Global Cement Newsletter

Issue: GCW566 / 20 July 2022

Headlines


It’s been a good week for carbon capture projects in Europe with the announcement of who the European Union (EU) has selected for a grant from its Innovation Fund. 17 large-scale projects have been pre-selected for the Euro1.8bn being doled out in the second round of awards. On the cement and lime sector side there are four projects. These include projects at Holcim’s Lägerdorf cement plant in Germany, HeidelbergCement’s Devnya Cement plant in Bulgaria, Holcim’s Kujawy plant in Poland and Lhoist’s Chaux et Dolomites du Boulonnais lime plant in France. Large-scale in this instance means projects with capital costs over Euro7.5m. To give readers some sense of the scale of the projects that the EU has agreed to pay for, if the funding was shared out equally between the current bunch, it would be a little over Euro100m per project. This is serious money.

Devnya Cement’s ANRAV carbon capture, utilisation and storage (CCUS) project in Bulgaria has received little public attention so far so we’ll look a little more closely at this one first. No obvious information is available on what capture technology might be in consideration at the plant. HeidelbergCement’s leading experience in carbon capture technology at cement plants gives it a variety of methods it could use from a solvent scrubbing route to something less common. What the company has said is that, subject to regulatory approval and permitting, the project could start to capture 0.8Mt/yr of CO2 from 2028.

What has also been revealed is that the project is linking up via pipelines to a depleted part of the Galata gas field site in the Black Sea. Oil and gas company Petroceltic Bulgaria is a partner and the aim of the project is to start a CCUS cluster in Eastern Europe. with the potential for other capture sites in Romania and Egypt to join in. This is noteworthy because much of the focus for the burgeoning cement sector CCUS in Europe so far has been on usage on local industrial clusters or storage in the North Sea.

The other new one is the Go4ECOPlanet project at Holcim’s Kujawy plant in Poland. Lafarge Cement is working with Air Liquide on the project. The latter will be providing its Cryocap FG adsorption and cryogenics technology for direct capture of flue gas at the plant. The transportation of the CO2 is also interesting here as it will be by train not pipeline. Liquid CO2 will be despatched to a terminal in Gdańsk, then transferred to ships before being pumped down into a storage field under the North Sea.

Turning to the other two grant recipients, the Carbon2Business project plans to capture over 1Mt/yr of CO2 using a second generation oxyfuel process at Holcim Deutschland’s Lägerdorf cement plant. This project is part of a larger regional hydrogen usage cluster so the captured CO2 will be used to manufacture methanol in combination with the hydrogen. Finally, Lhoist’s project at a lime plant in France is another team-up with Air Liquide, again using the latter’s Cryocap technology. The capture CO2 will be transported by shared pipeline to a hub near Dunkirk and then stored beneath the North Sea as part of the D'Artagnan initiative. Around 0.61Mt/yr of CO2 is expected to be sequestered.

The key point to consider from all of the above is that all of these projects are clear about what is happening to the CO2 after capture. The days of ‘carbon capture and something’ have thankfully been left behind. CO2 transportation infrastructure is either being used or built and these cement plants will be feeding into it. This will inevitably lead to questions about whether all these new CO2 networks can support themselves with or without EU funding but that is an argument for another day.

Finally, in other news, four residents from the Indonesian island of Pulau Pari started legal proceedings against Holcim last week for alleged damages caused by climate change. Industrial CO2 emissions are unquestionably a cause of this along with other sources but what a court might think about this remains to be seen. Yet, it is intriguing that the plantiffs have decided to go after the 47th largest corporate emitter rather than, say, one of the top 10. Regardless of how far the islanders get this is likely not to be last such similar attempt. If the case does make it to court though it seems likely that Holcim will mention its work on CCUS such as the two projects above. Only another 200-odd cement plants in Europe to go.


Saudi Arabia: Mohammed Saeed Attia has resigned as the chair of Al Jouf Cement. He will continue working for the company as a part-time consultant until mid-2023. Mohammed Saeed Attia was originally appointed as the chair of the cement producer in 2020.


China: Italy-based Bedeschi has appointed Michele Gatto as the managing director of its new Hong Kong-based subsidiary Bedeschi Far East. The company is intended to assist local customers and to support the Far East market both commercially and technically.

Gatto was previously the Sales Director East Asia and Asia Pacific for Aumund from 2019 to 2022. Prior to this he worked for Bedeschi in area manager and sales roles with a focus on Asia. He has also worked for Danieli, Brevnini Power Transmission and Carraro.


