Global Cement Newsletter

Issue: GCW594 / 08 February 2023

Headlines


Cement 2 Zero (C2Z) has officially launched in the UK this week. The project is an industrial scale pilot of the Cambridge Electric Cement (CEC) process. The Materials Processing Institute will lead on this stage with two-year funding of around Euro7m provided by UK Research and Innovation (UKRI). Partners include the University of Cambridge, Atkins, Balfour Beatty, Brewster Brothers, Celsa Group, Day Aggregates and Tarmac.

CEC’s method uses recycled concrete paste in place of lime-flux in steel recycling. Slag is formed as the steel melts and this is then used in place of clinker to make more cement. This way of making cement cuts out the decarbonisation of limestone step from conventional clinker production. If renewably-sourced electricity is used to power the heating and grinding parts of manufacture, then cement production in this way could potentially cut out most of its CO2 emissions. The first phase of trial melts by C2Z will be conducted by the Materials Processing Institute using a 250kg induction furnace and this will be scaled up to 6t in an electric arc furnace (EAF). Later, industrial scale melts will be tested in Celsa Steel's EAF in Cardiff, Wales.

CEC is taking a similar approach to HeidelbergCement with its research into using recycled concrete paste. However, HeidelbergCement says it is using the paste to help capture CO2 in an enforced carbonation step it is testing at cement plants. It too though wants to create a secondary cementitious material (SCM) afterwards. There are also links here to construction and demolition waste and electric cement kilns as covered by Global Cement Weekly previously. The latter is different with regards to what CEC is doing because it is recycling concrete waste to produce an SCM (slag) rather than using an electrically powered kiln to make clinker from limestone. Coolbrook, VTT and the like have had to build electric kilns effectively from scratch or adapt technology from elsewhere for their approaches whilst CEC appears to be about to use existing EAFs in its industrial scale pilot.

Figure 1: Projection of how the Cambridge Electric Cement production process could be used at scale in the UK. Source: UK FIRES.

Figure 1: Projection of how the Cambridge Electric Cement production process could be used at scale in the UK. Source: UK FIRES. Click to view larger version.

CEC’s forecast of how its process could be used at scale in the UK can be seen above in Figure 1. If the majority of the country’s steel scrap was recycled in this fashion each year then 2.4Mt/yr of CEC cement could be produced. This would represent a quarter of the c10Mt of cement sales reported by the MPA in 2021. Assuming the EAFs were powered by renewables then this could reduce the cement sector’s CO2 emissions significantly. Although it would still leave the industry looking for other decarbonisation routes for the other three-quarters of cement demand.

C2Z and CEC offer a novel spin on cement production by recycling concrete waste, using an electrical heating step and dodging the process emissions associated with normal ordinary Portland cement (OPC) clinker production. If it did progress to a commercial stage then it would see a continued relationship between steel and cement producers. Currently this is mainly centered around iron and steel slag usage as a SCM. One point of interest here would be how much higher levels of steel recycling and a process like CEC being used regularly would affect existing slag usage as an SCM. It doesn’t look like CEC could solve the cement sector’s CO2 emission problem all on its own but it could certainly make a difference if it progressed to a commercial stage. As ever with cement sector decarbonisation there appear to be a range of options available to producers.


China: West China Cement has appointed Cao Jianshun as its chief executive officer (CEO) and as an executive director. He succeeds Ma Weiping, who has resigned for personal reasons. Cao’s appointment is for one year with the option for re-election.

Cao, aged 50 years, has worked in the cement sector since the early 1990s. He joined Yaobai Special Cement Group in 1994 and eventually became the general manager in the Ankang region of Yaobai Group from 2013 to 2015. He was the general manager of Chzhungtsai Mohir Cement from 2016 to 2018 and vice president of International Cement Investment Management Company until early 2023. He holds a bachelor’s degree in economics management from Central Party School of the Shaanxi Provincial Committee and a master’s degree in business administration from Northwest University in China.


India: Grasim Industries is preparing to appoint Ananya Birla, and Aryaman Vikram Birla as directors. The pair are the children of company chair KM Birla, who is also the chair of the parent company, Aditya Birla. Both companies are parent organisations to UltraTech Cement.

Ananya Birla is a musician and a businesswoman. She released her first single ‘Livin the Life’ in 2016 after signing with Universal Music India. She also set up her first company Svatantra Microfin, a microfinance institution, in 2012.

