Global Cement Newsletter

Issue: GCW680 / 09 October 2024

Headlines


Adani Group’s latest target for acquisition in the cement sector was revealed this week to be Heidelberg Materials’ India-based business. The Economic Times newspaper reported that talks have started between the companies with a tentative value of US$1.2bn. As might be expected, Adani Group is said to be keen to close the deal down quickly. It wants to avoid an auction situation where it might face competitors. However, there may be some disagreement about the actual production capacity of Heidelberg Materials’ companies in India. If a deal were finalised, it might be completed by early 2027.

Heidelberg Materials’ capacity in India was listed as 14Mt/yr by the press but this could include the company’s grinding plants as well as its integrated ones. Heidelberg Materials, itself, says it has a capacity of 12.1Mt/yr from three integrated cement plants, four grinding plants and a terminal across 12 states. Data from the Global Cement Directory 2024 suggests that this refers to the group’s integrated cement capacity. The plants are roughly split equally between subsidiaries Heidelberg Materials India and Zuari Cement. Heidelberg Materials entered the Indian market in 2006 when it acquired Mysore Cement, Cochin Cement and established a joint-venture with Indorama Cement. It later added Zuari Cement to its portfolio when it bought Italcementi in 2016. The group used to run four integrated plants in India until in May 2024, when it shut down clinker production at its Ammasandra plant in Karnataka, although grinding activity has continued at the site.

Back in 2021 Heidelberg Materials’ CEO Dominik von Achten said that the group had considered selling anything following a business review. "There are no sacred cows. Everything was on the table." Indonesia was generally perceived by analysts as a likely sale target in the developing markets but nothing happened in the end. India wasn’t mentioned at this time, although no doubt it was being considered. Yet Holcim divested its businesses there in 2022. These were picked up by Adani Group for US$6.4bn. This, in turn, kicked off the rivalry in the Indian cement sector between market leader UltraTech Cement and Adani Group. Both companies are now in a race to build production capacity through expansion, new plants and acquisitions.

One reason why Heidelberg Materials may have decided now in particular to talk to Adani Group can be seen in its recent financial reports. In 2023 it said that its “cement and clinker deliveries increased moderately, as massive excess capacities persist in our core markets.” It then followed this up in 2024 by noting that deliveries were slightly down year-on-year in the first half of the year. It blamed this on excess capacity in South India. The subsidiary reported a net loss of €6.3m in 2023. An article by Holtec Consulting in the October 2023 issue of Global Cement Magazine implied that capacity utilisation was 56% in 2023, the lowest of the country’s regions. This is a particular problem for the company given that Zuari Cement is based in the south.

Funnily enough, a sale of 12.1Mt/yr capacity for US$1.2bn suggests a price of US$99/t, a similar figure to what Adani Group paid to buy Holcim’s assets in India in 2022. This may explain why Adani Group is trying to avoid an open sale for the Heidelberg Materials assets. Then again, maybe the market in southern India really is suffering. By comparison, when Adani Group concluded a deal to buy Penna Cements in August 2024 it paid US$1.2bn for an integrated capacity of about 7Mt/yr or around US$170/t. Factor in the low capacity utilisation rate in south India and this potential Adani-Heidelberg Materials deal ends up at roughly the same price.

Something that may help Adani Group reach its goal might be a formal merger between its two main cement companies, Ambuja Cements and ACC. The Mint newspaper reported on it this week, saying that Jefferies and Axis Capital has been hired as an advisor. This certainly makes sense in synergy savings but moving all the mining and leasing rights around might prove cumbersome. Regardless, Adani Group is on an expansion drive, with a capacity of 140Mt/yr targeted by 2028. All the smaller cement companies in the country are potentially targets.


Austria: Haimo Primas has been appointed as the CEO of Holcim Austria. He succeeds Berthold Kren in the role.

Primas, aged 53 years, has worked for Holcim for over 20 years. He started working for Lafarge Zementwerke in the early 2000s and has worked for related companies, including Holcim CE Holding and Lafarge Slovenia. His responsibilities have included senior positions at cluster and national level in finance, business development, supply chain and human resources. Amongst other roles, he was the plant manager of the Retznei cement plant from 2022 to October 2024. Primas studied business administration at the Karl-Franzens-University Graz.


