Global Cement Newsletter

Issue: GCW537 / 22 December 2021

Headlines


Two stories tie into larger trends this week as Global Cement Weekly says goodbye to 2021. Firstly, the state government of Odisha dropped a bombshell this week with its approval for an 18.75Mt/yr cement plant. Keen readers of the Global Cement Directory should note that, if built, this would be around the 10th largest plant worldwide and possibly the biggest outside of China. Credit to Odisha and India though for showing us how to end the year!

Odisha has been encouraging steel production in recent years. In March 2021 local press reported that Arcelor Mittal Nippon Steel (AMNS) had signed a memorandum of understanding with the state government for a US$6.6bn steel plant in the same district. Notably, a more binding agreement was intended to be signed once land and mining leases had been secured. This week the state said that its High Level Clearance Authority had approved an enlarged plan with AMNS worth US$13.5bn. This includes a 24Mt/yr steel plant and a 18.75Mt/yr cement plant. Both are to be built in phases over seven years. No further word on those land and mining leases though. How this fits into India’s overall plans for net zero CO2 emissions by 2070 is anyone’s guess. Yet this is another cement project linked to steel production. Readers may recall that steel producer Companhia Siderúrgica Nacional (CSN) Cimentos picked up Holcim’s Brazilian cement plants in September 2021.

The other story of note this week was Cembureau’s calculation that if the European Union (EU) emissions trading scheme (ETS) CO2 price reached Euro90/t then this could represent up to 15% of a cement plant’s production costs. The European cement association made the calculation using data from Ecorys, WIFO, the National Institute of Economic and Social Research for the EU Commission and Agora Energiewende. It wants the EU to bolster carbon leakage measures as soon as possible to fight rising import rates from outside the region. It is pushing for a delay to phasing out the free allocation in the ETS, bringing forward the proposed carbon border adjustment mechanism (CBAM) and for legislators to tackle rising carbon and energy costs generally. It should be noted that the EU ETS price reached Euro88/t on 8 December 2021 but it has stayed below that level since then.

As mentioned at the start, both of the stories above connect to larger trends, principally the cement sector’s adjustments to meet its sustainability goals. A new cement plant with a readily available supply of ground granulated blast furnace slag, such as a potential AMNS unit might have, can reduce its clinker factor more easily than its competitors. One major story in Europe over the last two years has been the steep increase in the ETS price, and Cembureau is highlighting the problems this has caused its members. Global Cement Magazine has run a number of annual round-ups in the last two issues that cover these issues and others. Dr Robert McCaffrey’s news and trends list for 2021 from the Global Cement LIVE broadcast on 21 December 2021 pulls together many of these ideas and more and is well worth watching.

We’ll finish with a list of the top 10 news stories on the Global Cement website in 2021. This reflects what readers all over the world are interested in at a particular time and the list is also biased towards stories that were published in the first half of the year as they have had more time to gather views. Yet, note, new plants in Africa and South Asia, a cement shortage story, Holcim’s decision to change its name and the problems a European producer, Cementa, has had with its quarrying. All of these touch upon larger themes.

Top 10 news stories on Global Cement website in 2021

1. Dzata Cement bagging plant to open in mid-2021
2. UK faces short-term cement shortage
3. LafargeHolcim shareholders agree to change group name to Holcim
4. SRM Concrete acquires 24 concrete plants in Dallas from Cementos Argos
5. Bestway Cement to build new cement plant in Mianwali
6. ThyssenKrupp abandons sale of ThyssenKrupp Industrial Solutions cement section
7. Holcim launches new corporate brand identity
8. Swedish supreme court rejects application by Cementa to renew mining permit for Slite cement plant
9. Larsen & Toubro wins new 3.5Mt/yr cement plant contract in Rajasthan
10. ACC breaks ground on 2.7Mt/yr Ametha cement plant project

Enjoy the Christmas and New Year break if you have one.

Global Cement Weekly will return on 5 January 2022


Oman: Oman Cement Company has invited contractors to submit bids for work at its integrated Rusayl plant. It wants to build a new 10,000t/day production line (Line 4) and upgrade an existing line (Line 3) to 5000t/day from 4000t/day. The plans were originally released in September 2021. The company also intends to shut down Lines 1 and 2 once work is completed.

