Global Cement Newsletter

Issue: GCW436 / 18 December 2019

Headlines


It’s the end of the year so it’s time to look at trends in the sector news over the last 12 months. It’s also the end of a decade, so for a wider perspective check out the feature in the December 2019 issue of Global Cement Magazine. The map of shifting production capacity and the table of falling CO2 emissions per tonne are awesome and inspiring in their own way. They also point towards the successes and dangers facing the industry in the next decade.

Back on 2019 here are some of the main themes of the year in the industry news. This is a selective list but if we missed anything crucial let us know.

European multinationals retreat

LafargeHolcim left the Philippines, Malaysia and Indonesia, HeidelbergCement sold up in Ukraine and reduced its stake in Morocco and CRH is reportedly making plans to leave the Philippines and India, if local media speculation can be believed. To be fair to HeidelbergCement it has also instigated some key acquisitions here and there, but there definitely has been a feel of the multinationals cutting their losses in certain places and retreating that bit closer to their heartlands.

CRH’s chief executive officer Albert Manifold summed it up an earnings meeting when he said, “…you're faced with a capital allocation decision of investing in Europe or North America where you've got stability, certainty, overlap, capability, versus going for something a bit more exotic. The returns you need to generate to justify that higher level of risk are extraordinary and we just don't see it.”

The battle for the European Green Deal

One battle that’s happening right now is the lobbying behind the scenes for so-called energy-intensive industries in Europe as part of the forthcoming European Green Deal. The cement industry is very aware that it is walking a tightrope on this one. The European Union (EU) Emissions Trading Scheme (ETS) CO2 price started to bite in 2019, hitting a high of Euro28/t in August 2019 and plant closures have been blamed on it. The rhetoric from Ursula von der Leyen, the new president of the European Commission, has been bullish on climate legislation and the agitation of Greta Thunberg internationally and groups like Extinction Rebellion has kept the issue in the press. Cembureau, the European Cement Association, is keen to promote the industry’s sustainability credentials but it is concerned that aspects of the proposed deal will create ‘uncertainty and risks.’ Get it wrong and problems like the incoming ban on refuse-derived fuel (RDF) imports into the Netherlands may proliferate. What the Green Deal ends up as could influence the European cement industry for decades.

The managed march of China

Last’s week article on a price spike in Henan province illustrated the tension in China between markets and government intervention. It looks like this was driven by an increase in infrastructure spending with cement sales starting to rise. Cement production growth has also picked up in most provinces in the first three quarters of 2019. This follows a slow fall in cement sales over the last five years as state measures such as consolidation and peak shifting have been implemented. The government dominates the Chinese market and this extends west, as waste importers have previously found out to their cost.

Meanwhile, the Chinese industry has continued to grow internationally. Rather than buying existing assets it has tended to build its own plants, often in joint ventures with junior local partners. LafargeHolcim may have left Indonesia in 2018 but perhaps the real story was Anhui Conch's becoming the country's third biggest producer by local capacity. Coupled with the Chinese dominance in the supplier market this has meant that most new plant projects around the world are either being built by a Chinese company or supplied by one.

India consolidates but watches dust levels

Consolidation has been the continued theme in the world's second largest cement industry, with the auction for Emami Cement and UltraTech Cement’s acquisition of Century Textiles and Industries. Notably, UltraTech Cement has decided to focus its attention on only India despite the overseas assets it acquired previously. Growth in cement sales in the second half of 2019 has slowed and capacity utilisation rates remain low. Indian press reports that CRH is considering selling up. Together with the country's low per capita cement consumption this suggests a continued trend for consolidation for the time being.

Environmental regulations may also play a part in rationalising the local industry, as has already happened in China. The Indian government considered banning petcoke imports in 2018 in an attempt to decrease air pollution. Later, in mid-2019, a pilot emissions trading scheme (ETS) for particulate matter (PM) was launched in Surat, Gujarat. At the same time the state pollution boards have been getting tough with producers for breaching their limits.

Steady growth in the US

The US market has been a dependable one over the last year, generally propping up the balance sheets of the multinational producers. Cement shipments grew in the first eight months of the year with increases reported in the North-Eastern and Southern regions. Imports also mounted as the US-China trade war benefitted Turkey and Mexico at the expense of China. Alongside this a modest trade in cement plants has been going on with upgrades also underway. Ed Sullivan at the Portland Cement Association forecasts slowing growth in the early 2020s but he doesn’t think a recession is coming anytime soon.

