Global Cement Newsletter

Issue: GCW658 / 08 May 2024

Headlines


Kenya-based East African Portland Cement (EAPCC) made the news this week with the reopening of the company’s Athi River cement plant after a month-long shutdown. The closure was conspicuous because the company is gradually working towards increasing the integrated plant’s production capacity. The first phase of the maintenance and upgrade project saw the replacement of the production line’s kiln shell in September 2022. The current aim is to increase the unit’s cement production capacity to 1Mt/yr by mid-2026. The recent shutdown appears to have been a more normal annual renewal and repair job but EAPCC has used it as a promotional opportunity. Notably, a spokesperson for EAPCC described clinker as the “new gold” in a recent video explaining what was going on.

It’s an improvement on the financial trouble EAPC found itself stuck within in the late 2010s before the government ended up taking a controlling share in the cement producer. On this front local media reported in July 2023 that the government had found a 'strategic investor' to buy a 30% stake in the company. Nothing more has been said on this topic since then though.

The highlighting of the recent shutdown is likely to be a public relations exercise intended to project stability, but that focus on clinker is telling given that the government introduced its Export and Investment Promotion Levy in July 2023. This legislation imposed a 17.5% fee on imported clinker in order to encourage the local industry. Cement producers that rely on imported clinker - including Rai Cement, Bamburi Cement, Savannah Cement, Ndovu Cement and Riftcot - attempted to lobby against the levy but it remains in place. This business environment helps to explain EAPCC’s renewed focus on clinker production.

One company that stands to benefit from the levy is National Cement, producer of the Simba Cement brand and a subsidiary of Devki Group. It made the news at the start of April 2024 when its subsidiary Cemtech commissioned a 6000t/day clinker plant at Sebit in West Pokot. National Cement already operates an integrated plant near Athi River, south of Nairobi. However, hot on the heels of the West Pokot plant, it is already considering building another integrated plant in the north of Kitui County, to the east of Nairobi. As reported in the local press this week, Cemtech has submitted an environmental impact assessment for the project to the local authorities.

The country has two other clinker producers: Holcim subsidiary Bamburi Cement and Mombasa Cement. The former company announced at the end of 2023 that it had signed a contract to build solar plants at its integrated plant in Mombasa and its grinding plant in Nairobi. The deal was framed as a money saver but additionally it may have been in response to a less than reliable local grid. It also said that it was removing Ordinary Portland Cement (OPC) from its product line from the start of 2024. This move challenged expectations about sustainability initiatives outside of richer countries. Yet, considering how Bamburi Cement argued against the clinker levy, there might have been some commercial thinking here too in order to sell products that use less clinker. Finally, despite completing its divestment of Uganda-based subsidiary Hima Cement for US$84m in March 2024, Bamburi Cement reported a loss of US$2.99m in 2023 compared to a profit of US$1.36m in 2022. Although it reported a rise in turnover and operating profit, it appears that taxes and legal costs related to the sale of Hima dragged the company into a loss.

Graph 1: Rolling annual cement production in Kenya, 2019 - September 2023. Source: Kenya National Bureau of Statistics (KNBS). 

Graph 1: Rolling annual cement production in Kenya, 2019 - September 2023. Source: Kenya National Bureau of Statistics (KNBS).

It’s been a difficult business environment in Kenya over the last decade given the number of companies that have faced serious financial difficulties. This list includes ARM Cement, EAPCC and Savannah Cement. The last of these companies, Savannah Cement, is currently in administration and is trying to sell its integrated plant. Yet, rolling annual cement production in Kenya has remained above 9.5Mt/yr since early 2022. The government is sticking to promoting local clinker production, and companies like Bamburi Cement, EAPCC and National Cement are making investments of varying scales. The focus, for now at least, is on clinker production in Kenya.


