Global Cement Newsletter

Issue: GCW531 / 10 November 2021

Headlines


Volvo Autonomous Solutions and Holcim Switzerland announced this week that they are testing and developing the use of autonomous electric haulers in a limestone quarry. It’s a two-part project, as being able to run electric dump trucks will help Holcim to meet its sustainability goals by switching to renewable energy supplies. Automating the control of the trucks then lets Holcim work towards its digitisation targets as part of its ‘Plants of Tomorrow’ initiative. Holcim Switzerland has also been running a drone programme at the plant (see GCW520) and has been using a few electric concrete mixer trucks since early 2021.

The use of autonomous haulage systems (AHS) in quarries by the cement industry seems to mark the start of something new. As far as Global Cement Weekly can tell, the Volvo Autonomous Solutions - Holcim Switzerland project is the first one in the cement sector that has been announced publicly. Most of the examples of AHS to date have been for heavy mining applications such as iron ore, copper, oil sands and coal. Automation in limestone and aggregate extraction has been slower. One recent example in the aggregate sector was announced in late 2020 when Norway-based technology company Steer said it had signed a contract with Romarheim to supply three autonomous dump trucks for use in a stone quarry. Previously Steer has used its vehicles to clear unexploded ordinance for the Norwegian army.

AHS have been around commercially since the mid-2000s when Komatsu tested and then deployed one at a copper mine run by Codelco in Chile. By September 2021 Komatsu said it had commissioned over 400 trucks with its autonomous system and that these had hauled over 4Bnt of materials. For its part Caterpillar says it started its first automated vehicle research program in 1985 and was even testing a pair of Cat 773 dump trucks in the 1990s. However, it then took a pause before resuming after 2000 and starting its commercial projects in the 2010s. In April 2020 it hit 2Bnt of hauled materials by AHS using its MineStar Command product. Hitachi, Liebherr and Belaz have also been working on their own AHS products in conjunction with third party technology providers and these were developed later in the 2010s. Most of these products are complimentary control systems that have been added to existing models or can be added to new ones. Autonomous vehicle company ASI is the other big name in the field with its Mobius product. Unlike the other systems, this is purely a retrofit product. ASI does not make its own vehicles. Komatsu and Caterpillar have also developed retrofit kits for their systems.

Most of the products above look mostly like normal trucks with the addition of extra kit. Volvo and Scania have also been working on AHS but their products have been taking it further by removing the cab entirely. Scania launched its AXL product in September 2019. Volvo launched its Volvo Autonomous Solutions subsidiary in 2020 and its Tara system electric dump truck the same year. Volvo had previously planned to run a pilot for its Tara truck with Harsco Environmental carrying slag at the Ovako Steelworks in Hofors, Sweden. Unfortunately the pilot was disrupted by the start of the coronavirus pandemic shortly after it started.

It’s early days yet with the use of autonomous vehicles in the quarries of the cement and aggregates sectors. Obvious advantages are additional operational hours, better worker safety and reduced costs. As ever with automation, cutting out human jobs would be one disadvantage for the current workers at least. There is also the possibility that an experienced human driver using efficiency software tools might be better than a fully AHS. A challenge in the field is developing open standards or methods to allow autonomous machines to communicate or work with both products by the same manufacturer and its rivals, as well as with conventional human-driven ones. Another challenge is for the mining and quarrying industry to determine how flexible it wants its heavy vehicles to be. One thought to end with this that an autonomous vehicle with a cab and a steering wheel can still be driven by a human. The cab-less vehicles being tested by Volvo and Scania would be rather less useful if they get into a situation where the software can’t cope. Lots to consider.

If readers are aware of other examples AHS in the cement industry, please let us know at editorial@propubs.com


Pakistan: Fecto Cement has renewed Amir Ghani as its chair and Mohammed Yasin Fecto as its chief executive officer (CEO). Both positions will have a term of three years from the start of November 2021.

Ghani joined his family textile business in 1991 and is currently is a director in Ghani Dyings. He is a member of the Pakistan Hosiery Manufacturers Association and Karachi Chamber of Commerce and Industry. He holds a Master of Business Administration (MBA) from the University of Boston in the US.

Fecto was first appointed as the CEO of Fecto Cement in 1993 and has held the position since then. He holds a MBA from the Quaid-e-Azam University.