Aryaman Vikram Birla is a former professional cricketer who played for the Rajasthan Royals in the Indian Premier League. His work with Aditya Birla has included helping to steer the group’s TMRW venture in the fashion and lifestyle sectors. He has also invested in the hospitality business and worked with the group’s venture capital fund, Aditya Birla Ventures.

The board of Grasim Industries has also appointed Yezdi Piroj Dandiwala as an independent director. Dandiwala is a corporate lawyer. He is a partner at Mulla & Mulla and Craigie Blunt & Caroe, Advocates & Solicitors. He holds experience in corporate and commercial transactions.

All of these appointments are subject to approval by the board.


Australia: Boral recorded sales of US$1.17bn during the first half of its 2023 financial year, up by 12% year-on-year from US$1.05bn during the first half of its 2022 financial year. Cement sales were US$128m, 11% of group sales. The producer’s net profit fell by 91% year-on-year to US$62.5m from US$715m.

During the half, Boral’s subsidiary Geelong Cement commissioned a new 0.8Mt/yr grinding unit at its 0.6Mt/yr Waurn Ponds grinding plant in Victoria. The group also upgraded the chlorine bypass system at its Berrima cement plant in New South Wales to support increased alternative fuel (AF) co-processing. Throughout 2022, Boral substituted 15% AF into its fuel mix.


India: Ramco Cements recorded revenues of US$674m during the first nine months of its 2023 financial year, up by 33% year-on-year from US$509m in the corresponding period of the 2022 financial year. Costs rose, including a 45% rise in the company’s raw material costs to US$110m from US$76m. This precipitated a 75% decline in the producer’s net profit, to US$23m from US$93.1m.


UK: Cambridge Electric Cement (CEC) has launched the two-year trial of its Cement 2 Zero project, aimed at scaling up production of its net zero-CO2, demolition waste-based alternative cement. It aims to produce 20t of the material for use in a low-impact construction project. CEC’s method, developed at the University of Cambridge, is based on the conversion of demolition waste into a slag-forming material within a steel furnace.

Developer Julian Allwood said “By combining steel and cement recycling in a single process powered by renewable electricity, we could supplement the global supply of the basic construction materials to support the infrastructure of a zero emissions world and to enable economic development where it is most needed.”


India: Amplus Solar has secured a contract with JK Lakshmi Cement for construction of a 56MW solar power plant at the producer’s 1.7Mt/yr Durg cement plant in Chhattisgarh. The producer expects to eliminate 73,000t/yr of CO2 emissions as a result.

JK Lakshmi Cement’s president Arun Shukla said "We support the country's vision to achieve net zero emissions by 2070. We have taken multiple steps to reduce both direct and indirect carbon emissions. Last month, for the first time in India, we deployed liquefied natural gas (LNG) trucks to transport raw material. Now, with the switch to solar energy at our Durg plant, nearly 80% of the plant’s energy requirements will be met renewably.”

Amplus Energy previously partnered with UltraTech Cement for a 50MW solar installation at one of its cement plants in 2019.


Sri Lanka: Tokyo Cement recorded sales of US$74.8m during the first nine months of the 2023 financial year, up by 25% year-on-year. Its cost of sales dropped by 2% to US$49.7m, while its profit for the period rose by 60% to US$2.35m.


Türkiye: OYAK Çimento and Taiwan Cement Company (TCC)s’ joint venture says that it has successfully restarted one of its Turkish cement plants following an earthquake on 6 February. The Netherlands-based joint venture said that two further plants remained at a standstill due to a regional power outage.

Two major tremors, of magnitudes 7.8 and 7.5 on the Richter scale, originated near Gaziantep in Türkiye’s Southeastern Anatolia Region. TCC immediately activated its Employee Care Plan to assist and arrange aid for employees and their families, dispatching 100 emergency kits by courier.

On 8 February 2023, rescuers had reported that 9460 people had died in the catastrophe, 6960 in Türkiye and 2500 in Syria.


Zimbabwe: South Africa-based PPC is reportedly considering selling PPC Zimbabwe for US$200m. The Zimbabwe Independent newspaper has reported that the group received an unsolicited offer from a local company.

PPC said “PPC’s board has a duty to assess any such approaches on their respective merits.”


US: The Department of Energy’s (DOE) Carbon Storage Assurance Facility Enterprise (CarbonSAFE) initiative has awarded funding of US$8.9m to Heidelberg Materials North America to study the subsurface geology for suitability for the storage of carbon dioxide at the Mitchell integrated cement plant in Indiana. The proposed project will geologically characterise several prospective reservoirs under the Mitchell plant for storage of more than 50Mt of CO2 over a 30-year timeframe.

