Global Cement Newsletter

Issue: GCW631 / 25 October 2023

Headlines


Cementos Molins has been celebrating the first anniversary this week of its alternative raw materials unit at its Sant Vicenç dels Horts plant near Barcelona. It has processed 75,000t of waste since September 2022 when the site started up. More is yet to come as the unit has a production capacity of up to 200,000t/yr. The facility receives waste in coarse, granular, powder and sludge formats. Waste from concrete plants is crushed and screened to produce recycled aggregate. Industrial and construction waste is dosed and homogenised to produce alternative raw materials for cement production.

Global Cement Weekly has covered construction and demolition waste (CDW) a couple of times already so far in 2023. A number of cement producers are investing in the sector - including Holcim, Heidelberg Materials, CRH, Cemex – by developing technology, buying up other companies, setting up internal CDW divisions and so on. Holcim and Heidelberg Materials have been the more obviously active participants over the past six months based on media coverage. In September 2023 Holcim France commissioned the Saint-Laurent-de-Mûre alternative raw materials plant and Holcim Group invested in Neustark, a company promoting technology to sequester CO2 in CDW. In August 2023 Lafarge Canada also completed the first stage of a pilot project to use CDW in cement production at its St. Constant plant in Quebec. Heidelberg Materials meanwhile announced in October 2023 that a forthcoming upgrade to its Górażdże cement plant in Poland would include a new CDW recycling unit and in September 2023 it launched a CDW division for its subsidiary Hanson UK.

Previously we have described how the European Union (EU) has set recovery targets for CDW. However, McKinsey & Company published research in March 2023 setting out the economic case for cement and concrete companies looking at CDW. It estimated that “an increased adoption of circular technologies could be linked to the emergence of new financial net-value pools worth up to roughly Euro110bn by 2050.” It is not a certainty and there is risk involved, but adopting circular practices is one way to reduce this risk. It then went on to predict that recirculating materials and minerals could generate nearly Euro80bn/yr in earnings before interest, taxation, depreciation and amortisation (EBITDA) for the cement and concrete sectors by 2050. The biggest portion of this could come from using CDW in various ways such as a clinker replacement or as an aggregate in concrete production, or the use of unhydrated cement ‘fines.’ Capturing and using CO2 and increasing alternative fuels (AF) substitution rates would have a financial impact but not to the same scale.
Graph 1: CO2 abatement cost via circular technologies for cement and concrete sectors. Source: McKinsey & Company.

Graph 1: CO2 abatement cost via circular technologies for cement and concrete sectors. Source: McKinsey & Company.

Graph 1 above puts all of the McKinsey circular technology suggestions in one place with the prediction that all of these methods could reduce CO2 emissions from cement and concrete production by 80% in 2050 based on an estimated demand of 4Bnt/yr. The first main point they made was that technologies using CO2, such as curing ready-mix or precast concrete, can create positive economic value at carbon prices of approximately Euro80/t of CO2. Readers should note that the EU emissions Trading Scheme CO2 price has generally been above Euro80t/yr since the start of 2022. The second point to note is that using CDW could potentially save money by offering CO2 abatement at a negative cost through avoiding landfill gate fees and reducing the amount of raw materials required. This is dependent though on government regulation on CO2 prices, landfill costs and so on.

Cement producers have been clearly aware of the potential of CDW for a while now, based on the actions described above and elsewhere, and they are jockeying for advantage. These companies are familiar with the economic rationale for AF and secondary cementitious materials (SCM) in different countries and locations. CDW usage is similar but with, in McKinsey’s view, existing CO2 prices, landfill costs, and regulatory frameworks all playing a part in the calculations. Graph 1 is a prediction but it is also another way of showing the path of least resistance to decarbonisation. It is cheaper to start with AF, SCMs and CDW rather than barrelling straight into carbon capture. The beauty here is that cement and concrete sold, say, 50 years ago is now heading back to the producers in the form of CDW and it still has value.


Denmark: FLSmidth has appointed Christopher Ashworth as the president of its Cement division. He succeeds Asger Lauritsen, who left the post in August 2023. Group chief financial officer Roland M Andersen has acted as the interim president of FLSmidth Cement in the intervening period. Ashworth was previously the vice president and managing director of Eurotherm, a subsidiary of Schneider Electric. Prior to this he worked for Invensys and Wonderware.