Taiwan: Lucky Cement has appointed Yun-Ju Chen as its chair. She succeeds Liang-Chuan Chen, her father, who has died. Yun-Ju Chen has been a director of the company since 2001.
The Taiwan-based cement producer operates an integrated plant at Tung-Ao and a grinding plant at Pu-Shin.

This company is not related to the larger Pakistan-based producer of the same name.


France: Calderys has appointed Sander Bovee as its Chief Financial Officer (CFO).

Bovee, a Dutch national, previously worked for Nouryon (formerly known as AkzoNobel Specialty Chemicals), a specialty chemicals company, as its Vice President of Group Control & Treasury. He was also the company’s interim CFO for a period. Prior to this he worked for AkzoNobel in a variety of business and corporate finance roles based in the US, China and the Netherlands. He holds a master’s degree in economics and an executive masters in Finance and Control at Maastricht University.


Greece: ThyyssenKrupp Polysius has signed a front-end engineering design contract with Titan Group for the Ifestos carbon capture project at Titan’s Kamari cement plant. The project will equip the plant’s two kilns with oxyfuel systems to reduce CO2 emissions by 1.9Mt/yr, ‘almost completely’, said ThyssenKrupp. The captured CO2 is then liquefied and transported to a permanent storage site in the Mediterranean region. Full operation is expected by the end of 2029.

Cetin Nazikkol, chief strategy officer at ThyssenKrupp Decarbon Technologies, said “With the oxyfuel technology we have developed, around 1.9Mt/yr of CO2 can be captured at the Kamari plant alone. This corresponds to around 12% of greenhouse gas emissions from all Greek industries. We are thus making a significant contribution to one of the largest CO2 capture projects in Europe.”

Christian Myland, CEO of ThyssenKrupp Polysius, said “For our customer Titan Group, we will be using the latest CO2 separation technology. We will design and equip the first kiln line with the proven oxyfuel technology. When modernising the second kiln line, the latest generation of this technology will be used with the pure oxyfuel system. Overall, this will enable us to capture almost 100% of CO2 emissions.”


Saudi Arabia: In 2023, Saudi cement and clinker exports exceeded 8.48Mt. According to Al Riyadh news, the country ranks 10th globally with a production capacity of over 80Mt/yr from 20 plants. Local demand for cement reached 47.3Mt in 2023, with construction sector spending expected to hit US$1.6tn by 2030.

Minister of industry and mineral resources Bandar Alkhorayef said "The cement sector in the Kingdom has a promising future, with several leading companies constantly adopting the latest manufacturing technologies, helping to improve production efficiency. Recently, some companies have been active in upgrading and replacing some of their production lines to enhance quality."


Pakistan: Cement exports from Pakistan significantly increased in September 2024, rising by 71% year-on-year to 0.98Mt, compared to 0.57Mt in September 2023. Despite this growth in exports, domestic cement sales continued to decline, falling by 18% in September 2024. Overall, cement sales for the month decreased by 5.6%, totalling 3.54Mt compared to 3.75Mt in September 2023. From July to September 2024, domestic sales were down by 20%, totalling 8.13Mt, while exports rose by 22%, reaching 2.14Mt.


India: Shree Cement has signed a memorandum of understanding with the Department for Promotion of Industry and Internal Trade (DPIIT) to support startups in India's manufacturing sector. This partnership aligns with the government's ‘Make in India’ vision to encourage domestic manufacturing and build a self-reliant economy. Through this collaboration, startups will gain access to Shree Cement’s industrial expertise, network and resources, which will help them scale their operations and develop solutions. This initiative is expected to create new job opportunities, boost local production and reduce import dependency.


Philippines: Cemex Philippines has extended Aboitiz Construction’s contract to provide technical services for the commissioning of the upcoming Line 4 of its Antipolo City cement plant in Rizal. The Manila Times newspaper has reported that the new date on which the contract will conclude is in December 2024.

Aboitiz Construction chief operating officer Ramez Sidhom said "Our recent partnership with Cemex Philippines demonstrates our commitment to execution excellence and affirms our ability to provide reliable maintenance solutions while prioritising safety and quality of work.”