India: Ambuja Cements' sales were US$495m in the first quarter of its 2023 financial year, up by 18% year-on-year from first-quarter 2022 financial year levels. Its net profit rose by 45% to US$131m from US$90.4m.The company said that it experienced rising fuel prices and related inflationary impacts during the quarter. It mitigated their impacts through the improved efficiencies delivered under its I Can operating strategy. Meanwhile, its master supply agreement with ACC also helped to restrict growth in transport costs.

Holcim India chief executive officer (CEO) and Ambuja Cements managing director and CEO Neeraj Akhoury said "Ambuja has recorded robust volume growth of 15% and top line growth of 18%. Ambuja Kawach, our green cement, demonstrated a sales growth of 22% year on year."


El Salvador: Holcim El Salvador has officially inaugurated an upgrade to its Maya cement plant. The company has invested US$11.6m towards increasing clinker production capacity by 0.45Mt/yr at the unit. Total cement production capacity of the plant has increased to 1.9Mt/yr from 1.2Mt/yr previously. The Maya cement plant previously reduced production levels significantly in 2008 in response to the global financial crisis at the same time. Oliver Osswald, Region Head of Holcim LATAM, attended the inauguration. The event was also used to launch Holcim’s new corporate branding in the region.


US: Lehigh Hanson’s Lehigh Cement plant in Union Bridge, Maryland plans to fully switch from Ordinary Portland Cement (OPC) to Portland limestone cement (PLC) production by January 2023. It will manufacture its EcoCemPLC product. The company says that the Union Bridge plant is currently the company’s largest cement plant in North America.

The decision to move to PLC follows similar changes at the company’s Mason City plant in Iowa and three cement plants in Indiana. Lehigh Hanson produced over 2Mt of PLC in 2021 and it says it is set to double this figure in 2022.


US: Dome Technology has commissioned a 169,000t dome at Lehigh Cement's Mitchell cement plant in Indiana. The dome is equipped with three reclaim tunnels, enabling 83% live reclaim.

Dome Technology sales manager Lane Robertssaid “It’s a colossal project. It’s one of our bigger domes as far as storage capacity goes."


UK: Cemex UK has commissioned a new 25kg plasticcement bag packing line at its Rugby cement plant in Warwickshire. The line will operate alongside an existing paper bagging line.

Cemex UK's packed cement sales manager Graeme Barton said “The packaging of our products is under routine scrutiny to meet customer demand and reduce waste. We have listened to what our merchants and customers need, and by investing in higher, more reliable capacity, Cemex can now meet the demand from the market in peak months with greater confidence. In turn, our stockists can meet their customers’ requirements by supplying what they need, in a format that works better for them. Our merchants and end-users are already seeing the immediate benefits of the new packaging by reporting fewer breakages in branch and onsite – which helps to cut down on waste."


India: Grasim Industries plans to establish a building materials sales platform with a total investment of US$250m over the five-year period to 2027. The Business Standard newspaper has reported that the new platform offers clear adjacencies with the cement and building materials producer's existing businesses and associate companies.

Parent company Aditya Birla's chair Kumar Mangalam Birla said "The building materials segment presents a huge scalable business opportunity with a proven path to profitability. With this foray, Grasim will be able to leverage the large business-to-business ecosystem within the Aditya Birla Group."


India: Andhra Pradesh Chief Minister Yeduguri Sandinti Jagan Mohan Reddy has laid the foundation stone for the upcoming Ramayapatnam Port in his state's Nellore district. Phase 1 of the port's construction will cost US$467m and is due to conclude in July 2025. The Hans India newspaper has reported that the new 25Mt/yr-capacity port will ship cement and other goods from four berths. Phase 2 of construction will subsequently increase the number of berths to 15, with a total export capacity of 139Mt/yr.


Brazil: Sales of cement fell by 2.7% year-on-year to 30.8Mt in the first half of 2022 from 31.6Mt in the same period in 2021. Data from the Brazilian National Cement Industry Association (SNIC) shows that domestic sales and exports decreased by 2.7% to 30.6Mt and by 8.5% to 0.19Mt respectively.

Paulo Camillo Penna, president of SNIC said, “Throughout the year, with the successive worsening of the economic environment, high interest rates, inflation and commodity prices added to geopolitical instability, caused by the conflict between Russia and Ukraine, have impacted the economy and the entire Brazilian industrial sector. In view of this scenario, the cement industry's expectation of ensuring the gains obtained from 2019 to 2021 is heading towards an undesirable frustration.”


Peru: Cement production grew by 7% year-on-year to 6.4Mt in the first half of 2022 from 6Mt in the same period in 2020. Data from the Association of Cement Producers (ASOCEM) shows that cement exports rose by 15% to 98,000t and clinker exports fell by 8% to 289,000t. Cement and clinker imports fell by 69% to 150,000t and 40% to 549,000t respectively.


