Global Cement Newsletter

Issue: GCW660 / 22 May 2024

Headlines


Delegates at the Global CemCCUS Conference last week applauded when Anders Petersen, the Senior Project Manager Brevik CCS, Heidelberg Materials said that the Brevik cement plant will be capturing CO2 and permanently storing it within the year. Rightly so. This moment will mark a historic milestone for the sector when it arrives. Net zero cement production is coming.

Last week’s event in Oslo delivered an overview of the current state of carbon capture in the cement and lime industries. It explored the practical challenges these industries face in capturing CO2 emissions and - crucially – then working out what to do with them afterwards. Incredibly, delegates were able to view the construction site of Heidelberg Materials’ forthcoming full-scale carbon capture unit at its Brevik plant in Norway. On the same day as the tour, Holcim broke ground on the Go4Zero carbon capture project at its Obourg plant in Belgium.

The key takeaway at the conference was that a (dusty) bulk solids sector is starting to work with handling (clean) gases in a way it hasn’t before. This recurred repeatedly throughout the conference. Petersen summarised it well when he described Brevik as a meeting pointing between the cement industry and the petrochemical one. It looks likely at present that there will not be a single predominant carbon capture technology that the majority of cement plants will deploy in the future. Similarly, CO2 storage infrastructure and sequestration sites differ. Utilisation plans are less developed but also offer various options. Yet, if carbon capture becomes common at cement and lime plants, then these companies will need to learn how to filter and handle gases regardless of the capture method and destination for the CO2. So presentations on filtration and compressors were a revelation at CemCCUS.

The key obstacle remains how to pay for it all. By necessity, most of the big early projects have received external funding, mostly from governments. Although, to be fair, the private companies involved are often investing considerable amounts of their own money and taking risks in the process too. In the European Union (EU) CO2 is being priced via the Emissions Trading Scheme and investments are being made via the EU Innovation Fund and other schemes. In the US the approach lies in tax breaks, on-shoring and investment in new sustainable technologies.

However, other countries have different priorities. Or as a South Asian contact told Global Cement Weekly at a different conference, “How can our government think about sustainability when it can’t feed everyone?” The world’s biggest cement producing countries are China and India, and then the EU and the US follow. Brazil, Türkiye and Vietnam are at similar levels or not far behind. The EU and the US represent about 9% of global cement production based on Cembureau figures for 2022. China and India cover 61% of production. Neither of these countries has announced a plan to encourage the widespread construction of carbon capture units. Once China ‘gets’ cement carbon capture though, it seems plausible that it will dominate it as it has in many other sectors such as solar panel production. Exporters such as Türkiye and Vietnam will have to adapt to the rules of their target markets.

The march by the cement and lime sectors towards carbon capture has been long, difficult and expensive. It also has a long, long way to go. Yet, the next decade promises to be exciting as new technologies are developed and tested, full-scale projects are commissioned and CO2 pipelines, sequestration sites and usage hubs come online. The next key milestones to look out for include the first full-scale installations using other capture methods (such as oxy-fuel kilns), the first CO2 pipeline network that hooks up to a cement plant, the first land-based sequestration site, the first industrial hub that uses CO2 at scale to manufacture a product, new government policies in China and India, and the first large unit that is funded entirely from private finance. To end on a positive note, a Cembureau representative at the Global CemCCUS Conference reckoned that Europe will be able to capture 12Mt/yr of CO2 by 2030. If it happens, this will be a major achievement and a serious statement of intent towards net zero for the sector.

This short recap of the event barely touches the surface of what happened so be sure to read the full review of the 1st Global CemCCUS Conference.

The 2nd Global CemCCUS Conference will take place in Hamburg in May 2025


Thailand: Siam City Cement has appointed Ranjan Sachdeva as its Group CEO from the start of May 2024. He succeeded the previous CEO, Aidan Lynam, on an acting basis in January 2024. He will also continue to work as the Group Chief Financial Officer until a replacement is found.

Sachdeva has worked for Siam City Cement since 2017, first as the Group Head Internal Audit and Compliance and then as the Group Chief Financial Officer, from April 2023. Prior to this he worked in procurement and audit roles for Holcim in India. He has also spent time at Vedanta and Nestle during his career. He holds a bachelor of engineering from the Thapar Institute of Engineering & Technology and a master of business administration (MBA) degree from the University of Leicester, among other qualifications.


