Global Cement Newsletter

Issue: GCW525 / 29 September 2021

Headlines


Raysut Cement Company (RCC) announced this week that it is preparing to commission its Duqm grinding plant in late 2021. It follows the news from earlier in September 2021 than Oman Cement Company (OCC) is planning to build a new clinker production line at its Rusayl cement plant.

First some detail on the RCC project. The new US$30m unit will have a production capacity of 1Mt/yr, bringing the company’s total cement production capacity to 7.4Mt/yr. As part of the development process, RCC signed a land lease and Port of Terminal services agreement with the Port of Duqm Company. The new grinding unit is also intended to complement RCC’s expansion and new investments and acquisitions in Oman, Asia and East Africa.

Other relatively recent RCC news include, in 2019, its acquisition of Sohar Cement Company in Oman for US$60m, the announcement of plans to build a new 1.2Mt/yr integrated plant in Georgia for US$200 and a joint-venture deal to establish a 1Mt/yr grinding plant in Somaliland for US$40m. Then in 2020 it obtained a 75% stake in a cement terminal in the Maldives owned by subsidiaries of Holcim, and a project to build a 0.75Mt/yr grinding plant in Toamasina, Madagascar, for US$30m was detailed in the local press. More recently in 2021, China-based Sinoma started building a waste heat recovery (WHR) unit at RCC’s Salalah cement plant, RCC gained certification for some of its cement products for export to the European Union, and the Competition Authority of Kenya granted RCC permission to sell a majority stake in its East African based business.

OCC’s upgrade to its Rusayl cement plant will see it add a new production line and increase the capacity of one of the existing lines. Overall the project will increase the unit’s nominal clinker production capacity to 15,000t/day from 8700t/day at present by adding a new 10,000t/day line and increasing the current Line 3 to 4000t/day from 2700t/day at present. Lines 1 and 2, at 2000t/day and 2700t/day, will then be decommissioned after the new line starts operation. OCC says that the new line, when built, will be the biggest in the country. Scant detail has been released beyond the main vision but the company says it wants to focus on low power consumption, consider using a waste heat recovery unit, increase its fuel efficiency, use alternative fuels and adhere to ‘best’ environmental standards. It has hired PEG Resources, a Switzerland-based engineering consultancy, to conduct a technical study, tendering and contracting as well as supervision of the project execution. The company had also been working towards building a new integrated plant at Duqm. However, this project was put on hold in the first quarter of 2021 pending confirmation of fuel availability and as the Rusayl upgrade took priority.

The Omani cement sector is dominated by OCC and RCC since they own the biggest plants and they have consolidated this by buying competitors and building new plants. Both companies suffered from reduced sales year-on-year in 2019 due to imports from the neighbouring UAE. The government duly implemented anti-dumping measures in 2020 and company revenues recovered that year. However, the coronavirus pandemic then hit, leading to losses at RCC in 2020 although the situation appears to have improved for the company in the first half of 2021. OCC reported continued ‘intense’ price competition between local producers and importers in the same period.

OCC is majority owned by the government via an investment fund. As the recent announcement shows, it has decided to focus on building production capacity domestically. This week’s launch of its Al Burj Cement as a distinctive local product looks like another part of this approach. However, as Bloomberg reported in May 2021, the government was considering selling its stake in the producer and had been in discussions with financial advisors on the matter. By contrast, RCC’s biggest shareholder at the end of 2020 was the Abu Dhabi Fund for Development, with a 15% share. RCC has taken a more international approach, operating an integrated plant in the UAE and focusing on trading and grinding cement around the Arabian and African parts of the Indian Ocean.

Similar to other Gulf States, the building materials markets in Oman are dominated by government spending and the price of oil. Market forecasts predict recovery in the building materials markets in 2021 but in the longer term growth depends on general economic diversification. Oman, like its neighbours, is trying to do this. In this context it is instructive to see that OCC and RCC are pursuing different business strategies.


Spain: Votorantim Cimentos España has appointed Pablo Viedma as the director of its integrated Niebla cement company in Huelva.

Viedma joined Votorantim in 2015 as its Regional Maintenance Manager for Europe Africa and Asia. Prior to this he worked for industrial minerals company Sibelco as a Maintenance Manager. Before this he worked for Holcim España for over a decade as a Maintenance Manager. He has worked in Spain, Portugal, France, Italy, Turkey and Egypt. Viedma holds a degree in industrial engineering from the Universidad de Jaén.