Oman: The Financial Services Authority has reconstituted the board of directors of Raysut Cement. It has appointed Shabib Mohammed Al Darmaki as its chair with Naser Jumaa Al Zadjali, Badr Awad Al Shanfari, Ali Rashid Ali Al Shuhi and Abdulhameed Ahmed Al Balushi as members. The new board is intended to follow the role of the previous board by completing the “reorganisation and restructuring of the company and fine-tune its governance to ensure stability of its financial and operational positions to correct its path to ensure sustainable performance and protect the interest of all the shareholders and enhance the stability of the market.”

In December 2022 the Capital Market Authority (CMA) replaced the board of directors of Raysut Cement and appointed a temporary one following a financial audit. This followed the CMA publicly questioning the validity of the company’s third quarter results in 2022 when it detected ‘material misrepresentation.’


Morocco: The Moroccan Cement Association (APC) has elected Said El Hadi as its president. He succeeds Khalid Cheddadi in the role, according to Les Echo newspaper. El Hadi is the president of LafargeHolcim Maroc. The APC represents cement producers in the country including Asment Temara, Atlas Cements, Ciments du Maroc, LafargeHolcim Maroc and Novacim. The members of the association operate 14 plants with a production capacity of over 24Mt/yr.


Nigeria: Mathew Philip retires as the Deputy Group Managing Director of Dangote Cement. He has also left the company’s board of directors. He spent two years in the post. No successor has been announced.

Philip holds over 35 years of experience in the cement industry. Prior to working for Dangote Cement, he was Head of Cement Manufacturing Excellence for LafargeHolcim APAC region. He also worked as the Chief Manufacturing Officer for India-based ACC in the late 2010s. Before this he worked for Lafarge in a variety of roles and countries including Director - Performance and Progress in Kuala Lumpur and Relations Director in China. He originally started his career working as a process engineer for ACC. He is a chemical engineer from the Indian Institute of Technology (IIT) in Madras.


Nigeria: BUA Cement has appointed Chikezie Ajaero as its Acting Chief Financial Director (CFO). He succeeds Jacques Piekarski in the full post of CFO.

Ajaero has worked as the Finance Director of BUA Cement’s Obu plant since 2020. He is an accountant with a master’s of business administration from the University of Lagos. He is a fellow of the Institute of Chartered Accountants of Nigeria and holds over 25 years of experience in financial reporting and control.


Ireland: Ecocem has appointed Sally Anne Sherry as the Managing Director for its UK and Ireland business operations. She succeeds Susan McGarry in the post, who has become the group’s Director of Public Affairs and Sustainability.

Sherry holds around two decades of experience in the property sector and has worked as a non-executive director for several companies. Notably she worked as a Director and General Counsel for property development and investment company Bartra from 2015 to 2023. She holds legal qualifications from the University of Galway.


Germany: Buzzi subsidiary Deuna Zement plans to invest €350m to install a carbon capture system at its cement plant in Deuna, having completed two feasibility studies. The Thüringer Allgemeine newspaper has reported that, when operational in 2029, the system will capture 620,000t/yr of CO2. This will make the Deuna cement plant carbon neutral. The company has applied for government funding for the project.

Buzzi Unicem said that its subsidiary is ‘Doing pioneering work on the path to decarbonising the cement industry.’ It added “The system will be efficient and take all relevant environmental considerations into account.”


India: Jaiprakash Associates has defaulted on loans worth US$553m, including principal of US$210m and interest payments of US$343m. The Deccan Chronicle newspaper has reported that the producer has total borrowings of US$3.57bn, repayable by 2037. The borrowings are comprised of fund-based working capital, non-fund-based working capital, term loans and foreign currency convertible bonds.

Jaiprakash Associates will now transfer US$2.27bn to a special purpose vehicle as part of a scheme of arrangement, subject to the approval of the National Company Law Tribunal.


Ukraine: CRH has invested €465m in Ukraine since entering the country in 1999, €74.5m of it since the start of Russia’s invasion in February 2022. CRH Central and Eastern Europe president Guillaume Cavalier noted the double role of locally-produced cement in generating employment and state revenues.

Cavalier said "Investing in the expansion of production now is crucial to ensure the potential growth of the Ukrainian cement market following its integration into the EU."