Colombia: Cementos Argos' nine-month consolidated sales rose by 9% year-on-year in the first nine months of 2021 to US$1.87bn from US$1.72bn in the corresponding period of 2020. The group increased its consolidated cement sales by 20% to 12.9Mt from 10.7Mt. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 31% to US$416m from US$319m.

Chief executive officer Juan Esteban Calle “In the context of cost inflation pressures, Argos holds a privileged position given its capacity to locally produce clinker and cement in each of the regions where we operate. Additionally, the strategic geographic location of our network of ports and our own fleet of vessels facilitate the integration of the Cartagena cement plant, which is one of the most efficient in the Americas, with grinding plants and ready-mix operations in the US and the Caribbean.”


US: Summit Materials' nine-month consolidated sales were US$1.68bn in the first nine months of 2021, up by 7.7% year-on-year from US$1.56bn in the corresponding period of 2020. The group's net income rose by 4.8% to US$110m from US$105m. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 31% to US$416m from US$319m.

The company's consolidated cement sales for the period were US$208m, up by 10% from US$189m. Its sales volumes rose by 6.5% to 1.8Mt from 1.69Mt.


US: The Portland Cement Association (PCA) has expressed its support of the House of Representatives' new Infrastructure and Jobs Act, consisting of a US$1.2Tn infrastructure spending plan. The plan includes US$550bn in new federal investments before 2027. US$16bn is set aside for 'major projects' requiring special funding arrangements. The legislative body voted in favour of the bill on 7 November 2021. The act awaits the signature of US President Joe Biden. Biden previously unveiled a proposed US$2.25Tn infrastructure package in March 2021.

PCA president and chief executive officer Michael Ireland said "The PCA applauds the US House of Representatives for finally passing the Infrastructure Investment and Jobs Act. This bipartisan infrastructure bill not only addresses years of underinvestment in the nation’s infrastructure but will spur economic growth and job creation in communities across the country, improving the quality of life and our nation’s global competitiveness. As many are still recovering from the Covid-19 pandemic, this legislation will further our nation’s recovery, creating thousands of well-paying jobs."

He continued "PCA members across the country appreciate the legislation passing a long-term reauthorisation of the surface transportation programme, including significant investments in our water infrastructure, providing funding for the department of energy to focus on the research, developmentand deployment of technologies for manufacturers to capture carbon emissions, and the exemption of cement from Buy America requirements. We are eager for President Biden to sign this legislation into law and start building a better future for America.”


Spain: Votorantim Cimentos has started a Euro2m project to install a new clinker cooler at its Toral de los Vados plant. The work is expected to last until early December 2021 at the subsidiary run by Cementos Cosmos. The project will improve the energy efficiency of the plant. In August 2021 construction started on a 6.2MW solar plant to supply electricity to the site.


Algeria: Lafarge Algeria announced that it had exported a total of 2Mt of cement on 9 October 2021 from the start of its operations in 2016. Horizons News has reported that the company exported 0.8Mt of cement in the first nine months of 2021, more than double that in the corresponding period of 2020. It aims to exceed 2.5Mt of cement exports by the start of 2022. Its target for 2022 is full-year cement exports of 2.6Mt, double its 2021 target of 1.3Mt.


Algeria: Groupe des Ciments d'Algérie (GICA) expects that its cement exports should reach 2Mt by the end of 2021. The cement producer started exporting in 2018 with a total of 0.27Mt and has increased this since then. It renewed its desire for a new port to support its Chlef plant in the west of the country to further boost exports.


Vietnam: Cement producers have raised their prices due to mounting coal costs. In October 2021 Bim Son Cement increased the cost of its products by 6%, according to the Viet Nam News newspaper. Other manufacturers have done likewise. Data from the Vietnam Association of Construction Contractors shows that local coal prices have grown by 7 – 10% recently. Coal represents around 40 – 45% of the production cost of cement. Prices of diesel and additives have also risen.


Iceland: Sementsverksmidjan has decided to sell cement from competitor Aalborg Portland Islandi due to a cement shortage in the country. It said it wants to help the local supply situation after seeking guidance from the local competition authority. Rival company Steinsteypan has made a formal complaint to the regulator. Sementsverksmidjan, a cement importing subsidiary of HeildebergCement, says that it also sold cement supplied by competitors earlier in the year.


