sweden: Cementa has started using a gas-powered truck for bulk cement deliveries. The Volvo FH460 LNG will use the Skövde cement plant as its main base and delvier cement to customers in the west of the country. Typically gas-powered vehicles in Sweden use a mixture of 50% biogas and 50% natural gas, although this may change is greater amounts of biogas become available. The truck is owned and operated by Tommy Bremans Åkeri in Skövde, a supplier to XR Logistik.


Greece: Titan Group’s turnover has benefited from the US market and growth in southeastern Europe. Its turnover grew by 12.5% year-on-year to Euro363m in the first quarter of 2019 from Euro323m in the same period in 2018. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 1.9% to Euro44.3m from Euro43.5m. It blamed its limited earnings growth on ‘challenging’ conditions in Turkey and Egypt.


Algeria: Algematco Steel, part of Rahmoune Group, has ordered a modular Ready2Grind MVR vertical roller mill from Germany’s Gebr. Pfeiffer. Erection and commissioning of the unit are scheduled for early 2020. No value for the order has been disclosed.

The cement grinding plant includes: a feed module with material dosing and transport; a MVR 2500 C-4 type vertical roller mill with a SLS 2650 BC ctype lassifier and drives; plant filter, fan and hot gas generator; electric switchgear with plant control system; silo plant; packing and palletising plants; and laboratory equipment. The plant is designed to produce different cement types at a production rate of 50 - 70t/hr.


US: Sesco Cement plans to build a new white cement terminal at Gibsonton in Florida. The unit will have a ship and railway links, according to the Tampa Bay Business Journal newspaper. The project will have an investment of US$19m. Construction is expected to take 18 months at the site. Based in Texas the company has links to the Royal El Minya white cement plant in Egypt via Sesco Group.