Benelux: Ireland-based Ecocem has appointed Paul Roos as Ecocem Benelux Managing Director and Joris Schoon as Technical Developer.

Prior to this appointment, Roos was the Europe, Middle East and Africa (EMEA) Commercial Director at Huntsman Corporation. At Ecocem, he will be responsible for managing Ecocem Benelux.

Schoon holds a PhD in civil engineering, specialising in concrete and environment. He holds over 20 years of industry experience. He will be based in Belgium for this role.


Turkey: Sanko Holding subsidiary Çimko Çimento has agreed to acquire several assets from Sabanci Holding subsidiary Çimsafor US$127m. The Dünya newspaper has reported that the deal covers two cement plants – the Nigde plant and Kayseri plant – the Ankara grinding plant and seven ready-mix concrete plants.


Nigeria: Finland-based Wärtsilä has extended its operation and maintenance agreement with Lafarge Africa by another five years. The agreement covers the 100MW Ewekoro power plant, which provides a dedicated supply of electricity to the company’s concrete and cement manufacturing processes. The extension of the deal was signed in July 2021 and it follows a previous 10-year agreement. The scope of the agreement includes the operating crew, performance guarantees, plant availability and spare parts.

The captive Ewekoro plant was supplied and commissioned by Wärtsilä in 2011. It consists of six Wärtsilä 50DF dual-fuel engines, operating primarily on gas, but with the flexibility to automatically switch to liquid fuel in case of a disruption to the gas supply. The engines are also designed to function efficiently with a low-pressure gas supply, a necessity given the region’s vulnerability to supply interruptions.

“We have benefited significantly from the efficient way by which Wärtsilä has operated and maintained this plant for the past 10 years, and we had no hesitation in extending the agreement for a further five years. An uninterrupted reliable supply of electricity is essential to our production, and having our own power plant, built, operated and maintained by Wärtsilä, gives us this assurance,” said Lanre Opakunle, Strategic Sourcing Director, Power & Gas, Middle East & Africa, Holcim.

Wärtsilä has also supplied Lafarge Africa with another 100MW power plant located in Mfamosing.


US: California Governor Gavin Newsom has signed a bill requiring the California Air Resources Board (CARB) to develop a plan by mid-2023 for the state’s cement producers to achieve net zero emissions of greenhouse gases by the end of 2045 at the latest. A 40% reduction compared to 2019 levels would also be required by the end of 2035 with interim targets set beforehand. CARB will also be obliged to ‘define a metric for greenhouse gas intensity,’ monitor emissions data, set a baseline to measure emissions reduction progress, evaluate measures to support market demand and financial incentives to encourage the production and use of low-carbon cement amongst other actions.


Germany: HeidelbergCement has invested in a 45% stake in Thoma Bravo’s supply chain software subsidiary Command Alkon. The group says that the companies’ collaboration can help advance heavy building materials supply chains’ digital transformation. It said that this will entail more transparent industry standards for seamless connectivity, improved solutions to customers’ everyday pain points, an increased pace in innovation and an acceleration of sustainability efforts. HeidelbergCement will continue to autonomously operate its proprietary digital product suite HConnect.

Chair Dominik von Achten said “As part of our Beyond 2020strategy, our clear goal is to become the first industrial tech company in our sector.” He added “We have made significant progress in our independently developed HConnect digital customer experience since its development in 2018. The investment in Command Alkon and the partnership with Thoma Bravo now allows us to monetise the hidden potential of our assets and translate it into a new growth path for HeidelbergCement. Together, we will build the digital ecosystem of the future for the heavy building materials industry.”


Thailand: SCG Packaging has taken a US$148m four-year loan from Bank Ayudhya. The loan is subject to environmental, social and governance (ESG) criteria and key performance indicators. The loan’s interest rate is tied to the company's sustainability performance targets, namely reducing greenhouse gas emissions, managing water resources and increasing the sales portion of its Green Choice label products and services. Bank Ayudhy will serve as sustainability coordinator, with the ability to adjust it down annually if sustainability goals are met.


France: Hoffmann Green Cement Technologies has signed a contact with Réunion-based retailer Ravate Group, under which the latter will stock its H-Iona slag cement in its shops in Réunion, Mauritius and Mayotte until 2025. The producer says that the first deliveries will follow in late 2021.