Europe: Cembureau has released an update to its net zero roadmap. The roadmap now aims for a 37% reduction in CO₂ emissions related to cement production by 2030, 78% by 2040 and net zero cement production by 2050, with potential to become carbon negative.

The roadmap also states the key policy measures needed to meet these updated goals, including: The implementation of a watertight carbon border adjustment mechanism (CBAM), the increase in funding for decarbonisation initiatives, the need for guaranteed access to affordable decarbonised energy, infrastructure and raw materials, as well as the creation of lead markets for low carbon, circular products.

President of Cembureau, Ken McKnight said "In the past four years, the European cement sector has clearly moved from ambition to deployment. We have the potential to scale up our climate ambition, but we need policymakers to match this ambition through decisive policies."


Australia: Veolia ANZ and ResourceCo have secured a contract to supply over 1Mt of refuse derived fuel (RDF) from their Adelaide facility to Adbri Cement's Birkenhead plant, aiming to replace natural gas and reduce greenhouse gas emissions. According to Veolia, around 1.5Mt of waste will be diverted from landfill during the course of the contract.

Brett Brown, chief operating officer at Adbri, said "Adbri has pioneered the use of RDF in Australia. Cement manufacturing is energy intensive, and the use of alternative fuels is one of the levers we are using to reduce our emissions as part of our goal of net zero by 2050."


Indonesia: The Jakarta administration has commenced the construction of the Rorotan refuse derived fuel (RDF) plant on a 7.8-hectare site in North Jakarta, aiming to process 2,500t/day of waste. The US$75m project is funded from the 2024 regional budget and is expected to be completed by December 2024 and start operations in early 2025. The city of Jakarta produces nearly 8,000t/day of waste, the majority of which goes to the Bantar Gebang landfill in West Java. The facility will convert 35-40% of the waste processed into about 875t/day of alternative fuels.

The Rorotan facility is the second RDF plant initiated by the Jakarta administration, following the Bantar Gebang facility, which began operations in 2023. This new facility marks a shift from the planned waste-to-energy incinerator in Sunter, which was cancelled due to high costs and bureaucratic delays.

Acting Jakarta governor Heru Budi Hartono said "This technology is still a very small part of our larger efforts to address the city's waste problem."

Head of the Jakarta Environment Agency Asep Kuswanto said "The RDF can become another source of revenue for the city, as we can sell the alternative fuel from the facility to industry."


India: The National Council for Cement and Building Materials has inaugurated the NCB Incubation Centre (NCB-IC) in New Delhi, designed to support small businesses and startups in the cement industry through mentorship, training and access to advanced laboratories.

This initiative is expected to create new opportunities for employment and technology development in the region, while also contributing to the overall growth and development of the country.

This development is part of the government's broader strategy to enhance the cement sector's contribution to national growth by promoting market-ready products and services.


Zambia: Grizzly Mining has announced an investment of US$200m to establish a cement plant in Solwezi, Northwestern Province. The announcement was made by the company’s vice chairperson Abdoul Ba during an interview, according to the Times of Zambia.


Brazil: Italy-based Buzzi will acquire complete ownership of cement producer Cimento Nacional in a deal valued between €290m and €310m. The transaction involves the exercise of a put option on a 50% stake by Grupo Ricardo Brennand, making Buzzi the sole owner, according to local sources.

Cimento Nacional operates five cement plants and two grinding sites, with a production capacity exceeding 7.2Mt/yr. Buzzi will finance the acquisition using existing liquidity and expects to finalise the transfer at the end of 2024.


Philippines: PHINMA Corporation, through its subsidiary Philcement Corporation, is set to acquire 100% of Petra Cement for US$8.6m. The Share Purchase Agreement was signed on 21 May 2024, with the transaction expected to close by 31 December 2024, according to the Manila Bulletin. This acquisition from Petra is part of PHINMA's expansion in the Mindanao region. The Petra Plant, with a capacity of 500,000t/yr, is located in Zamboanga del Norte.

Additionally, PHINMA plans to construct a 1.5Mt/yr cement packaging plant in Davao, raising its total capacity to approximately 5Mt/yr upon completion of all projects.