Nigeria: Finland-based Wärtsilä has signed a 10-year operations and maintenance (O&M) agreement for a captive power plant that provides the energy for Mangal Industries’ cement plant located in Kogi State. The cement plant has limited access to the local electricity grid and its power plant operates with five Wärtsilä 34DF dual-fuel engines delivering an output of 50MW. The O&M agreement is designed to ensure that the facility can reliably maintain its cement production target of 3Mt/yr.

The 10-year agreement starts immediately as the unit commences operations in the second quarter of 2024. It will run on liquid fuel initially but then switch to gas operation when a natural gas pipeline is commissioned. The power plant’s dual-fuel engines can be operated both on liquid fuel and natural gas. They could also be potentially converted to operate with low- or zero-carbon fuels in the future subject to availability.

Patrick Borstner, Director, Operations Africa at Wärtsilä Energy said, “Wärtsilä now has more than 400MW of installed capacity for the cement industry in Nigeria, and we are operating three captive power plants in three different states. This successful track record clearly indicates our capabilities and highlights the added value we can deliver to our customers through our experience and expertise in supporting their operations.”

Mangal Industries signed a contract with China-based Sinoma International Engineering in 2021 for the construction of a 3Mt/yr new integrated cement plant. Construction at the site commenced in mid-2022.


Zambia: Chilanga Cement has started lime production at its Ndola plant. The new lime unit at the plant has a production capacity of 108,000t/yr, according to the Times of Zambia newspaper. The project had an investment of US$5m. The subsidiary of Switzerland-based Holcim has launched a new lime produced called ‘PAWA Lime’ targeted at the mining and industrial sectors.


Spain: The Spanish cement manufacturers' association, Oficemen, and Siemens Energy have signed a two-year collaboration agreement to develop decarbonisation techniques and solutions for Spain's cement industry. The agreement was signed by Siemens Energy's Industrial Sales Director for Southwest Europe, Angel Cillerruelo, and Oficemen's General Director, Aniceto Zaragoza.

Zaragoza said "The Spanish cement industry's commitment to climate neutrality by 2050, outlined in our roadmap, includes exploring the most effective levers for emission reduction, such as the decarbonisation of energy sources or the comprehensive energy management of industrial processes."


Germany: Heidelberg Materials has reported its 2024 quarterly financial report for January – March 2024. Revenue for this period was €4.48bn, representing a year-on-year decrease of 8.1% from €4.89bn. Result from current operations before depreciation and amortisation was €542m, a year-on-year decrease of 2.6% from €557m. Poor weather conditions in key regions and a reduced number of working days in the first quarter of 2024 contributed to declining sales volumes, according to the company.

Dr Dominik von Achten, Chair of the Managing Board of Heidelberg Materials, said "Despite declining revenues compared to a strong prior-year quarter, we have further increased our profitability. This was in particular due to the very good start to the year in North America and strict cost management. The good start allows us to look forward confidently to the rest of the year.”


India: Birla Corporation recorded a significant increase in its consolidated net profit, rising by 127% to US$23m for the quarter ending March 2024. The company reported a consolidated revenue of US$321m, up 6.8% year-on-year. This was reportedly due to reduced power and fuel costs.

Chair Harsh Vardhan Lodha said "As cement consumption in India continues to grow, Birla Corporation is rolling out its next phase of capacity expansion to increase cement production to 25Mt/yr by 2026-27."


Global: The Global Cement and Concrete Association (GCCA) has announced new collaborations between global cement manufacturers and technology start-ups, focusing on the development of low carbon concrete. Four start-ups—EnviCore in Canada, Queens Carbon and Chement, both in the US and NeoCrete in New Zealand—were part of the 2023 GCCA Innovandi Open Challenge and have now partnered with cement manufacturers. These partnerships aim to reduce the carbon footprint of concrete.