India: Adani Group is considering a merger of Ambuja Cements and ACC into a single entity, Adani Cement, by 2028. Mint News has reported that the group, which began integrating the operations of the two companies recently, may also include Sanghi Industries in the merger. The proposed merger would involve a share swap between the companies, with all existing brand identities retained.


Colombia: Cementos Argos says that it exported 1.5Mt of cement and clinker through its terminals at the Argos Cartagena cement plant in the first nine months of 2024, up by 10% year-on-year from the volumes recorded in the corresponding period of 2023. The plant exports cement and clinker to the US and Caribbean and Central American countries. Its terminals give a combined loading capacity of 1000t/hr of cement or 800t/hr of clinker.

Plant manager Alberto Carlos Riobó said "In 2022, we launched the port expansion project for our Free Trade Zone and, since then, we have continued to invest in the realisation of a dream that has allowed us to export products on a larger scale, receive a larger number of vessels with greater capacity, and continue serving markets beyond our borders. In this way, we continue to confirm that the customer is at the heart of our decisions.”


Ireland: Mannok, Sweden-based minerals company Boliden and the South Eastern Applied Materials (SEAM) research centre at South East Technological University in Carlow, Wexford and Wicklow in Ireland have launched a 30-month project to reduce the embodied CO2 emissions of cement. The project will investigate possible uses of shale as a supplementary cementitious material (SCM) in cement production and the CO2 curing of cement paste-based mine backfill. Enterprise Ireland has supplied funding worth €700,000 for the collaboration.

Mannok operations director Kevin Lunney said "We are delighted to be working with SEAM and Boliden on this critical research for the cement sector, which could have many far-reaching benefits for the construction sector more generally. Finding local, viable, low-carbon solutions for the industry can make a major contribution to lowering emissions in Ireland."

Boliden specialist development engineer Adam McElroy and section-mill process head Colum Burns said "This project will greatly enhance our knowledge and understanding of the potential for developing low carbon cement for mine backfill purposes and for utilising backfill systems as a carbon sink. The project will also investigate synergies between the cement manufacturing and mining industries that could enhance the sustainability of both industries."


Azerbaijan: The Azerbaijan Cement Producers Association (ASIA) has held the third Net Zero Accelerator workshop to discuss the final report on its 2050 Net Zero Roadmap. ASIA members, construction companies and government and non-governmental organisations (NGOs) all participated in the two-day event. TurkicWorld News has reported that topics include Azerbaijani cement’s clinker factor, alternative fuel (AF) substitution rate, construction and design aspects, carbon capture and related regulatory frameworks. ASIA will launch its finalised roadmap in partnership with the European Cement Research Academy (ECRA) and the Global Cement and Concrete Association (GCCA) at the COP29 climate conference in Baku, Azerbaijan.

ASIA said "The association is making use of the expertise of the GCCA and ECRA to ensure our roadmap aligns with national policies."


Brazil: Buzzi has finalised the acquisition of the remaining 50% stake in Companhia Nacional de Cimentos (CNC) from Brennand Cimentos, securing full control over the joint venture. The deal, valued at US$311m, was approved by Brazil's Administrative Council for Economic Defense (CADE), according to Movimento Econômico. CNC has been operational since 2018 and has five integrated cement plants and two grinding plants in Brazil, with a total production capacity of 7.2Mt/yr. This acquisition follows initial transactions that began in June 2024.


India: Adani Group is negotiating the purchase of Heidelberg Materials' cement business in India, potentially valued at US$1.2bn, according to Reuters. Heidelberg Materials has been present in India since 2006, and owns four plants with a total capacity of 12.6Mt/yr. The acquisition discussions come amidst increased consolidation in the Indian cement sector, driven by heightened demand due to government investment in housing and infrastructure.


India: Orient Cement has won an order from Madhya Pradesh Power Generating Co to install a clinker grinding unit at Satpura Thermal Power Station, Sarni. The ‘work order’ was issued by the company to install the grinding unit, along with a 25-year fly ash supply contract. Earlier in August 2024, Orient Cement said that it anticipates a robust demand recovery in the second half of the financial year post-monsoon.