India: Sagar Cement has appointed J Raja Reddy as its company secretary and compliance officer with effect from 11 November 2023. He succeeds R Soundararajan in the post, following his retirement for health reasons. Reddy has worked for Sagar Cement since 2013 and is currently working as the company’s assistant company secretary.


China: China Shanshui Cement recorded sales of US$1.92bn during the first nine months of 2023, down by 15% year-on-year from US$2.25bn during the first nine months of 2022. Reuters has reported that the company made a US$25.7m loss during the period, compared to a profit of US$139m in the corresponding period of 2022.


Mexico: GCC recorded US$1.02bn in sales during the first nine months of 2023, up by 16% year-on-year from US$880m in the first nine months of 2022. The producer’s cement volumes rose by 5.5% in Mexico, but fell by 8.1% in the US. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 31% to US$354m from US$271m.

GCC chief executive officer Enrique Escalante said “The ability of our teams to face market conditions allowed us to further strengthen our margins Throughout the third quarter of 2023, we continued to invest in the business and focus on commercial performance to offset cost inflation and increase margins, as well as strengthening our market position to build a stronger future for GCC.”


Indonesia: Semen Indonesia subsidiary Semen Baturaja reported sales revenue of US$91.3m during the first nine months of 2023, up by 10% year-on-year. Cement sales contributed US$89.5m towards the total (98%). The producer raised its net profit by 25% year-on-year to US$3.4m. It also distributed US$169,000 as part of its Social & Environmental Responsibility Programme Fund, up by 61%.

General director Daconi Khotob said “The increasing net profit was also supported by a decrease in interest expenses as a result of refinancing bank debt and accelerating principal payments on syndicated credit loans.”


Belgium: The municipal council of Evergem has advised planning authorities to reject Cemminerals’ application to expand it Ghent grinding plant to 1.6Mt/yr in production capacity. The Het Nieuwsblad newspaper has reported that the expansion will entail the construction of a new grinding unit and six storage silos. Cemminerals currently holds a licence to produce 700,000t/yr at the site.

Councillor Josse Verdegem said that 400 residents signed a petition against the planned expansion of the Ghent grinding plant. He said that dust from the plant ‘regularly’ covered solar panels, cars and garden furniture. Residents have also complained about its noise and vibrations.


UAE: The director of the World Cement Association (WCA), Ali Emir Adiguzel, told listeners at the association’s 6th Annual Conference in Dubai that the world has ‘enough cement for the next 25 years.’ Adiguzel addressed the issue of overcapacity by noting a ‘substantial’ drop in demand and pointing out that high input costs had led the sector to raise its prices, by as much as 15% in Europe. He also said that the primary challenge facing the cement industry was “meeting stringent emission targets and embracing carbon capture technologies.”

Adiguzel added "Despite our achievements, there is more work to be done in the years to come. To reach our net zero goal by 2050, we must significantly reduce carbon emissions. The technologies and mechanisms for this endeavour appear available, though currently minuscule and not economically fully feasible. Regulatory frameworks must evolve to minimise costs for end customers. Collaboration between the private and public sectors is imperative to facilitate carbon reduction."


Ghana: Wan Heng Ghana has issued a statement clarifying its position after the Ghana Revenue Authority (GRA) found that it had failed to pay US$60.6m in taxes. The company markets cement from its Tema grinding plant as Sol Cement.

The producer said “We acknowledge that we are indebted to the GRA for unpaid taxes. We are fully committed to resolving this matter in a responsible and timely manner. We want to reassure our valued customers, stakeholders and the public that we are taking immediate and proactive steps to address this issue. We are in discussions with relevant tax authorities to develop a structured repayment plan that aligns with our financial capabilities and ensures that our tax obligations are met.”

It continued “Sol Cement remains dedicated to its mission of contributing to the growth and development of Ghana. We understand that paying our taxes is an essential part of fulfilling this commitment. We apologise for any concerns or inconveniences this situation may have caused, and we promise to keep all our stakeholders informed throughout this process. We appreciate the trust and support that our customers and partners have placed in us over the years, and we are determined to rectify this situation while continuing to provide top-quality cement products and services. We thank you for your understanding and patience during this challenging period. Sol Cement remains committed to being a responsible corporate citizen and a reliable contributor to the Ghanaian economy.