Japan: Taiheiyo Cement has revealed that a weakness in an evaporator tube in a fluidised bed heat exchanger in a captive power plant was the cause of an explosion that took place at its Hidaka cement plant in April 2021. It said that inspections had been carried out annually but that it was difficult to detect defects visually. The company has apologised for the incident. It says it will make changes including a review of inspection standards, including more personnel in the process, improved information sharing and starting regular training on the issue. These changes will be implemented across all of the company’s plants.

The 50,000kW circulating fluidised bed (CFB) boiler was supplied by Mitsubishi Heavy Industries and commissioned in 1996. It ran on coal, wood chips and refuse-derived fuel. No blame for the explosion has been attributed to the manufacturer.

The explosion took place in the evening of 27 April 2021. No major injuries were sustained. However, 40 vehicles parked outside a Pachinko gambling parlour near the plant were damaged. Scattered debris was noted nearby and ash was reported up to 5km from the cement plant.


India: Finland-based Betolar has launched a partnership with sustainable housing company Tara. The arrangement is intended to enhance India’s ‘green’ construction sector by encouraging the use Betolar’s pre-cast concrete products. These use waste inputs to create a low-carbon alternative to Ordinary Portland Cement. Betolar has been working with Tara since around 2019 to bring its commercial products to the local market.

Betolar's Head of Asia said, "There is a tremendous appetite for sustainable construction materials in India which we are tapped into through our work with Tara and its mission to develop alternative and sustainable models for rural development, democratizing construction from the bottom up."


US: Mississippi Lime Company says it will increase its prices for its quicklime, hydrated lime, specialty, and calcium carbonate products by up to 15%, subject to contractual obligations, in January 2022. It has blamed this on “significant cost pressures and unprecedented supply chain challenges” caused by the coronavirus pandemic and the subsequent economic recovery. Energy, labour, freight and material costs have all been reported as rising.


Germany: Cool Planet Technologies and Hereon have signed a memorandum of understanding with Holcim Deutschland to deliver a carbon capture system for a carbon capture and storage (CCS) trial at the producer’s Höver cement plant in Lower Saxony. Cool Planet Technologies will install their system, which is based on Hereon’s PolyActive membrane technology. The system will have a capture capacity of 5600t/yr and operate from early 2022 to early-mid-2023. If successful, two subsequent expansions will increase the system’s capacity to 170,000t/yr, commencing operation in 2024, and 1.3Mt/yr, commencing in 2026.

The suppliers say that their membrane-based capture system is capable of reducing the energy intensity and eliminating the need for other chemical inputs in CCS.


India: Dalmia Cement plans for 100% of its cement to be low carbon by 2031. The company has a US$405m carbon capture and utilisation (CCU) investment plan to help it to realise its goal. It will also undertake carbon offsetting measures.

Business Line News has reported that the company plans to spend US$1.35bn to increase its installed cement capacity by 52% to 50Mt/yr from 33Mt/yr before the 2024 financial year.


Australia: James Hardie recorded consolidated sales of US$1.75bn in the first half of its 2022 financial year, up by 28% year-on-year from US$1.36bn in the first half of the 2021 financial year. Its earnings before interest and taxation (EBIT) more than doubled to US$398m from US$197m. Fibre cement board sales increased by 17% in North America to 463Mm2 from 395Mm2 and more than doubled to 96.5Mm2 from 47.3Mm2 in Asia Pacific.

During the 2022, 2023 and 2024 financial years, the group plans to complete expansions of its Prattville, Alabama, cement board plant in the US and a European cement board plant, and to establish a new cement board plant in Victoria, Australia. It also aims to purchase land in the US for a future new cement board plant there.

CEO Jack Truong said "Our mission is to be a high-performance global company that delivers organic growth above market with strong returns, consistently. Ten consecutive quarters of growth above market with strong returns has led to an acceleration in operating cash flow, which is allowing us to expand our global manufacturing capacity, accelerate our growth initiatives, return to ordinary dividends, reduce our debt position, and increase the cash contributions to the Asbestos Injuries Compensation Fund (AICF)."


India: UltraTech Cement has committed to the Global Cement and Concrete Association’s 2050 roadmap for net zero concrete. It says that in realising the commitment, it hope to contribute to building the sustainable world of tomorrow. The Roadmap also includes a sectoral commitment to cut CO2 emissions by a further 25% by 2030.