Owners Julien Blanchard and David Hoffmann said “Providing professionals and the general public with the possibility of buying very low-carbon cement, and thus of helping fight global warming, is a source of great pride for Hoffmann. We are delighted to have signed this first H-Iona distribution contract with Ravate Group, an independent family-run business with which we share many values such as innovation and respecting the environment. This partnership will allow us to increase our current order book and generate deliveries of bags of cement from 2021. We intend to sign more partnership deals of this type in order to be able to supply H-IONA and its exceptional benefits, notably environmental benefits, to as many people as possible.” Ravate Group operates over 40 outlets.


Kenya: Nairobi Business Ventures (NBV) plans to start building its new 1Mt/yr cement plant at Machakos near Nairobi by the end of 2021. Construction is expected to be completed by the end of 2023, according to the Business Daily newspaper. Cement sold from the plant will be marketed under the Delta Cement brand. The announcement follows the approval by NBV’s shareholders of its acquisition by Delta Cement. The company was acquired by UAE-based Delta International Holdings in late 2020.


Ghana: Daniel Asenso-Gyembibi, the director of the Building and Road Research Institute of the Council for Scientific and Industrial Research (CSIR-BRRI), has told parliamentarians that the institute’s Pozzolana cement plant needs US$4m to reopen. The unit at Gomoa Mprumem in the Central Region was forced to close due to a lack of private investment, according to the Ghanaian Times newspaper. Asenso-Gyembibi said that CSIR-BRRI had spent around US$250,000m on the project.

Commercial production started at the plant in 2011 with a capacity of around 5000bags/day. However, the unit stopped operation later in the same year due to poor sales and a lack of investment.


UK/Ireland: Mannok has launched a comprehensive biodiversity report, the Natural Assets Action Plan, in partnership with the conservationist group Ulster Wildlife. The report examines the entirety of the company’s landholdings, which span 800ha on both sides of the EU/UK border. Habitats include grasslands, wetlands, woodlands, ponds and quarries. The report will provide a roadmap for the conservation, restoration and enhancement of each area of land to help Mannok to meet its sustainability targets. Key aims include increasing biodiversity awareness among Mannok staff, customers and local communities, improving biodiversity monitoring, maximising carbon absorption in soil and vegetation, rewilding the natural landscape and ensuring resilience to predicted climate change effects.

Chief executive officer Liam McCaffrey said “This report informs our understanding of the value of natural assets to the business and wider community and will help guide our long-term planning and strategic investment decisions in a way which aims to maintain and enhance those assets. Already it has started to change our perspectives of what was previously considered wasteland. Now, we can see opportunities for careful and considered restoration into valuable natural assets for the future. Additionally, the work involved in creating the plan has allowed us to focus on the whole area of carbon mitigation in ways which we would not have considered before. The way in which we are looking at carbon reduction through careful management of our land is a relatively novel concept in industry, but we now recognise it as a critical tool in the fight against climate change.”

He added “The report is full of very valuable recommendations on what we can practically do over the next three - five years and beyond to continue enhancing and restoring our land assets, and we are very much committed to delivering on this. We will commit resources, time, people and finances to develop the recommendations.”


India: The Telangana government says that it has failed to persuade the Indian government to reopen the mothballed Cement Corporation of India Adilabad cement plant. The Press Trust of India newspaper has reported that this is despite an offer by the state’s government to contribute to costs.

IT and Industries Minister Ramon Rao said that the Telangana government aims to create 50,000 new jobs and claimed that the state is the fourth largest contributor to India’s economy.


Azerbaijan: Holcim Azerbaijan recorded sales of US$59.2m in 2020, down by 16% year-on-year. Turan Information Agency News has reported that the producer’s net profit was US$24.5m, down by 23%. During the year, the company reduced its debt by 14% to US$67m from US$78m.


Spain: Cementos Cosmos plans to install a new screw compressor in the cement discharge system at its Ourense grinding plant in Galicia. The producer says that the new equipment will improve the energy efficiency of the process of discharging cement from railway tanks to storage silos. The cost of the work is Euro23,500, towards which Cementos Cosmos has received a Euro8140 grant from the European Reagional Development Fund (ERDF) under its A New Way to Build Europe programme.