UK: Heidelberg Materials UK has acquired Bristol-based B&A Group. B&A Group employs a team of 70 and specialises in recycled and primary aggregate supply, site clearance, earthworks, land remediation and sustainable land regeneration. In its most successful year in 2023, the company achieved over US$63.5m in turnover and a pre-tax profit of US$11.5m.

CEO of Heidelberg Materials UK, Simon Willis, said “This announcement follows the completion of our acquisition of Mick George and adds an additional source of high-quality recycled materials for use in our sustainable building materials. It is an exciting opportunity for us, and I am looking forward to working with the B&A Group to grow the business further.”


Uzbekistan: By the end of 2024, Uzbekistan will commission new cement production capacity of 8Mt/yr, according to the Uzsanoatkurilishmateriallari Association. This expansion will raise the country’s total capacity to 40.8Mt/yr.

Currently, there are 38 cement companies in Uzbekistan, contributing to an existing capacity of 35.3Mt/yr. From January to April 2024, the country produced 4.8Mt of cement, marking a 19% increase from the previous year, Uzbekistan Daily reports. The projected cement production for 2024 is 16.7Mt, closely aligning with last year's demand of 16.8Mt.


Türkiye: Türkiye's exports of cement products to China grew 3% year-on-year to US$1.6m from January to April 2024, Trend News Agency reports. In April 2024, exports surged to US$537,000, up by 30% from April 2023, according to the Trade Ministry.

Conversely, Türkiye's global cement product exports fell 8% to US$1.4bn in the same period, with April 2024 witnessing a 9% decline to US$339.2m. Over the past 12 months, from April 2023 to April 2024, Türkiye's total cement exports reached US$4.5bn.


India: Dalmia Bharat has launched a new mill at its Ariyalur manufacturing unit in Tamil Nadu. The new 1Mt/yr cement unit increases the company's total manufacturing capacity to 45.6Mt/yr. This brownfield expansion is valued at US$24.5m and aligns with the company’s aim to increase its capacity to 110-130Mt/yr by 2031.

Managing director & CEO Puneet Dalmia said "Driven by robust infrastructure development, housing and investments, we anticipate cement demand to rise. This increased capacity will facilitate the growing demand in the southern region."


US: Eagle Materials will modernise and expand its Laramie, Wyoming cement plant, increasing its capacity by 50% to approximately 1.2Mt/yr. The expansion includes a new cement distribution facility in northern Colorado. This project aims to cut manufacturing costs by about 25%, generated by the replacement of traditional fuels with lower cost alternative fuels and natural gas, as well as improved operating efficiency. This upgrade will also reduce CO₂ intensity by nearly 20%, according to the company. The US$430m investment also includes upgrading the existing plant, which became operational in 1927 and currently has a capacity of 800,000t/yr. Construction is set to begin immediately, with completion expected in the second half of 2026.


Spain: Molins has launched a new corporate identity, consolidating its commercial brands—Cementos Molins Industrial, Promsa, Propamsa, Pretersa-Prenavisa and Precon—into the single Molins brand. This move represents a broad array of construction products and solutions under one unified identity. In line with this, Molins also introduces Susterra, a new range of sustainable solutions.

CEO Julio Rodríguez said "Cement is the foundation of this company, accounting for 60% of our current business. However, today we are a company that offers a wide range of construction solutions, and our long-term strategy is to continue growing in all types of construction solutions to provide increasingly better service to our customers."


US: Holcim’s Hagerstown plant in Maryland has increased its alternative fuels substitution rate to 45%, equivalent to 58,000t/yr of engineered fuel. This US$11m initiative utilises end-of-life materials like non-recyclable paper, plastics and fibres, sourced from commercial and industrial materials like packaging. Geocycle, a subsidiary of Holcim US, will process these materials at its new Cumberland facility, which has a capacity of up to 75,000t/yr.

Senior vice president of Manufacturing North for Holcim US, Michael Nixon, said "Expanding our alternative thermal energy use to 45% provides multiple environmental and economic benefits, from lowering the net carbon intensity of our cement to reducing our consumption of traditional fuels. Importantly, it enables us to play a role in the circular economy, offering a highly safe and ecological solution for unused materials."