Mixed picture in Latin America

There have been winners and losers south of the Rio Grande in 2019. Mexico was struggling with lower government infrastructure spending hitting cement sales volumes in the first half of the year although US threats to block exports haven’t come to pass so far. Far to the south Argentina’s economy has been holding the cement industry back leading to a 7% fall in cement sales in the first 11 months of the year. Both of these countries’ travails pale in comparison to Venezuela’s estimated capacity utilisation of just 12.5%. There have been bright spots in the region though with Brazil’s gradual return to growth in 2019. The November 2019 figures suggest sales growth of just under 4% for the year. Peru, meanwhile, continues to shine with continued production and sales growth.

North and south divide in Africa and the Middle East

The divide between the Middle East and North African (MENA) and Sub-Saharan regions has grown starker as more MENA countries have become cement exporters, particularly in North Africa. The economy in Turkey has held back the industry there and the sector has pivoted to exports, Egypt remains beset by overcapacity and Saudi Arabian producers have continued to renew their clinker export licences.

South of the Sahara key countries, including Nigeria, Kenya and South Africa, have suffered from poor sales due to a variety of reasons, including competition and the local economies. Other countries with smaller cement industries have continued to propose and build new plants as the race to reduce the price of cement in the interior drives change.

Changes in shipping regulations

One of the warning signs that flashed up at the CemProspects conference this year was the uncertainty surrounding the new International Maritime Organistaion (IMO) 2020 environmental regulations for shipping. A meeting of commodity traders for fuels for the cement industry would be expected to be wary of this kind of thing. Their job is to minimise the risk of fluctuating fuel prices for their employers after all. Yet, given that the global cement industry produces too much cement, this has implications for the clinker and cement traders too. This could potentially affect the price of fuels, input materials and clinker if shipping patterns change. Ultimately, IMO 2020 comes down to enforcement but already ship operators have to decide whether and when to act.

Do androids dream of working in cement plants?

There’s a been a steady drip of digitisation stories in the sector news this year, from LafargeHolcim’s Industry 4.0 plan to Cemex’s various initiatives and more. At present the question appears to be: how far can Industry 4.0 / internet of things style developments go in a heavy industrial setting like cement? Will it just manage discrete parts of the process such as logistics and mills or could it end up controlling larger parts of the process? Work by companies like Petuum show that autonomous plant operation is happening but it’s still very uncertain whether the machines will replace us all in the 2020s.

On that cheery note - enjoy the winter break if you have one.

Global Cement Weekly will return on 8 January 2020


Australia: In a statement to the Australian Securities Exchange on 13 December 2019 Adelaide Brighton announced the appointment of Darryl Hughes as an additional company secretary, effective from 11 December 2019. Marcus Clayton will retain the position of Adelaide Brighton Company Secretary.


Vietnam: Tan Thang Cement has announced that it will commission its 2.0Mt integrated Nghe An cement plant in 2020. Its total investment in the plant, which is installed with equipment from Bedeschi, Lilama and Vinaconex, is US$211m.
Viêt Nam News has reported that this will help raise the total number of Vietnamese cement production lines to 86 in 2020, with a combined installed capacity of 106Mt/yr.


Mexico: Grupo Cementos de Chihuahua (GCC) has signed a 15-year power supply agreement with a Mexico-based solar energy provider. The Awareness Times newspaper has reported that the contract covers the supply of solar power to GCC’s 0.2Mt/yr Juarez cement plant in Chihuahua, as well as its head office and ready mix and aggregates operations, constituting roughly 20% of its electricity consumption. The agreement, which enters force on 1 January 2021, will save GCC US$2.5m/yr and cut 0.3Mt of CO2 emissions throughout its duration.


Tanzania: Dangote Cement has partnered with local police and other stakeholders to train the 600 drivers it employs in Tanzania in road safety compliance. The Citizen has reported that the training programme will involve sessions four times a year, with the objective of reducing road traffic incidents to zero. Dangote Cement Head of Transport Gerald Osagia said, “This training is aimed at ensuring that out drivers avoid any temptation that may cause accidents.” Global Cement has previously reported alleged overloading of a Dangote truck as a contributing factor in collision in August 2019 that killed three and injured 69 in Ikorodu, Nigeria.