Thailand: SCG International has chosen US-based Black & Veatch to help with the acceleration of its electric vehicle uptake across hundred of sites spanning its operations, including cement. The US Trade and Development Agency has given the group a grant towards three logistics fleet electrification pilot projects.

Parent company Siam Cement Group (SCG)’s managing director Abhijit Datta said "I would like to express our sincere gratitude to USTDA as well as Black & Veatch for their support, guidance and efforts that have made this project possible."


UK: Global building materials supplier Cemex UK has launched its Buildings Made Better range of renovation and refurbishment products and services. The company says that the range offers customers easy access to low carbon, energy efficient or water-conserving building solutions. It includes a wide selection of existing and new products including its Vertua low carbon concrete. The producer said that the solutions support the construction phase and the whole lifecycle of the building.

Cemex Materials West Europe quality and product technology director Steve Crompton said “The renovation of existing buildings can lead to significant energy savings for all, as buildings account for over 40% of energy consumed. More than 220m buildings in Europe, representing approximately 85% of the building stock built before 2021, will mostly still be standing in 2050, yet currently only 1% of buildings undergo energy-efficient renovation each year. The energy performance of buildings is a major area for improvement in public policies, for new build and the renovation of the existing stock. From residential housing, to public buildings and urban schemes, across the board, we’re demonstrating to our customers that by improving the built environment, we can significantly improve our natural environment too.”

He added “Concrete has a critical role to play in the transition to a low-carbon economy. We have the aspiration to deliver net zero CO2 concrete globally by 2050, which will contribute to the development of climate-smart urban projects, sustainable buildings and climate resilient infrastructures. By bringing together a comprehensive range of sustainable products that support the important area of retrofit, we are offering our customers easy access to the right products for the job whilst keeping the environment front of mind.”


Kazakhstan: Korcem, a joint venture of International Cement Korday and Nurzhan Shakirov, plans to invest US$150m in the upcoming 1.5Mt/yr Korday cement plant in Zhambyl region. The company has a mining licence for 11ha of land in Korday district. International Cement Korday, a subsidiary of Singapore-based International Cement Group, holds 88% of shares in the venture. The plant is scheduled for commissioning in mid-2023.

Chair Ma Zhaoyang said “With our accumulated capabilities and experience in the cement industry in Central Asia, as well as Nurzhan Shakirov’s extensive local expertise in Kazakhstan, we are confident that this joint venture will be another success.”


India: Dalmia Cement has begun cement production at the new 2.3Mt/yr Line 2 of it Kapilas cement plant near Cuttack in Odisha. The plant now commands a production capacity of 4.0Mt/yr.


India: Orient Cement has signed a memorandum of understanding (MoU) with Adani Power Maharashtra for the establishment of a grinding plant on land belonging to the latter. The power company will secure a licence to sublet its land to Orient Cement and for the producer to use railway sidings at the site. Orient Cement plans to begin work on the project before April 2022.


Taiwan: The Asia Responsible Enterprise Awards (AREA) awarding body has named Taiwan Cement Corporation among winners in the Green Leadership category at its 2021 event. The company won the award for its concrete product traceability system, which enables customers to access production details via QR code. The system achieved 100% traceability in 2020. Taiwan Cement Corporation is committed to carbon neutral cement production by 2050.


Poland/US: Holcim has announced two new acquisitions in the area of raw materials and aggregates. In Poland, it has acquired granulated calcium carbonate producer Polcalc. The company employs 78 people. In the US, the group has acquired Utah-baed Utelite. The company produces lightweight aggregates and employs 40 people.

CEO Jan Jenisch said “We are pleased to welcome the employees of Utelite and Polcalc and look forward to their experience and capabilities. These two bolt-on acquisitions strengthen our presence in two important growth markets while contributing to Holcim’s overall strategy to expand our range of low-carbon products and solutions.”


Morocco: LafargeHolcim Maroc says that it is on schedule to commission its new 1.6Mt/yr Agadir-Souss cement plant in Souss-Massa region before 2022. The Ajourd’hui le Maroc newspaper has reported that the plant will rely on artificial intelligence (AI) in its cement production process. The total cost of the project is US$335m. The producer says that, when operational, the plant will create 1400 jobs.