It was previously reported in October 2021 that the cement producer was spending US$300m on the project and that it had hired Switzerland-based PEG Resources. At this time the project had a commissioning date of 2024.


India: State Bank of India (SBI) has acquired a minority stake in JSW Cement with worth US$13.2m. The bank acquired the stake as compulsorily convertible preference shares. JSW Cement plans to add the capital infusion to its on-going investments in a planned 79% expansion of its total capacity to 25Mt from 14Mt.


India: UltraTech Cement has announced its decision to temporarily suspend production at its Awarpur cement plant in Maharashtra after it became impossible to operate the plant due to the activities of sit-in protestors. The Times of India newspaper has reported that informal union Vijay Kranti Kantrati Kamgar Sanghatna (VKKKS) organised sit-ins at all five cement plants in Chandrapur district. The organisation is protesting workers’ pay.


Mexico: Cemex has signed a five-year agreement with India-based HCL Technologies for information technology (IT) services related to employee services, increased automation and analytics. HCL will work on IT managed services, infrastructure and application services and end-user support. It will also collaborate with Neoris, a subsidiary of Cemex, on customer services and supply chain resiliency. HCL will use its DryICE and Software products, along with various other automation products.

“Cemex selected HCL Technologies because we have a vision of working smarter to cater to the global company’s fast-growing operations,” said Fausto Sosa, vice president of Information Technology of Cemex.


Taiwan: Zhang Anping, the chair of Taiwan Cement, has expressed doubts about the strength of the Chinese market in the short term. Whilst being interviewed by the state-owned Central News Agency at a community event, he said that increased raw material and energy prices looked set to remain high until at least mid-2022. The price of coal in China had more than tripled in 2021 before easing somewhat. He also raised the risks of growing global market uncertainty from an anticipated rise in interest rates in the US by the Federal Reserve and the spread of the Omicron variant of Covid-19.


Philippines: Holcim Philippines has signed a collective bargaining agreement (CBA) with the union at its Norzagaray cement plant in Bulacan. Under the agreement employees have pledged to support the company’s efforts to drive performance. The CBA is effective until 2026 with the economic provisions in the third and fourth year of the deal open to renegotiation by 2024.

Horia Adrian, the president and chief executive officer of Holcim Philippines, said “Bulacan made tremendous operational and sustainability improvements this year due to the hard work and dedication of its people including members of Holcim Philippines Employees Association (HPEA). With this CBA’s closing, we can refocus on further transforming our Bulacan plant into one of the best sites in the Holcim Group and the country. My sincerest thanks to HPEA for your support and the sustained dialogue that allowed us to finalise this agreement.”


Australia: Boral says that its emissions reduction targets have been approved by the Science Based Targets Initiative (SBTi) as being consistent with the levels required to meet the goals of the Paris Agreement. Boral released its targets in August 2021 when it said it intends to reach net-zero emissions by no later than 2050. It subsequently joined the SBTi’s Business Ambition for 1.5°C and the United Nations Framework Convention on Climate Change Race to Zero campaign.

The Australia-based building materials company plans to reduce its Scope One and Two emissions by 46% by 2030. It also plans to decrease its relevant Scope Three emissions per tonne of cementitious materials by 22%. It intends to do this by: transitioning to 100% renewable electricity by 2025 and increasing alternative fuels usage at its Berrima plant kiln; growing the proportion of revenue from its lower carbon concrete product range and optimising the efficiency of its cement plant; reducing transport emissions in its own and contractor fleet; prioritising lower carbon intensity suppliers; and exploring and testing emerging carbon capture use and storage technologies.

Boral’s Chief Finance and Strategy Officer, Tino La Spina, said “Boral is determined to become a leading innovator in sustainability through decarbonisation of cement and concrete and increasing our contribution to a more circular economy” He added “We continue to support our customers in their transition to net zero, broadening our range of high performing lower carbon concrete products to cater for all building and infrastructure applications, and offering Climate Active−certified net carbon neutral concrete.”


Nigeria: Sinoma International Engineering has announced the commissioning of the new 3Mt/yr production Line 3 at BUA Cement’s Sokoto cement plant at Kalambania in Sokoto state. The supplier, a subsidiary of China National Building Material (CNBM), says that work continues on the plant’s upcoming Line 4.