China: Cement or asphalt roads will connect every settlement in China by 31 December 2019, according to an announcement by the Ministry of Transport. Sichaun province is the last part of the country to receive fully paved roads, which were yet to reach one town and one village as of 15 December 2019. Xinhua’s China Economic Information Service has reported that China has invested US$87.5bn in the construction of 6.34 million km of auxiliary roads since it began construction of the system in 2003.


UK: Quinn has announced that it will proceed with the exclusive supply of its Master Grade cement to the UK-based wholesale builders’ merchant National Buying Group (NBG) until the end of 2021, extending the term of the companies’ 2018 agreement. “Our partnership with NGB has made a significant contribution to the success of our bagged cement range, so we’re delighted to agree an extension to our exclusivity deal with NBG for supply to their merchant members,” said Lee Gillman, Quinn’s Great Britain Sales and Marketing Director. Quinn’s bagged range also consists of Premium Grade and General Purpose cement.


Spain: Asociacón Española de Pavimentos Continuos (AEPC), the body which represents manufacturers and maintainers of cement-based and other related flooring, has welcomed LafargeHolcim Spain as a new member. AEPC states its aims as ‘promoting and demanding the highest levels of safety, quality and integrity in all paving sector activities.’

LafargeHolcim Spain operates an installed capacity of over 7.0Mt/yr across five integrated plants. In 2019 it announced an investment of Euro20m in upgrades aimed at reducing its net carbon dioxide (CO2) emissions by 90,000t/yr by the end of 2022.


Germany: Gebr. Pfeiffer has appointed the current head of its Malaysia office Timothy Burden as president of its US subsidiary Gebr. Pfeiffer Inc., effective 1 January 2020. Burden brings 15 years’ materials handling and crushing engineering and sales experience to the role. He studied at Queen’s University Belfast and attained his Masters in engineering from the University of Southhampton in 2004.

Gebr. Pfeiffer will replace Burden in the Malaysian office with Vesa Peurakari, an experienced project and service manager and sales professional with a mechanical engineering degree from the University of Gothenburg.


Switzerland: Maerz has reported the successful installation of two Maerz PFR lime kilns with a capacity of 200t/day and 300t/day at Daesung MDI in South Korea, which was commissioned on 19 October 2019. The company also installed a 150t/day E2 two-shaft lime kiln at Easternbulk Lime Products Private Ltd in July 2019. Three further new plants with Maerz kilns are scheduled to enter operation in 2020 in China, Mexico and Russia and a second kiln will increase production of petcoke at Caleras’ San Juan plant in Argentina beginning in mid-2020.


Africa: German-based lubricants supplier Fuchs has taken over direct ownership of 50% of three distribution subsidiaries of its regional subsidiary Fuchs Southern Africa. The companies are based in Zambia, Zimbabwe and Mozambique. The acquisitions will support Fuchs’ aim of increasing its supply to African markets, according to Fuchs executive board chairman Stefan Fuchs. "Investment in a state of the art, fully automated grease manufacturing plant which opened in Isando, Johannesburg, in 2018” signifies the company’s commitment to sustainable social development of the continent, said Fuchs, adding, “Further plant expansions are already being planned.”


Germany: Frankfurt-based fashion designer Concrete Jungle has won the Inhorgenta Fashion Jewellery Award 2019 and the German Design Award for Excellent Product Design 2019 for its Grey Rosé range of jewellery. The collection includes earrings, pendants and wedding rings, which showcase the beauty of concrete. The concrete is inlaid with metallic shards. “The particular challenges of mixing these elements necessitated particular techniques. We were able to work extremely delicately while achieving the enormous stability that characterises our jewellery,” said Concrete Jungle partner Madlen Thorwarth.


Hungary: Lafarge Cement Hungary has announced plans to upgrade clinker production at its 1.0Mt/yr Kiralyagyháza integrated plant with a Euro1.79m investment in chlorine bypass technology, which uses powdered limestone to remove chlorine and one tenth of the carbon dioxide (CO2) from gases released in clinker production, which will then be used in clinker cooling. There will be a concomitant increase in the rate of alternative fuel (AF) substitution in the plant’s kilns, with an AF fuel store expansion in early 2020 set to raise AF usage to 80% from 60%.


India: Deccan Cements has shared plans to expand its Suryapet waste heat recovery (WHR) power plant in Telangana to 33MW from 18MW. Domex Power Genration Projects has reported that the cost of the development will be US$84.5m and it will take 24 months to complete once statutory clearance is received.