Latin America: Denmark-based FLSmidth says it has been awarded a new service contract with an unnamed cement producer in Latin America. The new contract builds on an existing relationship between the two companies and will last a period of 18 months. It will cover the complete production process, from quarry to packing plant. FLSmidth says that will support the customer in improving overall equipment efficiency and thus plant productivity. The scope of supply also includes training and mentoring of plant personnel to ensure successful execution of a jointly developed strategy long after the initial period of the contract ends. No value for the deal has been disclosed.

Jose Gil, Head of Service Execution - USA and Canada, FLSmidth, said “This contract is the result of conversations inspired by a reliability audit in the third quarter of 2022. From that, an action plan was developed in which FLSmidth has responsibility for the execution of activities in operations and the customer takes care of other support areas.” He added “The result is a tailored solution, encompassing a range of factors, including maintenance, reliability and operations, that will ultimately deliver much more efficient and productive cement plants.”


Dominican Republic: Domicem held a ceremony marking the lighting up of the kiln on the new second production line at its Sabana Grande de Palenque cement plant in San Cristóbal province in mid-October 2023. Company engineers, staff from China-based CBMI Construction and representatives from parent company Colacem were present for the event. The cement company signed a contract with China-based Sinoma Construction for a 3500t/day clinker production line in 2021. The project had a reported investment of US$120m. The official inauguration of the new line is scheduled to take place on 22 November 2023 and the President of the Dominican Republic is expected to attend.


Yemen: Ahmed Al-Masawa, the governor of Taiz, has taken an inspection tour of the Al-Barah Cement plant in Maqbana District. The site was damaged in a bombing raid in 2021 led by the Saudi Arabia-backed coalition in the Yemen Civil War, according to the pro-Houthi Yemen News Agency. At the time damage worth US$26m was reported at the unit. During his visit Al-Masawa discussed how the plant could be repaired and restored to a working condition once again. He also praised the efforts of the workers to preserve what remained of the plant despite all the difficulties they had faced.


US: Summit Materials has entered into a memorandum of understanding (MOU) with hydrogen producer PCC Hydrogen (PCCH2). The MOU establishes an alliance to develop a fuel replacement strategy for Summit Materials’ cement production. PCCH2 will build a hydrogen plant to supply green hydrogen at a cement plant belonging to Summit Materials subsidiary Continental Cement.

Continental Cement president David Loomes said "Continental Cement has a longstanding commitment to environmental stewardship, seeking out opportunities to develop innovative practices and differentiated solutions to build a better tomorrow. Our company has signed on to the Portland Cement Association (PCA)'s Roadmap to Carbon Neutrality, with a goal of achieving carbon neutrality across the value chain by 2050. By coupling PCCH2's hydrogen production process with our cement manufacturing know-how, we are taking a bold stride towards achieving that goal, while continuing the push to cost-effective decarbonisation of cement manufacturing."


France: Holcim France has commissioned its new Saint-Laurent-de-Mûre alternative raw materials plant in Rhône Department. The unit produces cementitious paste from construction and demolition waste using Holcim’s ECOCycle upcycling process. It will source construction and demolition waste from the Lyon Metropolitan Area.

Holcim’s global head of circular construction Vincent Teissier said “Advancing such circular technologies is one of the main pillars of our sustainability strategy. This new advanced crushing unit in Saint-Laurent-de-Mûre is a major step toward using construction and demolition materials to their full value.”


Ghana: The Ghana Revenue Authority (GRA) has shut down Wan Heng Ghana’s 0.5Mt/yr grinding plant in Tema after the company failed to pay US$60.6m in taxes. GhanaWeb reports that the GRA gave the China-based company 10 days in which to pay its taxes, otherwise the closure will continue. Wan Heng Ghana operates in the country using the Sol Cement brand.


Spain: Cementos Molins has processed 75,000t of waste into alternative raw materials for use in its cement production since opening its Barcelona alternative raw materials plant in September 2022. The plant has a production capacity of 200,000t/yr. It produces the materials from construction and demolition waste and various industrial by-products.