Turkey: Germany-based Aumund Fördertechnik has secured a contract to supply equipment for a sustainability-enhancing upgrade to Bursa Çimento Fabrikasi’s Bursa cement plant. The order consists of six belt bucket elevators, four chain bucket elevators, seven pan conveyors, three arched plate conveyors, three spillage conveyors and three drag chain conveyors. The equipment will be involved in cement production from raw material preparation through to clinker grinding.

The Bursa cement plant currently operates using an Aumund bucket apron conveyor and chain bucket elevators.


Germany: Cemex Deutschland’s carbon capture partner Carbon Clean has hired US-based engineering company KBR to carry out installation of the planned 100t/day CycloneCC carbon capture system at the producer’s Rüdersdorf cement plant in Brandenburg. KBR will provide front-end engineering design (FEED) services for the project.

KBR global technology solutions president Jay Ibrahim said "Reaching net zero targets requires expertise from different industries to work together, and we make a powerful team. Hopefully, it will be the first of many such projects."


Germany: Christian Pfeiffer has launched its new FlexCore hardened rolled steel plates for ball mill diaphragms. With a hardness of 60HRC, the plates are wear and breakage resistant, enabling maintenance to be planned to the day, according to the supplier.


Ecuador: Holcim Ecuador has launched its new portfolio of ECOPlanet reduced CO2 cements. The products bear the new green and blue branding of the Holcim group.

CEO Dolores Prado said that the company began its green transition with the September 2019 carbon neutral certification of its Agrovial, Base Vial and Maestro cements.


Poland: Switzerland-based Holcim has concluded an agreement to acquire ready-mix concrete producer Ol-Trans. Ol-Trans operates five batching plants and is the market leader in Gdansk, Gdynia and Sopot. Holcim says that its new customers in the region will benefit from access to its CO2-saving products, including Agila Fibro self-compacting concrete, which can reduce steel reinforcement usage in construction by up to 50%.

Holcim’s Europe, Middle East and Africa regional head Miljan Gutovic said “With this acquisition we will further expand the footprint of ECOPact green concrete, the first and most comprehensive sustainable concrete range in Poland.”


Germany: Holcim Deutschland announced a planned upgrade to its Lägerdorf cement plant’s kiln on 14 July 2022. The producer will install a second generation oxyfuel kiln, which uses an air separation unit to supply oxygen directly, emitting CO2-rich flue gas. A new carbon capture system will supply captured CO2 to a synthetic hydrocarbons plant, which will produce methanol for other industrial applications. The upgrade will result in the capture of 1.2Mt/yr
of CO2 emissions and make Lägerdorf one of the world’s first carbon neutral cement plants, according to Holcim Deutschland.

The project, called Carbon2Business, was among four cement plant projects and 13 other EU-wide projects to win a share of a US$1.81bn EU Innovation Fund funding pot. CEO Thorsten Hahn acknowledged that the awarding of funds was ‘good news for Holcim and all partners working with us to decarbonise cement.’ He said “Climate change means cement change.”


Bulgaria/Poland: The EU Innovation Fund has awarded funding to Devnya Cement’s ANRAV carbon capture, utilisation and storage (CCUS) project in Bulgaria and Lafarge Polska’s Go4ECOPlanet CCUS project in Poland.

ANRAV is a full-chain CCUS project connecting Devnya Cement’s Devnya cement plant in Varna Province over 30km to the Black Sea for storage. Go4ECOPlanet applies a similar model to the capture and storage of CO2 from Lafarge Polska’s Kujawy cement plant offshore in the North Sea. The Kujawy cement plant is situated 200km inland in Kuyavian-Pomeranian Voivodeship. The plan is part of Lafarge Polska’s strategy to realise carbon neutrality at the Kujawy cement plant by 2027.

Regarding the ANRAV project, Mihail Polendakov, Bulgaria, Greece and Albania managing director at Devnya Cement’s parent company HeidelbergCement said “Our vision in the ANRAV consortium is to realise an economically viable CCUS cluster for Bulgaria and the neighbouring regions.” He continued “Subject to regulatory and permissions aspects, it could start operation as early as 2028, with a capture capacity of 800,000t/yr of CO2.


Pakistan: Kohat Cement has informed the Pakistan Stock Exchange of its plan to establish a 10MW solar power plant at the site of its Kohat cement plant in Khyber Pakhtunkhwa. The producer says that the plant will be connected to the national grid.


US: Titan Cement Group has invested in renewably powered Heat Battery developer Rondo Energy, in the California-based company’s Series A funding round. The Heat Battery is a 98% efficient electrical heater with high scalability, according to the supplier. Its modular battery provides grid load flexibility, with the possibility of continuous operation. Titan Cement Group says that it will now work in a technological partnership with Rondo Energy to develop new concepts for cement decarbonisation using Rondo Energy’s ‘unique innovation.’