Pakistan: The end of 2019 has seen a flurry of 13 proposals for the construction of new plants and one proposed upgrade submitted to different government departments across Pakistan’s five Punjabi districts. The Balochistan Times has reported that Punjab Minister for Trade and Industries Mian Aslam Iqbal stressed the need for cement companies to provide plans for minimal water use in order to receive clearance.


UK/Ireland: Sean Quinn has bought ‘substantial’ tracts of limestone-rich land in Cavan and Fermanagh on 99-year leases, giving him sole extraction rights, over the past three and half years since his final severance with Quinn Industrial Holdings in mid-2016, according to the Sunday Times. The purchases may have been aimed at strengthening his position in his campaign to re-attain control over the company. It has stated that it has succeeded in supplementing its on-site limestone supply with material from further afield. “These materials are of a higher quality,” said a Quinn Industrial Holding spokesperson.


Nigeria: Chinese-owned FabCom has unveiled a new fibre cement board at a ceremony celebrating the fifth anniversary of its presence in Nigeria. The Sun has reported that the company will manufacture 5Mm2/yr at its fibre cement board plant in Ambuja, which will be operational before 1 January 2021. FabCom managing director Liuxing Wang praised the product’s environmental friendliness, noting its durability, sound insulation, fire and water resistance and multi-use workability. FabCom’s investments in Nigeria total US$190m and have created 200,000 jobs, the company says.


Bangladesh: The Institute of Cost and Management Accountants of Bangladesh (ICMAB) has presented its Best Corporate Awards 2019 to 34 companies across 12 categories. The cement award winner was LafargeHolcim Bangladesh for its ‘excellent corporate governance.’ HeidelbergCement Bangladesh came second and Premier Cement Mills third.


India: Ireland’s CRH is planning to sell its 50% stake in My Home Industries, according to sources quoted by investor information services group VCCircle. It is reportedly in talks to sell the stake to My Home Group, the company that owns the other half of the subsidiary. My Home Industries operates two integrated plants and two grinding plants with a production capacity of 10Mt/yr. It also runs two ready-mixed concrete plants.

In November 2019 CRH was reported to be looking to sell its assets in the Philippines. At the time of its second quarter results in 2019 chief executive officer (CEO) Albert Manifold described emerging markets as a small part of the group’s business with, “too much disruption, too much dislocation, too much uncertainty.” He added that the company’s focus was on its developed market businesses.


Pakistan: Punjab’s Minister for Industries & Trade Mian Aslam Iqbal says that the provincial government has lifted a ban on the cement industry after 12 years. He made the statement following a meeting reviewing investment in the cement sector and installation of new plants in the province, according to the Business Recorder newspaper. He also expressed regret that obtaining no objection certificates (NOC) for new projects had taken too long and that the local government has set up a special section of its industries department to hasten the process.


Nepal: Industry experts have told the parliamentary Public Accounts Committee that the government should follow the existing Cement Standard 1997 because the new standard has proposed increasing the magnesium oxide and insoluble residue content of cement. They said that doing this would erode the strength of the building material, according to the Kathmandu Post newspaper. So far Nepalese cement producers have been using Indian standards instead.

The Nepal Bureau of Standards and Metrology had intended to examine and grade locally produced cement from mid-November 2019 but the government delayed this. The parliamentary committee plans to meet with government officials including the secretary of the Ministry of Industry and representatives of the bureau to discuss the matter further. The new Cement Standard 2019 proposes to increase the magnesium oxide content in cement from 5% to 6%. The amount of insoluble residue has been proposed to be increased by 2% to 4%.


France: Guy Sidos, the president and chief executive officer (CEO) of Vicat Group, has launched the company’s first cement carrier, Capo Cinto. The ship was acquired in partnership with ABCRM (Agency Bulk Chartering Vicat), according to Les Petites Affiches newspaper. The Capo Cinto will supply the Corsican ports of Bastia, Porto Vecchio, Ajaccio and Propiano with bulk and bagged cement, as well as Italy and the Mediterranean from the Grave de Peille integrated cement plant. French navy Vice Admiral Anne Cullerre was also in attendence at the launch.

The Capo Cinto, previously known as the Kurske, was built in 1997. The new name refers to Monté Cinto, the highest mountain in Corsica. The refitted carrier is 90.7m long, has a capacity of nearly 2000t and it has a self-unloader.