The award, which is managed by the National Energy Technology Laboratory, will be issued to the Illinois State Geological Survey at the University of Illinois (ISGS) as the prime contractor, with the company acting as a technical and industrial partner. Heidelberg Materials is contributing about US$1.5m in funding while ISGS will be contributing approximately US$0.6m for a project total of US$11.1m. The funding was part of a DOE initiative that generated nearly US$125m in funding for 10 projects to characterise suitability for carbon storage across the US.

Heidelberg Materials’ Mitchell cement plant is being upgraded with a new production line. Full production on the new line is anticipated to start in early 2023.


Senegal: China-based Sinoma CBMI Construction has commissioned a new production line at Ciments du Sahel’s Kirene plant near Dakar. The new 6000t/day line is intended to replace the plant’s existing third production line. Ciments du Sahel signed a contract with Sinoma CBMI to upgrade the plant in 2020.


US: Prometheus Materials has been awarded ASTM C129 certification for non-loadbearing concrete masonry units (CMU) and ASTM C90 for loadbearing CMUs for its bio-cement product. The company is commercialising a process to produce cement and concrete using microalgae.

Loren Burnett, the chief executive officer of Prometheus Materials, said “We are thrilled to have achieved these two foundational certifications as we proceed in full-force with our goal of decarbonising construction.” He added, “Prometheus Materials’ product is poised to change the future of construction, converting one of the most carbon-polluting industries to a low-carbon – and one day net-zero carbon – reality.”

Find out more about Prometheus Materials in the October 2022 issue of Global Cement MagazinePrometheus Materials in the October 2022 issue of Global Cement Magazine


Germany: Beumer Group is preparing to exhibit at the Solids Dortmund trade fair on 29 – 30 March 2023. The supplier will be showcasing its equipment for conveying, loading, palletising and packaging various bulk materials for the cement, building materials and chemical industries. Solids Dortmund covers equipment for granules, powder and bulk solids technologies.


India: Nuvoco Vistas recorded consolidated sales of US$315m during the third quarter of its 2023 financial year. This corresponds to a rise of 20% year-on-year from US$262m during the third quarter of the 2022 financial year. The producer's earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 13% year-on-year to US$33m from US$29.2m. As a result, the company was able to overcome increased costs to reduce its net loss by 12% to US$9.1m.


India: UltraTech Cement has commissioned a new 1.5Mt/yr grinding unit at its Jharsuguda grinding plant in Odisha. The unit more than doubles the plant's capacity to 2.5Mt/yr. The Hindu BusinessLine News has reported that UltraTech Cement now has a production capacity of 4.1Mt/yr in Odisha. The Eastern Indian state thus hosts 3.3% of the producer's total capacity of 123Mt/yr.


US: Holcim has signed an agreement with Duro-Last to acquire the roofing systems producer for US$1.29bn. Reuters has reported that the acquisition will be Holcim's largest for all of 2022 and 2023 so far. Once the parties complete the transaction, Duro-Last's business will join Holcim's products and systems division. Holcim expects the deal to yield synergies of US$60m/yr, primarily through a reduction in the cost of materials.

Holcim expects its products and systems division to contribute a majority of its profit in North America once increased investment under the US government's Inflation Reduction Act begins to take effect. In 2022, the division accounted for 40% of regional profit. The group is committed to a global target of 30% of sales being attributable to the products and systems division by 2025, compared to 19% of sales in 2022.


US: US cement companies produced 95Mt of cement in 2022, up by 2.2% year-on-year from 93Mt in 2021, according to the United States Geological Survey (USGS). The country exported 900,000t of cement and clinker, down by 4.3% from 940,000t. The USGS recorded a 9.1% leap in apparent national consumption, to 120Mt from 110Mt. Cement imports helped to close the gap, rising by 20% year-on-year to 24Mt from 19.9Mt.

Among the US's main trade partners for cement imports, cement production fluctuated in 2022. Turkish cement production rose by 3.7% year-on-year to 85Mt, Mexican cement production fell by 3.8% year-on-year to 50Mt and Vietnamese cement production rose by 9.1% year-on-year to 120Mt. Globally, the USGS estimated a year-on-year cement production decline of 6.8% to 4.1Bnt.


Nigeria: GE Gas Power expects to commission a new 50MW power plant at a Dangote Cement site in early 2023. The supplier said that the new power plant will provide energy for Dangote Cement's cement production and refinery operations.

The This Day newspaper has reported that the new plant is part of a total 500MW-worth of new power infrastructure which GE Gas Power expects to commission in Nigeria before July 2023.