Colombia: Cemex Colombia has received a US$16.8m fine from the Colombian Directorate of National Taxes and Customs (DIAN) for irregularities in its 2012 income tax payment. The company reportedly made an improper imputation of its balance for the year. Cemex Colombia says that it will take the matter to court. It has until March 2022 to file a suit.


Chile: Cementos Polpaico has submitted an environmental impact study for a US$60m upgrade of its Cerro Blanco cement plant in Tiltil, near Santiago. Business News America has reported that the proposed work consists of the installation of a new precalciner, an expansion to its four limestone quarries and the establishment of a new filtered tailings deposit and 3000t cement silo.

The producer hopes to launch the project in January 2023 in order to commission the upgraded plant before 2026.


Italy: Buzzi Unicem’s consolidated sales rose by 5.6% year-on-year to US$2.54bn in the first nine months of 2021 from US$2.41bn in the first nine months of 2020. It recorded consolidated cement sales of 23.4Mt, up by 7.5% from 21.7Mt in the corresponding period of 2020. Sales growth in Eastern Europe - especially the Czech Republic and Poland - and the US offset a partial slowdown in Italy, particularly in the third quarter of the year.

The group expects global construction activity to generally remain level into the fourth quarter of 2021. It forecast “favourable” volume and price effects in its full-year results for 2021. It nonetheless noted “growing concern” at rising energy, fuels, logistics, raw materials and services costs in various regions. It forecast group recurring earnings before interest, taxation, depreciation and amortisation (EBITDA) not in excess of 2020 levels.


Pakistan: Members of the All Pakistan Cement Manufacturers Association (APCMA) plan to reduce the CO2 emissions from their cement production. The Business Recorder newspaper has reported that companies will take three routes to emissions reduction while continuing to meet increased demand. These are to increase the efficient use of materials, increase energy efficiency and employ new technologies to capture or eliminate emissions.

President Muhammad Ali Tabba said "In a bid to achieve green growth going forward, the cement industry globally will have to adapt to climate change challenges and rework business models to ensure environmental stewardship and robust growth. The cement industry in Pakistan is committed to playing its role."


Vietnam: Local residents have blocked entrances to Van Ninh cement plant in Quang Binh’s Quang Ninh district in protest against alleged pollution violations. Van Ninh Cement previously incurred a US$3100 fine for dust emissions following a similar protest in 2017. The residents have put up tents in which to sleep in front of the plant in order to prevent the blockade’s removal.


Japan: Rigaku Corporation has launched its new MiniFlex XpC high-throughput rapid x-ray diffractometer (XRD) for analysis of cement samples. The supplier says that the product is able to quickly identify variations in cement’s composition. It uses an EasyX interface and can be automated using a sample-loading robot or conveyor belt.

President and chief executive officer Toshiyuki Ikeda said “The MiniFlex XpC is a manufacturing-optimised powder diffractometer for fast and accurate quality control measurements. Using the latest developments and lessons learned from class-leading products like the Rigaku SmartLab, this compact XRD offers unrivalled performance and ease-of-use.”


Nigeria: Mangal Industries has signed a contract with China-based Sinoma International Engineering for the delivery of a 3Mt/yr new integrated cement plant in the northern state of Kogi. The Daily Independent newspaper has reported that the plant will cost US$600m and generate ‘thousands’ of jobs when commissioned in early 2024. Sinoma International Engineering will also build a dedicated 50MW power plant for the plant.

Mangal Industries’ chair Alhaji Dahiru Mangal said “This investment is part of an ambitious investment programme under implementation by Mangal Industries. The factory will rely on the best available technology for cement production in line with highest environmental standards.” He added “Mangal is investing strategically in the Nigerian cement industry, to bridge the huge infrastructure and housing deficit in the largest economy of the region. This investment reinforces Mangal’s commitment to Nigeria’s infrastructural and economic development, and reflects its confidence in the favourable outlook of the economy in the country and the region.”


World: Three cement producers - Cemex, Dalmia Cement and Holcim – are founding members of COP26’s First Movers Coalition public-private partnership. The partnership plans to use its global purchasing power to create markets for emerging CO2 emissions reduction technologies, in order to accelerate and scale collective impact towards the global realisation of emissions reduction targets.