The startups will receive access to industry plants, labs and networks to fast-track their technologies. They will also demonstrate their progress on 6th June 2024 in Bangkok, Thailand, during the GCCA's CEO and Leaders Conference. The association continues its efforts under the 2050 Net Zero Concrete Roadmap, with 29 new start-ups shortlisted this year to work on carbon capture, utilisation and storage (CCUS) technology.


Vietnam: Amid weak domestic demand and rising costs of electricity and coal, the Vietnam Cement Association (VNCA) is focusing on boosting domestic consumption. The current domestic supply of cement is estimated at 60 – 62Mt, far exceeding demand. The excess 30Mt is planned to be exported, with cement and clinker exports already rising in April 2024 by 12% year-on-year to 2.85Mt. In the first quarter of 2024, exports grew by 4.6% to 10.9Mt compared to the same period in 2023.

The VNCA notes ‘challenging’ conditions in major markets, including China's oversupply and protectionist measures in the Philippines, Central America and South Africa. To counter these hurdles, the VNCA proposes several government-led initiatives to increase domestic consumption and help manufacturers, including tax relief on clinker exports and financial incentives such as reduced interest rates for local producers.


Pakistan: The cement industry saw a slight decrease in cement dispatches in April 2024, falling to 2.94Mt from 2.95Mt in April 2023, according to data from the All Pakistan Cement Manufacturers Association. Despite an 8% fall in local sales to 2.33Mt, an increase in exports by 46% to 614,264t in April 2024 partially offset this decline. Specifically, north-based plants saw a 4.8% reduction in dispatches to 2.1Mt in April 2024, while south-based plants experienced a 12.7% year-on-year increase to 854,911t. Export volumes also reflected regional differences, with north-based exports increasing by 73% and south-based by 39%.

In the 2024 financial year so far, total cement dispatches have risen by 2.5% to 37.5Mt, driven by a 65.4% increase in export dispatches to 5.72Mt compared to April 2023. However, domestic sales have declined by 4.1% to 31.7Mt. The north-based plants dispatched 26.2Mt domestically, a 3.6% year-on-year decrease, while south-based plants dispatched 5.55Mt, down by 6.5% from April 2023.

A spokesman for the All Pakistan Cement Manufacturers Association said "The government needs to announce industry-friendly measures in the upcoming budget that can boost construction activities in the country. We need to increase our capacity utilisation to bring in economies of scale and to control our operations costs in order to reduce the overall impact on the end consumer.”


Brazil: InterCement, part of the Camargo Correa Group, has now signed an exclusivity contract with Companhia Siderúrgica Nacional (CSN). CSN is interested in acquiring its operations in Brazil and Argentina. The contract is effective until 12 July 2024 and is part of efforts to address the company’s debt, which the market estimates at over US$1.5bn. The contract also involves the potential purchase of shares representing 100% of its capital. The value of the transaction is part of current negotiations, but it is reportedly valued at around US$700m, according to CE Noticias Financieras News.

InterCement operates plants in Argentina, Brazil, Paraguay and Egypt, as part of Camargo Correa's cement business divestment plan. Previously, in June 2023, InterCement divested its subsidiaries in Mozambique and South Africa.


Kenya: East African Portland Cement (EAPCC) has recommenced operations at its Athi River cement plant after a one-month shutdown for renovations and maintenance. The plant has undergone a US$3m upgrade to expand its capacity in order to meet the increasing regional demand for cement, anticipating an annual production of 1Mt/yr within the next two years. Before the upgrade, the plant’s capacity was 310,000t/yr.

Board chairperson Richard Mbithi said critical components used in cement production processes such as filter bags and refractory bricks were replaced during the upgrade. EAPCC also refurbished its grate cooler system, enabling the company to increase its production targets.

Mbithi said “With the finalisation of the plant refurbishment and the resultant improved production and efficiency, we are confident that the company will accomplish the production and revenue targets.”

The company undertook the first phase of maintenance two years ago and it involved the replacement of the kiln shell which was completed in September 2022. This led to improved clinker and cement production and resulted in a 38% increase in revenues, according to the Star Kenya.