Cementos Molins’ director of corporate development and sustainability, Carlos Martínez, said “Our commitment to the environment is intrinsically linked to our business model, which is based on the development of sustainable and innovative materials.” He continued “We provide a second life to industrial and construction waste that would otherwise end up in landfills, generating high-quality sustainable products from them. The plant has enabled all our cements to incorporate alternative raw materials in their production process. Furthermore, we are working to reduce the carbon footprint of all our concretes, ensuring that, in the short term, all of them include recycled aggregates in their manufacture."


UK: Cemex UK says that it has collected 130,000t of by-pass dust (BPD) from its Rugby cement plant in Warwickshire since 2015. The producer supplies the BPD to the agriculture sector, where it can replace traditional fertilisers and lime due to its high lime and potassium content. Additionally, Cemex UK has sponsored research into this and other circular economic uses of BPD, including an on-going study which claimed the Carbon Journey Award at the Eco Innovation North West Awards 2023.

Cemex’s Europe regional head of sustainability Paul Fletcher said “We are very proud of our partnership with Silverwoods and the considerable positive impact their innovation and expertise has had on our ability to reuse BPD for other applications. We believe it leads the way in our industry and presents real potential to be adapted elsewhere across our operations. Not only does it benefit the environment by reducing the amount of materials that need to be disposed of, but it generates a product that has a value for farmers and helps cut the use of traditional materials.” He added “This partnership demonstrates that to deliver true circularity, more industrial by-products, including those from different sectors of the economy, need to be used as secondary resources, rather than primarily be seen as waste. If this is to be achieved, a new perspective is needed to boost circular economy practices, with regulations and permitting supporting this proactively.”


US: Heidelberg Materials is rumoured to have hired advisors for a possible attempt to acquire Summit Materials. Bloomberg has reported that the company made two approaches to Summit Materials ‘in recent weeks.’ Meanwhile, the Colorado-based producer revealed in a statement that it has rejected two takeover bids from an unnamed party, the more recent on 18 October 2023.

Summit Materials previously agreed to merge with Cementos Argos subsidiary Argos USA in early September 2023.


Romania: Holcim Romania has successfully upgraded pyroprocessing and cement grinding equipment at its Câmpulung cement plant in Argeș County. Germany-based KHD Humboldt Wedag supplied equipment for the upgrade. For the plant’s pyroprocessing line, this included a downcomer duct, water injection system and induced draught fan, as well as an upgrade to the clinker cooler. Meanwhile, the grinding line has received a new SKS Z 2500 dynamic separator, cyclones, process ducts and separator fan. The supplier says that the upgrade has increased the Câmpulung plant’s clinker capacity and the efficiency of its operations. The work took 14 months to complete from the signing of the contract in mid-2023.


Croatia: Nexe Group has completed a US$3.3m upgrade to its Našice cement plant. SeeNews has reported that the project consisted of efficiency-increasing upgrades to the plant and other buildings at the site, and the construction of a solar power plant. The producer says that this will reduce the 600,000t/yr-capacity cement plant’s total energy consumption by 1.56GWh/yr.

The Našice cement plant is the site of an on-going expansion and carbon capture system installation project.


Mexico: The government says that if US-based Vulcan Materials continues to reject offers for land in Quintana Roo on which its Calica-Sac-Tun quarry is situated, then it will designate the land Protected Natural Area status. Reuters has reported that the government has previously offered US$328 – 383m for the property. Vulcan Materials has mounted on-going legal challenges worth US$1.9bn against the Mexican government over the previous closure of its operations.


Spain: Holcim España invested Euro4m in an upgrade to its 1.5Mt/yr Carboneras cement plant in Almería. Alimarket-Construction News has reported that the upgrade will raise the plant’s alternative fuel (AF) substitution rate to 70% and enable it to dispose of 50,000t/yr of waste through co-processing it as AF. Holcim España expects this to reduce its CO2 emissions by 22,000t/yr.


Germany: Heidelberg Materials preliminary reported a 4% year-on-year decline in its sales during the third quarter of 2023, to Euro 5.6bn. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 17% to Euro1.39bn from Euro1.28bn. The group succeeded in raising its profit in the quarter, by 24% year-on-year to Euro1.08bn.