Vietnam: The Vietnam Cement Association (VNCA) has requested the exemption of clinker from the current 10% export tax, arguing it does not qualify under the Value-Added Tax Law as a natural resource or unprocessed mineral. According to Viet Nam News, VNCA has formally appealed to the Ministry of Finance and the Ministry of Construction to review the tax, asserting that clinker, produced at temperatures around 1450 - 1500°C, should not be taxed as a mineral resource. The industry exported over 31.3Mt of clinker and cement in 2023, equivalent to US$1.32bn, representing a year-on-year decline of 1.2% in volume and 4.1% in value compared to 2022, marking the second consecutive year of export decline. The total production capacity of Vietnam's 61 cement plants is about 117Mt/yr, with domestic consumption reaching only 56.6Mt.


Spain: The Mexico-based owner of the Spain-based cement producer FCC, Carlos Slim, is reportedly planning to spin-off its cement and real estate assets into a separate business. The new entity, to be known as Inmocemento, would then be listed on the Madrid stock market, according to Reuters. Slim directly owns around 12% of FCC and controls a further 76% of the company through investment vehicles Inversora Carso and Operadora Inbursa.

Inmocemento would take FCC's cement plants, the majority stake it owns in the real estate developer Realia and a minority stake in Metrovacesa. Current FCC shareholders would receive Inmocemento stakes equivalent to their holdings in FCC.

FCC currently owns assets in different industries such as construction, water and sewage, waste management, cement and real estate. FCC's cement units reported revenues of €614m in 2023, while income from real estate was €254m. Together, these sectors represented 9% of FCC's revenue. It operates its cement business via the Cementos Portland Valderrivas subsidiary.

FCC said in a financial disclosure that its board believes that the move would boost shareholder value as the new and existing companies are likely to be worth more apart than together.


Belgium: Holcim kicked-off its Go4Zero project at its Obourg plant on 16 May 2024 in an event attended by the Belgian Prime Minister Alexander De Croo and the European Commissioner for Climate Action Wopke Hoekstra. The €500m Go4Zero project, supported with €230m of funding from the European Union, will enable the integrated plant to reduce its CO2 emissions by 30% by 2027 and to produce 2Mt/yr of CO2-free cement by 2029. When fully operational, the Obourg plant will capture 1.2Mt/yr of CO2.

The Go4Zero project incorporates a number of approaches to achieve net-zero CO2 cement. The centrepiece is an oxy-fuel combustion process to generate an easy-to-handle exhaust gas with up to 80% CO2. This will be coupled to a cryogenic purification unit to generate a >99%-pure CO2 stream .The project will also make use of waste heat recovery (WHR), new exhaust filtration equipment and Europe’s largest floating solar panel farm.


US: Sublime Systems has announced the first-ever commercial application of its low-carbon Sublime Cement product at WS Development’s One Boston Wharf building in Massachusetts. The concrete placement is located in the Paseo indoor public space at the office building. The floor will be marked with educational materials explaining the significance of decarbonised cement in combating global climate change.

Leah Ellis, the CEO and Co-Founder of Sublime Systems, said “Buildings are monuments to the values of the people who build them, and the One Boston Wharf project represents WS Development’s leadership in ushering in our post-carbon future.” She continued “They are creating not only the building but the world where people want to be. We are honoured to have Sublime Cement featured so prominently here and are confident this pioneering place will inspire infrastructure owners everywhere to embrace low-embodied-carbon materials as a powerful tool for achieving our global net-zero goals.”


Colombia: Cementos Argos reported revenues of US$1.3bn in the first quarter of 2024, 6.4% year-on-year lower than the same period of 2023. The company recorded adjusted earnings before interest, tax, depreciation and amortisation (EBITDA) of US$291m, 2% above the value in the same period of the previous year. It reported decreases of 13% and 6% in cement and concrete volumes respectively, which it attributed to there being five fewer business days in the 2024 period due to the timing of Easter holidays.


Saudi Arabia: The net profit of Southern Province Cement rose by 27% year-on-year to US$16.5m in the first quarter of 2024 from US$13.0m a year earlier. However, its revenues fell by 16% relative to the first quarter of 2023, reaching US$66.9m.


Tunisia: Les Ciments de Bizerte has announced that it experienced financial difficulties during the first quarter of 2024. The company was unable to import petcoke due to a lack of cash and looming loan repayments, leading to the total suspension of clinker production. This left the company only able to grind existing clinker and operate its quay. As a result, the company’s total sales in the first quarter of 2024 fell by 53% year-on-year compared to the same period in 2023, falling from US$8.3m to US$3.9m.