South Sudan: B Smart, an investment company owned by son of a former Malaysian Prime Minister, plans to invest US$100m in constructing a cement plant near the capital city of Juba. The plant is targeted to be operational within 24 months pending necessary approvals, and will use limestone from Kapoeta, 275km east of Juba.

Deputy Secretary for Commerce and Industry, Kuol Daniel Ayulo, said "The plant will reduce the country's reliance on costly cement imports and accelerate infrastructure development."


UK: Seratech has developed a process using olivine, a mineral abundant in Earth's mantle, to produce ‘carbon-negative’ cement. The company's method involves replacing some of the clinker with silica extracted from olivine. Magnesium sulphate derived from the olivine reacts with CO₂ to form nesquehonite, a mineral that sequesters CO₂. This method uses CO₂ captured from emissions sources or directly from the air.

Sam Draper, CEO, explained the process: “The researchers extracted these compounds by dissolving powdered olivine in sulphuric acid. After separating the silica and magnesium sulphate, they bubbled CO₂ through the magnesium slurry to form nesquehonite.”

According to Draper, replacing 35% of regular cement with this silica would yield carbon-neutral results, while a 40% substitution could achieve carbon negativity. Current building standards allow up to 55% of cement to be replaced by this material, although robust testing has yet to be conducted.


Vietnam: Cement production in Vietnam has fallen by 0.7% year-on-year in the first four months of 2024, reaching 57.6Mt, according to the latest data from the government’s General Statistics Office. In April 2024, the country’s cement output was 16.8Mt, a year-on-year decline of 0.7%.

In 2023, the country produced 120.1Mt of cement, representing a year-on-year decrease of 4.5% from the previous year.


Malaysia: Heidelberg Materials has announced its acquisition of ACE Group, a supplier of pulverised fly ash, effective 1 May 2024. Reusing fly ash from energy generation contributes to reducing the CO₂ intensity of composite cement. When used as an additive, fly ash can replace part of the energy-intensive clinker and thus reduce the CO₂ intensity of the cement.

The acquisition includes ACE Greencemt Venture, ASAS Asia and AGP Logistics, with the leadership team from ACE Group continuing to manage the operations post-acquisition. Both parties have agreed not to disclose the financial terms of the transaction.


India: Nuvoco Vistas has announced its audited financial results for the year ended 31 March 2024. The producer recorded earnings before interest, depreciation and amortisation of US$199m, representing a year-on-year increase of 35%, and profit after tax of US$17.6m. Its net debt fell by US$46m year-on-year to US$482m. Cement sales volumes totalled 18.8Mt and revenue from operations reached US$1.3bn.


Philippines: Phinma Corp is set to expand its cement business with new facilities in Mindanao, according to a spokesperson for the company. The producer will establish a cement plant in Davao, valued at US$34.7m, which will bring the company’s total capacity to 5Mt/yr once completed. The plant is currently awaiting its environmental clearance certificate.

Additionally, the Petra plant in Zamboanga del Norte has started operations, with a cement grinding capacity of 500,000t/yr.


India: Ambuja Cements has reported a rise in revenue from operations from US$954m to US$1.07bn in the financial year ending 31 March 2024, representing a 12% year-on-year increase. Profit before tax grew by 22% to US$166m. The company recorded a loss of US$13.7m. Sales volume of cement and clinker increased by 18% year-on-year to 16.6Mt. Earnings before interest, depreciation and amortisation increased by 37% to US$203m.


Türkiye/Georgia: Türkiye's exports of cement products to Georgia have increased by 7% year-on-year to US$17m from January to March 2024, according to its Trade Ministry. In March 2024, exports to Georgia reached US$7.6m, representing a 4% year-on-year increase.

However, Türkiye's global cement exports from January to March 2024 fell by 7% to US$1.1bn compared to the same period in 2023. In March 2024, exports were down by 11% year-on-year to US$390m. From March 2023 to March 2024, Türkiye exported cement products worth US$4.5bn.