The coalition expects technologies currently on the market to account for 82% of CO2 emissions reduction before 2030 and 50% before 2050, while it expects future technologies to account for 15% before 2030 and 46% before 2050.


Ukraine: The Ukrainian cement association Ukrcement has forecast a 17% year-on-year rise in domestic cement consumption in 2021 from 9Mt in 2020. Business World Magazine has reported that demand previously exceeded 10Mt in 2014.

Association head Pavlo Kachur said that the Ukrainian cement industry operated at 66% capacity utilisation in the first nine months of 2021. He added “Therefore, we have room to grow.”


Switzerland: Holcim Schweiz has partnered with Sweden-based Volvo Autonomous Solutions to test and develop automated electric dumpsters at its Gabenchopf quarry in the Siggenthal. The companies aim to develop a safe, efficient and sustainable dumpster for use in the cement industry.

CEO Simon Kronenberg said “We are very excited to be working with Volvo on this project. For us, this project means a further step towards realising our sustainability goals: in order to make a contribution to a sustainably built future, we continuously invest in measures to reduce our ecological footprint and look for solutions that are both innovative and sustainable."


UK: Cemex has agreed to sell its Cardenden, Dundee, Greenock and Perth ready-mix concrete plants to Tillicoultry Quarries. The company thanked its employees at the sites for their commitment. It said that the asset sale is part of a portfolio rebalancing strategy aimed at high growth metropolitan markets.


Germany: HeidelbergCement recorded consolidated sales of Euro14bn in the first nine months of 2021, up by 7% year-on-year from Euro13.1bn in the corresponding period of 2020. Revenues rose in all regions, except for North America, where they fell by 0.1% to Euro3.51bn. The company’s cement sales were 95.7Mt, up by 6% from 90.1Mt, while its ready-mixed concrete sales were 35.7Mm3, up by 4% from 34.4Mm3. Cement sales grew across every region, and recorded the sharpest increase in Western and Southern Europe, of 11% to 23Mt from 20.7Mt.

The group said that ‘significant’ energy cost inflation impacted upon results in the period. It launched a Euro500m cost mitigation programme and initiated the divestment of some Spanish assets and the acquisition of Tanga Cement in Tanzania.


Germany: Cementos Molins has concluded its acquisition of calcium aluminate cement producer Calucem following all regulatory approvals. Calucem operates the Pula grinding plant in Istria, Croatia and a bauxite quarry in Turkey. The new acquisition positions Cementos Molins as the world's second largest calcium aluminate cement producer. The company said that it expands and enhances its innovative and sustainable product range in line with its sustainable growth strategy.

CEO Julio Rodríguez said “I warmly welcome the Calucem team into the Cementos Molins family. Today marks a new and exciting milestone in the history of Calucem and Cementos Molins and, with this integration, we have excellent business development opportunities for a new step forward to our strategy of profitable and sustainable growth.”

Calucem CEO Yuri Bouwhuis said “We are excited about the integration into Cementos Molins, where we will accelerate our development and create together more value for all our stakeholders.”


Uzbekistan: The government has extended its suspension of tariffs on imports of cement until 1 November 2021. Business World Magazine News has reported that the policy aims to reduce the cost of housing. In order to support the domestic cement industry, producers’ tax rate will be reduced to 15% from 20%. The government will also halve taxes on natural resources.


India: The government of Kerala plans to increase its cement production in order to help lower the price of cement in the state. The Times of India newspaper has reported that the state owns 10% of its cement industry. It plans for state-owned Travancore Cements to increase grey cement, white cement and wall putty production at its Nattakom grinding plant in Moolavattom. Its other cement company, Malabar Cement, previously increased its cement production.

The state government also convened a meeting of private sector cement producers in order to discuss the possibility of a reduction in the price of cement.


US: Charah Solutions has signed a contract with Associated Electric Cooperative (AECI) to receive bottom ash, fly ash and boiler slag from its Thomas Hill Energy Center coal-fired power plant in Missouri until 2026. Charah Solutions will recycle the by-products to produce supplementary cementitious products and redistribute these through its MultiSource materials network. The network consists of 40 locations across the US.

President and CEO Scott Sewell said "We are delighted to partner with AECI to manage their ash marketing needs at Thomas Hill while supplying our concrete producers with the high-quality material they need."