India: The Odisha government has approved Arcelor Mittal Nippon Steel’s plans to build a 18.8Mt/yr cement plant in connection to a new steel plant to be established at Mahakalpara in the state’s Kendrapara district. The project will have a total investment of around US$13.5bn, according to the Hindu newspaper. Once operational both the cement and steel plant will be the largest of their type in the country. The company plans to carry out the project in phases, for completion by the late 2020s.


Sri Lanka: Tokyo Cement has commissioned its new 0.45Mt/yr cement terminal at the Port of Colombo in Western Province. The company invested US$12.3m in the facility. It is equipped with three 6000t cement silos. The Daily News newspaper has reported that it will increase the company’s total import capacity to over 1Mt/yr from 0.6Mt/yr. Tokyo Cement says that this will ensure an uninterrupted supply of cement to customers in Western Province.

The cement producer also started work on a 1Mt/yr upgrade project at its Trincomalee plant in November 2021. The work is scheduled for completion in early 2023. Once finished the cement producer will have a total production capacity of 4Mt/yr.


Denmark: Aalborg Portland Cement says that the market ‘warmly welcomed’ its new FUTURECEM calcined clay cement in 2021. The product has reached its sales expectations for the year and is now nearly sold out for 2022. The company says that its plan to ramp up FUTURECEM production to replace 50% of grey cement production at its Rørdal cement plant is on track.

Parent company Cementir Holding says that the success of FUTURECEM rests on four pillars, namely its suitability for intended applications, targeted communication, close dialogue with concrete producers and the entire value chain and strategic partnerships with leading construction clients. It said “The lesson learned is that the market needs thorough information about new products and its industrialisation to rely on and implement them in place of conventional products.” The group added that its experience in Denmark paves the way for limestone calcined clay technology rollouts in other markets in line with its sustainable roadmap towards 2030.


Kenya: Bamburi Cement has launched Women on Wheels, a women-centred recruitment programme aimed at encouraging more women into truck driving. The Kenya News Agency has reported that the company plans to recruit at least 100 new cement truck drivers annually under the scheme. Women on Wheels will additionally work to increase health and safety, challenge entrenched sexism and improve working conditions for all of the company’s drivers.

Managing Director Seddiq Hassani said “The gender gap is far from closed, however we are determined to increase the promotion of women in every aspect of our operations.”


US: Performance materials and technologies conglomerate Honeywell has entered into a collaboration with the University of Texas at Austin for the development of carbon capture systems. Honeywell has obtained a licence to use the university’s proprietary advanced solvent technology. The University of Texas at Austin will provide consulting services for the company as it seeks to develop a carbon capture system for industrial implementation using the technology. Honeywell will target ‘hard-to-abate’ CO2 emitting industries such as cement to which to supply its system.

University of Texas at Austin McKetta Department of Chemical Engineering professor and Texas Carbon Management Program (TxCMP) lead Gary Rochelle said “We are thrilled that our decades of research has led to carbon capture technology that can significantly reduce carbon emissions. The licensing agreement with Honeywell enables us to commercially scale this in ways that can make major contributions toward zero emissions efforts to address global warming and to reduce pollutants in surrounding communities.”


Mexico: 200 police officers in 80 police cars arrived outside the gates of Cooperativa La Cruz Azul’s Cruz Azul cement plant in Tula, Hidalgo, on 15 December 2021, but failed to enter the plant. The El Financiero newspaper has reported that the police were following a court order to remove the company from the plant. Supervisory board president Alberto Lopez reasserted the company’s right to occupy the property in line with federal government ordinances. Lopez suggested an alleged collusion between cooperativists and Omar Fayad’s Institutional Revolutionary Party (PRI) Hidalgo state government to decieve the courts.

Authorities have frozen Cooperativa La Cruz Azul’s accounts with outstanding bills of US$800,000 in electricity, gas, equipment and services bills, as well as the payroll of its 1100 workers.

Coopertiva La Cruz Azul chair Federico Sarabia said that the developments threaten the existence of the Cruz Azul plant. He said "In terms of quality, Cruz Azul’s cement exceeds the standard. At the time that Cruz Azul disappears as a cement producer, prices will increase.”