Sweden: SaltX Technology has secured a new grant from the Swedish Energy Agency for its project ‘Demonstration of new electric kiln technology at industrial scale to enable emission-free cement production.’ This funding follows previous support for testing and optimising electric quicklime production at its test and research facility in Hofors, Sweden. The grant aims to adapt and test SaltX's technology specifically for cement production, awarded under the pilot and demonstration program. It constitutes partial funding for the work that is planned to begin in March 2025 at the company's test and research facility.

Acting CEO of SaltX, Lina Jorheden, said "It is very encouraging that the Swedish Energy Agency supports us in our work to commercialise SaltX's electrification technology for the cement industry. The grant is an important component in the upcoming industrialisation phase."


UK: The Mineral Products Association (MPA) has endorsed the UK government's commitment to finance the country’s first carbon capture, utilisation and storage (CCUS) sites, which could help make the creation of the nation's first net zero cement plant a reality. One of the projects hoping to receive funding is Heidelberg Materials’ Padeswood Cement Works in Flintshire, part of the HyNet North West cluster of industrial sites poised to implement CCUS. The government's support for CCUS not only progresses the decarbonisation efforts of the UK concrete, cement, and lime sectors, but also reduces the pressure to import cement from overseas, protecting the UK economy by sustaining local industry and jobs.

MPA executive director for energy and climate change Diana Casey, said “It is very positive to see the Government’s commitment to two carbon capture clusters and this news provides an important signal of intent to businesses and the investor community. While we await the specific detail of the package of support, the support announced for the HyNet cluster creates an opportunity to bring forward the UK’s first cement carbon capture plant.”


UK: The government has announced a €26.3bn investment to develop carbon capture and storage (CCS) projects in northern England. The investment will subsidise three projects to capture CO₂ from various sources, including Heidelberg Materials’ Padeswood cement plant, and support infrastructure for transporting and storing CO₂ in Liverpool Bay and the North Sea. The initiative also plans to establish the UK's first large-scale hydrogen production plant. The funding, promised over the next 25 years, aims to establish two carbon capture clusters in Merseyside and Teesside. The investment is expected to create ‘thousands’ of jobs, attract €9.5bn in private investment and advance the UK's climate objectives.

Heidelberg Materials UK CEO Simon Willis said “Today’s announcement from the government to drive ahead with investment in CCS clusters is a major milestone in the decarbonisation of UK industry and sets the construction sector on the path to net zero. As part of the HyNet North West decarbonisation cluster, we are bringing forward our plans for the CCS plant at a UK cement works at Padeswood in North Wales. The government’s backing of this critical technology means that the production of zero carbon cement before the end of this decade has taken a big step forward.”


Canada: Lafarge Canada, a subsidiary of Holcim, has inaugurated a new low-carbon fuel facility at its Exshaw cement plant, in a joint effort with Geocycle Canada. The US$28m facility is supported by a US$7.4m contribution from Emissions Reduction Alberta through the government’s Technology Innovation and Emissions Reduction fund. It will reduce natural gas consumption by up to 50% for one of the plant’s kilns by substituting it with alternative fuels (AF) sourced from construction and demolition materials, primarily wood. Geocycle will process the materials into AF. This initiative is expected to divert up to 120,000t/yr of discarded materials from landfill, reducing CO₂ emissions by approximately 30,000t/yr.

President and CEO of Lafarge Canada (West), Brad Kohl, said "Our commitment to building a sustainable future is at the core of everything we do. The low-carbon fuel project is a prime example of how innovation and collaboration can drive positive change, lowering our environmental footprint through the use of discarded biomass materials while closing the material loop to conserve natural resources.”


Zimbabwe: Bulawayo City Council has granted approval for China-based Labenmon Investments to establish a grinding plant, expected to employ over 500 people, at Umvumila Industrial Park. Once operational, the facility will produce 900,000t/yr of cement, and plans to export to regional markets including Zambia, Botswana, and Mozambique. The grinding plant was previously planned for Cowdray Park, also in Bulawayo, but the application was rejected in July 2024.

The council report reads “The establishment of a cement mixing plant is expected to benefit Bulawayo Metropolitan Province and other provinces in many ways, such as increased supply of cement, employment for more than 500 local people, increased export earnings for the province, enhanced technology and better equipment for the domestic cement industry in Zimbabwe.”  