India: UltraTech has made a commitment to transition to 100% renewable energy use by 2050. The Aditya Birla subsidiary has joined the global RE100 group of companies committed to energy decarbonisation. Asian News International has reported that the producer is already targeting 34% renewable energy use by 2024 from 13% in 2020. It more than doubled its consumption of renewable energy between 2018 and 2020. UltraTech Cement is additionally targeting a CO2 emissions reduction to 462kg/t of cement. It is the first Indian producer to instigate sustainability target-linked financial commitments.


Oman: Raysut Cement has said that it will commission its upcoming 1Mt/yr Duqm plant, the country’s first clinker grinding plant, in late 2021. The cost of the project is US$30m. The company’s global capacity target is 10Mt/yr by 2022 and 22Mt/yr ‘in the near future.’ It operates the 3Mt/yr Salalah cement plant in Oman and holds minority stakes in three East African grinding plants.

Support services and business development chief Yousef Ahmed Alawi Alibrahim said “This has been a challenging year for manufacturing industries in general, but RCC has been able to negotiate the hurdles with effective planning focusing on health and safety.”


US: The Tennessee Concrete Association (TCA) has awarded Emerald Awards for Environmental Excellence to two Ready Mix USA concrete plants. The TCA awards the prize to member plants which demonstrate environmental leadership, maintain sound environmental management practices and implement environmentally friendly upgrades or plant procedures. Ready Mix USA's Boone's Creek plant in Johnson City earned the award in the Small Plant category, while its Morristown Plant in Morristown earned the Mid Plant category award.

President Marc Tyson said "At Ready Mix USA and Cemex USA, we strive to be good environmental stewards and look for opportunities to improve our processes and operations to be even more sustainable and environmentally friendly." He added "We are proud of the achievements at Ready Mix USA, and we remain dedicated to leading positive change for our industry."


UK: Tarmac has completed a seven-week repair job on its PC2000 backhaul excavator at its Dunbar, East Lothian, quarry. The East Lothian Courier newspaper has reported that the work consisted of a rebuild of all major components, including the 11t bucket, pins and bushes. The equipment has been in service since 2014. It will next require servicing in 2026. Marubeni Komatsu carried out the work.

Quarry manager Mark Grieve said “With the excavator playing an absolutely key role in our process, this was a major project for Tarmac Dunbar.”


Pakistan: Askari Cement has awarded a contract to Germany-based Gebr. Pfeiffer for the supply of three of its MVR vertical roller mills to replace the existing mills at its Nizampur cement plant. Two of the mills will be MVR 5000 C-4 cement mills with the capacity to grind 360t/hr of clinker to a fineness of 3250 blaine. The other mill, an MVR 5000 R-4 raw meal mill, will grind 520t/hr of clinker to a fineness of 12% R90µm. The Chinese contractor Hefei Cement Research & Design Institute will install an SLS V high-efficiency classifier on each of the mills. The upgraded plant is scheduled for commissioning in mid-late 2022.


India: Gujarat Sidhee Cement has restarted the kiln at its Sidheegram cement plant in Gujarat. Reuters News has reported that full operations will commence at the plant on 25 September 2021. The producer shut down its kiln line for routine maintenance on 7 September 2021.


Bolivia: Fábrica Nacional de Cemento (FANCESA) has received an order for 8000t of clinker from Chile. The Correo del Sur newspaper has reported that the company previously delivered 1000t of clinker to Chile-based Cbb’s grinding operations in the country. The producer says that it is in the process of securing a supply contract for 80,000t/yr of clinker with its Chilean customer.


UK: ZwickRoell UK and Ireland has begun the construction of its new headquarters in Worcester, Worcestershire. The facilities will consist of a customer experience centre, a suite of offices, meeting and seminar rooms and a comprehensively equipped demonstration laboratory. Managing director Benno Sadowski said “We are very happy to be establishing a new facility in the Worcester Six Business Park, with its excellent strategic location in the UK.” He added “With our experience of more than 160 years in the materials testing equipment business, we are always investigating ways in which we can better support our customers with our advanced technology testing solutions in addition to creating relationships which embody our brand, vision and values.”


US: The Texas Commission on Environment Quality has discarded legal limits on crystalline silica in ready-mix concrete plants’ dust emissions. Commissioner Bobby Janecka said "I am pretty comfortable moving forward and finalising the proposed revision of the standard permit to bring us back to the point we departed from in 2012." He added that the commission had confirmed the decision with analysis from before the previous rule change, which he attributed to a ‘clerical error.’