Mexico/Denmark: Cemex and 3D printing construction company Cobod International have launched D.fab, a range of admixtures which enable builders to use ordinary concrete in 3D printing. The partners say that the products eliminate the need for expensive specialised mortars. Power2Build implemented the admixtures in concrete to print a whole house in Luanda, Angola, in early December 2021.

Cemex’s executive vice president sustainability, commercial and operations development Juan Romero said “The introduction of this revolutionary 3D printing system is a testament to our customer-centric mindset and relentless focus on continuous innovation and improvement. Working together with Cobod, we have developed an experience for customers that is superior to anything that has been provided in the past,” said “Our innovation efforts position us at the forefront of new technologies that contribute to building a better future.”


Germany: Flender has launched the construction of a new 8000m2 storehouse at its Voerde, North Rhine-Westphalia, logistics centre. Along with the lease of an additional building from project developer Panattoni, the project will expand Flender’s total storage footprint by 19,000m2. The supplier says that the new facilities will reduce the Voerde centre’s CO2 by optimising its transport routes.

Flender CEO Andreas Evertz said "I am very happy that the expansion of our site in Voerde will allow us to centralise our logistics activities, bringing us another step closer to our goal of operating in a completely carbon neutral fashion by 2030. With the new warehouse space, we are making our logistics processes sustainable and thus reducing a significant part of the previous transport routes and the associated CO2 emissions.”


China: Sichuan Shuangma Cement’s board of directors voted in favour of a rebranding on 16 December 2021. In a filing to the Shenzhen Stock Exchange, the company stated that it will change its name to Sichuan Hexie Shuangma. The reason for the change is the producer’s diversification away from its original business of cement production into other industries, making the ‘Cement’ element less relevant than it had previously been. Hexie is Chinese for harmony.


Europe: Cembureau, the European cement association, has calculated that if the European Union (UN) emissions trading scheme (ETS) CO2 cost reaches Euro90/t then this could represent 12 - 15% of the production costs of cement producers. The association made its calculation for an average cement plant in the region using data from Ecorys, WIFO, the National Institute of Economic and Social Research for the EU Commission and Agora Energiewende.

Cembureau has called for the EU government to delay its proposed ETS free allocation phase-out and to bring forward the implementation of its proposed carbon border adjustment mechanism (CBAM) from 2026. It has called on policy makers to ‘use all the tools available to stabilise market prices, support energy intensive industries through state aid and examine the functioning of the European gas and electricity markets, as well as the EU ETS.’


India: Finance company ICRA reported all-India cement sales in the first half of the 2022 financial year of 124Mt, up by 22% year-on-year. Mint News has reported that the total value of cement sales rose by 5% in the period compared to the first half of the 2021 financial year. Producers’ raw materials costs rose by 16%, while power, coal and petcoke costs rose by 26% and freight costs rose by 7%. Granulated blast furnace slag (GBFS) and gypsum prices also rose.

ICRA corporate ratings assistant vice president and sector head Anupama Reddy said "Despite some easing in the cost-side pressures, the input costs are likely to remain elevated in the near term, and are expected to exert pressure on operating margins, which are likely to decline by 200 to 230 basis points (BPS) in the 2022 financial year as a whole. While the capacity additions are expected to increase year-on-year in the 2022 financial year, the reliance on debt is likely to be lower owing to the healthy cash generation and strong liquidity of the cement companies. The debt coverage metrics are expected to remain strong in the 2022 financial year."


Europe: Cembureau has announced the launch of its Map of Innovation Projects interactive map. The feature maps past and current sustainability-enhancing projects at European cement plants. It currently displays a total of 53 different projects. It is available here.


US: Conveyor Components Company has announced its launch of Model DB, a conveyor belt rip detector. The equipment relies on a cable pull concept to trip the belt drive. Different microswitch options allow customers to choose from four circuit designs. Thus, instead of shutdown, an alarm response is possible. The supplier says that the technology offers similar performance to embedded coil devices.


Azerbaijan: Cement companies produced 3.19Mt of cement in the first 11 months of 2021, up by 3.4% year-on-year from 3.09Mt. On 1 December 2021, total cement reserves in stockpiles were 113,000t. Ready-mix concrete production rose in the first 11 months of 2021 by 2.9% to 986,000m3 from 937,000m3, while precast concrete production more than doubled to 301,000m3 from 143,000m3.