Heidelberg Materials says that it expects to record a ‘moderate increase’ in its revenues in full-year 2023. The company raised its profit target range for the year to Euro2.85 – 3bn from Euro2.7 – 2.9bn.


India: Udaipur Cement Works commissions second kiln line at its Udaipur cement plant in Rajasthan. Reuters has reported that the new line doubles the plant’s clinker capacity to 3Mt/yr.


India: Sagar Cements reported sales worth US$136m in the first half of the 2024 financial year. This corresponds to a year-on-year rise of 9.1% from US$124m in the first half of the previous financial year. The producer recorded a loss for the period of US$6.31m, down by 3.9% from US$6.57m. This was in spite of a 7.8% rise in its total costs, to US$148m.


Mexico: Cementos Moctezuma has awarded a contract to France-based Fives FCB to supply an FCB Horomill 3800 grinding mill for its Morelos cement plant in Tepetzingo. The supplier says that the mill offers a lower power consumption than any competing product in the market. The latest mill will be the 15th Fives FCB mill at a Cementos Moctezuma cement plant in Mexico. Fives FCB says that its mills had accumulated 1.5m hours of operation across three different sites at the end of 2022.


Thailand: China-based intelligent dumptruck supplier Waytous has partnered with Siam Cement Group (SCG), as well as Thailand Advanced Info Service, Huawei, and Zhengzhou Yutong Mining Equipment, to develop full-scope automated operating systems for limestone mines. SCG will host a study at its Saraburi limestone mine in Central Thailand. The study will use Waytous’ driverless vehicles, supported by 5G, AI, cloud computing and new battery technologies.

Waytous CEO Chen Long "We've carried out two phases of unmanned mining research for this project and found the most comprehensive, efficient, and effective unmanned solution for cement mines in Saraburi.”


Qatar: Qatar National Cement recorded a net profit of US$41.6m during the first nine months of 2023. Reuters has reported that this corresponds to a drop of 11% year-on-year from US$46.9m in the same period of 2022.


Tanzania: The Fair Competition Tribunal (FCT) lamented the ‘mischief prevailing in the market’ in a ruling nullifying the Fair Competition Commission (FCC)’s approval of Scancem International’s planned acquisition of a 68% stake in Tanga Cement, dated 28 February 2023. The Citizen newspaper has reported that the FCT granted the parties leave to apply for a review of its earlier decision of 23 September 2022, in which it initially rejected the attempted deal. In its latest judgment, the tribunal drew on principles from South African law to show that companies should be able to submit a new application within one year of rejection, provided there is a ‘substantial change’ of circumstances or market dynamics. The court added that no blame lay with the parties for having lodged their second attempted merger notification within such a timeframe.


India: Adani Group has reportedly indicated an interest in acquiring the 1.2Mt/yr Shahabad cement plant in Karnataka from Jaiprakash Associates. The plant is the subject of an as yet incomplete deal between Jaiprakash Associates and Dalmia Bharat for the transfer of the former’s cement and power plants for US$671m.

The Business Standard newspaper has reported that Adani Group is in talks with ‘several companies’ over possible bolt-on acquisitions, with a view to doubling its cement capacity to 140Mt/yr by the end of 2028.


Switzerland: Reduced-CO2 cement catalyst developer Nanogence has secured an undisclosed sum from a consortium of investors led by investment fund CirCap. Nanogence’s catalyst reduces the CO2 emissions of cement production by 40%, without changing production processes. Tech EU News has reported that the catalyst is capable of increasing cement’s strength and durability compared with that of ordinary Portland cement (OPC) produced without it. Prior to the latest financial development, the company had raised US$2.7m-worth of funding.

CEO Abhishek Kumar said “We are excited to receive the support from incoming renowned investors in this essential journey to accelerate the transition towards a low carbon built world. With growing demand worldwide, we need to align with like-minded strong backers for our growth phase.”


Pakistan: The deputy general manager and a plant engineer of a cement plant in Iskandarabad died after being shot by a colleague on 18 October 2023. The shooter was a chemical engineer at the plant, who shot the men after ‘flaring up’ in a meeting. Emergency services took a third victim, an engineer, to hospital for treatment. The Dawn newspaper has reported that police are investigating the tragedy, including the matter of how the shooter managed to enter the plant armed.