Kyrgyzstan: Kant Cement has begun excavating the Severnaya Gryada limestone deposit near to its Kant cement plant. The producer says that the limestone has a higher purity than that from its existing Agalatas mine. It therefore expects the Kant plant to reduce its raw materials consumption and eliminate a part of its dust emissions. Kant Cement currently replaces a part of the limestone in the plant’s cement production with 65,000t/yr of fly ash.


Egypt: Misr Cement Qena commenced automated cement production at its Qena cement plant in early July 2022. The automation systems also cover plant maintenance processes. Misr Cement Qena awarded a technical management contract for the plant to Arab Swiss Engineering Company in June 2021.

Misr Cement Qena said "This step came in line with the company’s growth strategy to reduce operating costs and maximise asset utilisation in order to meet current challenges."


India: ACC recorded sales of US$559m in the first quarter of the 2023 financial year. The figure corresponds to a 15% year-on-year rise from US$486m in the first quarter of the 2022 financial year. The company's cement sales during the quarter rose by 13% to US$520m from US$460m. Its net profit was US$28.5m, down by 60% year-on-year.

Press Trust of India News has reported that ACC attributed the profit drop to 'rising global fuel costs and related inflationary impacts.' It said that waste heat recovery (WHR) installations at its Jamul, Kymore and Ametha cement plants will increase its renewable energy share to 15%, 'further accelerating the cost reduction journey.'


China: Tangshan Jidong Cement expects to record a 3.9 - 12% drop in its net profit in the first half of 2022. This would result in a figure of US$157 - 171m, compared to US$178m a year earlier.


India: The Indian Ministry of Mines and Indian Bureau of Mines have awarded UltraTech Cement Five Star ratings for 10 limestone mines across India. Assessment took place within the Indian mining Sustainable Development Framework, which quantifies sustainability, efficiency, land use and resettlement, besides other social impacts.


India: JSW Cement has dedicated a new temple at its Ankur commune in Salboni, West Bengal, to the goddess Maa Kali. The Orissa Diary newspaper has reported that architecture firm Dulal Mukherjee and Associates designed the temple in the 17th century Bishnupur style. The place of worship is made of locally sourced terracotta.

JSW Cement spokesperson Anushree Jindal said "JSW Cement believes in collaborating with local communities to empower them for a better future. I feel blessed and privileged to have facilitated the creation of a pious, safe haven of worship for the local community in Salboni."


China: Fitch Ratings expects West China Cement to record a first-half sales decline of 10% in 2022, due to ‘sluggish’ residential construction, on-going Covid-19 restrictions and high coal costs due to the Russian invasion of Ukraine. The rating agency predicted a ‘mid-single digit’ full-year sales decline in 2022, with a gross profit margin for the group of 28%, compared to 30% in 2021. This probability results from higher costs arising from overseas investments during the year.


Kazakhstan: Steppe Cement has received notification from Consilium Investment Management that funds under its management have ‘collectively ceased as a significant shareholder’ in the producer.

Consilium Investment Management previously represented a 5% stake in Steppe Cement’s shareholding.


Switzerland: Indonesian citizens of Pulau Pari have launched a legal case against Holcim in Switzerland for its contribution to climate change. Holcim operated in Indonesia from 1971 through its subsidiary Holcim Indonesia, which Semen Indonesia acquired from the group in 2019. Pulau Pari faces increased climate change-induced flooding, including two floods in 2020. Four residents have launched the present case against Holcim for damages, funding for flood defences and positive measures towards further group CO2 emissions reduction. Indonesia-based environmental organisation Walhi, Swiss Church Aid (HEKS) and the European Center for Constitutional and Human Rights (ECCHR) are supporting the case.


Trinidad & Tobago: Workers at Trinidad Cement’s Claxton Bay cement plant have launched a protest at the plant against an alleged breach of employment contracts. Troubled Company Reporter Latin America News has reported that Trinidad Cement has allegedly underpaid employees for more than seven years, with no cost of living allowance or gain share payments, and resulting pension miscalculations, according to a union representing the workers.


South Korea: SK Group subsidiary SK Ecoplant has partnered with CMD Group to launch pilot production of building materials made using up to 60% recycled bottom ash from waste incinerators. The partners say that an exothermic reaction in the presence of non-sintered inorganic binders and expansion-reducing reactants increases the compressive strength of the end product to match that of concrete containing ordinary Portland cement (OPC).

AJU News has reported that South Korean waste incinerators produced 2.16Mt of bottom ash from 9.12Mt of waste in 2020.