 


Egypt: Cemex Egypt has inaugurated new decarbonisation equipment at the Assiut cement plant, aligning with its ‘Future in Action’ sustainability strategy. The technology repurposes residual material into energy, incorporating high-efficiency separators and improvements to the calciner process, reducing CO₂ emissions by approximately 32kg/t of cement produced, totalling a reduction of 290,000t/yr.

President of Cemex Egypt & UAE, Yago Castro, said “The inauguration of the decarbonisation equipment at the Assiut plant is a testament to our ongoing efforts to create a more sustainable future for our communities and the planet. At Cemex, we are committed to leading climate action in the industry, using the highest alternative fuels substitution rate in the cement industry in Egypt.”


Finland/Germany: Tana Oy has entered a strategic partnership with Veneto Schwenter for the distribution of Tana Oy shredders in Germany. The collaboration will enhance Veneto Schwenter's portfolio of sales, rental and consulting services in manufacturing equipment, alongside machine service and repairs.


Spain: Packaging and paper manufacturer Mondi has co-founded Paper Sacks Go Circular Spain, an alliance aimed at enhancing the circularity of used paper bags within the construction sector. The alliance consists of 12 European companies collaborating to eventually elevate recycling processes for construction materials like cement, plaster and insulation. The alliance will start with paper bags, then expanding to other streams such as construction and demolition materials. The initiative aligns with the goal of increasing the recovery rate of construction byproducts in Spain, currently at 48%, according to the latest data from the Spanish National Statistics Institute.

Circular economy manager at Mondi Flexible Packaging, Carlos Martinez Ezquerra, said "This initiative demonstrates Mondi’s commitment to collaborating with industry partners across the value chain to increase recycling rates for used paper bags. It creates a scalable approach for the rest of Europe and other industries, leading to a reduction in ‘waste’ management costs and a significant increase in the valorisation rate, and supports transparency and traceability of the circular economy. We are proud to be one of the founding initiators."


Switzerland: ABB has entered into a memorandum of understanding with UK-based climate tech company Carbon Re, to explore integrated solutions aimed at accelerating the decarbonisation of cement production while improving productivity. The collaboration will reportedly combine ABB's expertise in automation and process control with Carbon Re's AI and machine learning technologies. The partnership follows a successful pilot at a cement plant in the Czech Republic, where ABB plans to augment its ‘Ability Expert Optimizer’ solution with Carbon Re's AI platform. This integration is expected to automate and optimise plant conditions, potentially reducing specific energy consumption by up to 5% and increasing alternative fuel use by 50% by maintaining optimal kiln conditions.

CEO at Carbon Re, Josh Vernon, said “At Carbon Re we are accelerating industrial decarbonisation through the use of cutting-edge AI – our models have demonstrated that AI can find efficiencies within the complex chemical processes of material production, especially cement.”

Global portfolio manager for Business Line Digital, ABB Process Industries, Tyron Vardy said “Driving down the emissions of cement production is a pressing priority for the industry. Our collaboration with Carbon Re will bring us closer to achieving this. Enhanced by cloud-based AI technology, our decision support software will be able to help customers enhance and improve the efficiency of their systems faster than ever before.”


Georgia: Hunnewell Cement, a subsidiary of HeidelbergCement Georgia, has launched a new project to use tyres as an alternative fuel at its Kaspi cement plant, with support from the Georgian government. The project has a budget of US$2.1m, and is expected to create additional job opportunities. It marks a shift from the use of coal and natural gas at the plant, to ‘significantly’ reduce environmental impact and contribute to sustainable development.

Economy minister Levan Davitashvili said "Our goal is to minimise environmental pollution from ‘waste’ while promoting economic development and creating added value.”


India: Orissa Bengal Carrier has entered into a three-month contract to transport coal and petcoke for Shiva Cement, a subsidiary of JSW Cement, effective until 31 December 2024. The company has not disclosed the value of the contract.


Pakistan: Dewan Cement reported a profit after tax of US$329,000 for the quarter ending June 2024, marking a 47% year-on-year decline compared to US$619,000 earned in the same period in 2023. Despite a significant improvement in gross margins, the company recorded a net loss of US$1.83m for the full financial year 2024, slightly less than the US$2.11m loss in the financial year 2023. Quarterly sales rose by 3.4% to US$19.14m, with gross profit increasing significantly by 106.5% to US$1.06m in the quarter.