India: JK Cement's consolidated sales were US$839m during the first nine months of the 2023 financial year, up by 23% year-on-year from US$682m during the corresponding period of the 2022 financial year. The producer's costs grew across all areas of expenditure, resulting in a net profit for the period of US$37.4m, down by 36% year-on-year.

JK Cement received approval for the issuance of up to US$12.1m in redeemable non-convertible debentures (NCDs) on private placement basis on 6 February 2023.


Mexico: GCC has secured validation by the Science-Based Targets Initiative (SBTI) for its latest CO2 reduction goals. The group has committed to reducing its Scope 1 emissions per tonne of cementitious product by 31% and its Scope 2 emissions per tonne of cementitious product by 57% between 2015 and 2030. It has also committed to a 37.5% absolute reduction in its products’ Scope 3 emissions over the same period. The goals will serve as sustainability performance targets for GCC’s US$500m sustainability-linked bond, which it issued in January 2022.

GCC's vice president of sustainability and environment Gina Lotito said "We are proud and excited to be a catalyst of progress towards a low-carbon future. Our laser-focus on our climate change strategy and emphasis on reducing CO2 emissions is a testament to our commitment to creating a sustainable future. While we celebrate our achievements, we acknowledge that there is still much work to be done and remain steadfast in our mission."


US: Mitsubishi Cement Corporation has reportedly abandoned its planned construction of a cement terminal at the Port of San Diego in California. The Union-Tribune newspaper has reported that the cement producer failed to produce a plan involving electric vehicle use for cement deliveries to the facility. Board of Port Commissioners rejected the company’s previous terminal proposal in 2020 because of its involvement of diesel-powered cement trucks.


Russia: Holcim’s divested Russian business has rebranded as Cementum. Local management concluded a deal to buy the company from Switzerland-based Holcim in December 2022. The new ownership agreed to change the name upon completion of the transaction. Holcim Russia had been operating as a deconsolidated subsidiary of Holcim since March 2022, following Russia’s invasion of Ukraine.


Tunisia: Les Ciments de Bizerte recorded a full-year consolidated turnover of US$40.1m in 2022, corresponding to a drop of 5.4% year-on-year from 2021 levels. The producer's clinker production fell by 24% year-on-year to 538,000t. African Manager News has reported that the company faced a forced stoppage during the year due to a disruption to its raw materials supply. Meanwhile, its costs increased amid rises in the price of petcoke, electricity, diesel and packaging materials.


Europe: The European cement association, Cembureau, has 'welcomed the objectives' of the European Commission's new Green Deal industrial plan. The Green Deal attempts to create a predictable and simplified regulatory environment in which to scale up the production and implementation of net-zero CO2 technologies.

Cembureau also issued its advise for a successful Green Deal implementation. The association said that the framework must match the US Inflation Reduction Act in its provision of tax rebates and other incentives. It said that the plan must establish stable renewable energy prices and rapid permit procedures, with a focus on deployment of renewables at industrial sites. It also called for funding under the plan to finance the development of infrastructure for CO2 transport and storage.


China: China Resources Cement (CRC) has inaugurated its Cement International Innovation Centre. The producer says that the centre will contribute to the sustainable growth of its operations across three platforms, namely: cutting-edge research and development, international technologies exchange and international talent introductions.

CRC chair Ji Youhong said that the start of operations at the Cement International Innovation Centre constituted a 'major achievement' under the government's 14th Five Year Plan.


Australia: Hallett Group said that a 42m-high storage dome at its upcoming Port Adelaide cement terminal deflated amid on-going construction work at the site on 2 February 2023. ABC News has reported that Hallett Group plans to rebuild the structure at the facility in South Australia. It said that the supplier of the dome's outer skin has sent representatives from Canada to supervise in the reconstruction.

When commissioned, the Port Adelaide cement terminal will distribute cement from Hallett Group's Port Augusta slag cement grinding plant in the north of the state.


Japan: Mitsubishi Heavy Industries (MHI) has won an Award for Excellence at the 41st Nikkei Excellent Products and Services Awards for its carbon capture system. It was among eight industrial products to win the award for the year. The panel of judges selected MHI's system for its compact and versatile module configuration, which shortens installation and transport times.

MHI's model has been in industrial operation since June 2022, when MHI inaugurated its first system at Taihei Dengyo Kaisha's Seifu Shinto biomass power plant. The technology is now in operation or under implementation at cement plants in Japan and overseas. Most recently, MHI secured a carbon capture contract with a UK cement plant, Hanson's Padeswood plant, in mid-December 2022.