Azerbaijan: Akkord Cement’s Gazakh cement plant plans to export its fifth batch of clinker to Georgia. Further export operations are also planned in December 2019, according to the Trend News Agency. The integrated plant exported over 500t of clinker to Georgia during the first 11 months of 2019 and it plans to export up to 700t in 2020. The unit is aiming for a production volume of 1.2Mt in 2019 and then 1.5Mt in 2020. Turkey’s Dal Teknik Makina started work on an upgrade project at the plant in mid-2019.


Mexico: France’s Fives has issued an update on the two raw meal grinding plants it is supplying to Cruz Azul’s Hidalgo and Oaxaca Lagunas cement plants.

Construction work at the Oaxaca Lagunas plant started in August 2018. Mechanical erection of the raw materials feeding workshop and the FCB Horomill grinding circuit started in July 2019. Electrical installation is currently under progress. The raw meal grinding workshop is scheduled to be operational by the end of March 2020.

Construction work at the Hidalgo plant started in December 2018. Mechanical erection started at the end of August 2019, electrical erection works will start in December 2019. First raw meal date is scheduled by the end of May 2020.

Both orders were finalised in November 2017. The Hidalgo plant ordered a 280t/hr grinding unit and the Oaxaca Lagunas plant has ordered a 300t/hr grinding unit. Each raw grinding plant features an FCB Horomill 4000mm grinding mill, a FCB TSV Classifier 6500 mm and a FCB Aerodecantor.


Mali: Diamond Cement Mali (DCM) has signed a deal with La Société Malienne de Cartonnerie (SCS MDC) to procure 50kg bags to hold cement. DCM operates two plants in the country with a production capacity of 1Mt/yr, according to local press. It requires over 20 million bags per year. SCS MDC became operational locally in 2019. It runs a plant at Kamalé near Bamako. Moussa Silvain Diakité, the chief executive oficer (CEO) of SCS MDC described the contract as the company’s first ‘big’ deal.


Rwanda/Tanzania: Edenville Energy says it has signed a new contract to supply 6000t/month of washed coal from its Rukwa Coal Project to an end user that is expected to be a cement producer based in Rwanda. The deal has been agreed with Tara Group, which is a wholly owned subsidiary of Tanzanian company, Kitanyoe Group Company, which currently supplies coal, gypsum, limestone and calcite to industrial users.

The contract is of note to the development of Edenville Energy because it has the potential to open up a new transport route for the company’s coal on Lake Tanganyika to both Rwanda and Burundi. However, the proposed supply arrangement is dependent on the company securing sufficient operating capital to fund production. Edenville Energy operates a coal mine in western Tanzania.


UAE: India-based JSW Cement has applied to borrow between US$50m and US$55m from two UAE-based banks to continue development on its planned 1Mt/yr integrated Fujairah plant, the capacity of which it plans to double to 2Mt/yr within a year of its scheduled January 2020 opening. Arabian Business has reported that the loan will bring the project’s total investment to US$110m with a 30:70 equity/debt ratio. The government has granted JSW Cement a 35-year quarry lease and a licence for the extraction of up to 6Mt/yr of limestone for use at the plant, which will be served by a Terex MPS 1200t/hr crushing plant.
550 local people directly or indirectly employed in cement production at Fujairah.


Germany: Four of Europe’s leading cement producers have partnered to found and operate a 100% carbon capture and storage (CCS) plant at Schwenk Zement’s 1.0Mt/yr Mergelstetten plant in southern Germany. HeidelbergCement has announced that the catch4climate project will enter operation in 2020.


UAE: A&K International Investment has divested itself of 29% of total shares from its stake in RAK Cement to an undisclosed buyer. RAK Cement’s profit fell by 79% year-on-year to US$0.39m in the first half of 2019 from US$1.88m. Its intended purchase of an integrated cement plant and quarry in the UAE was abandoned in September 2019.


Mexico: Cemex Ventures has partnered with BCG and Tracxn to launch a list of 2019’s global 50 ‘most promising’ construction start-ups. Assessment categories were technical innovation, project management and sustainability. Companies like the UK’s Cloud Cycle, a concrete management platform provider, and the US’s Concrete Sensors, which provides remote concrete strength, temperature and relative humility measurement solutions, typify the promising developments in how the construction industry uses its cement.