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Indonesia: According to the Jakarta Post, Semen Indonesia has lowered its prices by around 10% so far in 2015 to compete with rivals amid an economic slowdown that has seen a decline in the construction sector. With an increase in competition in the local market, Semen Indonesia had hoped that its exports would boost its revenues, according to company marketing director Amat Pria Darma.
President Joko "Jokowi" Widodo instructed state-owned cement producers to lower their prices in January 2015 to support the government's massive infrastructure projects. However, Darma added that state-run cement producers had to lower their prices further later in 2015 to cope with tighter competition and lacklustre demand. "A number of new plants have started operating and new supplies are coming in. We have to lower our prices to keep up with the market with overall plunging domestic demand," said Darma.
Semen Indonesia saw its domestic sales volumes fall by 5.3% in January – May 2015 to 9.91Mt, even steeper than the national decline in cement demand of around 3.8%. In May 2015 alone, the company's domestic sales fell by around 14%.
While cement demand has contracted since the start of 2015 on the back of the slowing economy, several cement producers have seen additional production from newly operating plants. New players have also entered the market, such as Semen Merah Putih. Semen Indonesia saw its market share in the country slip from 44% in 2015 to 43% in 2015. Darma said that he was pessimistic that Semen Indonesia could achieve its target of seeing sales volume up by around 6% in 2015, or even maintain it at the same position as 2014. The company will instead look to export markets as a strategy to cope with the domestic slowdown.
Semen Indonesia's exports rose by more than eight times from 22,155t in the first five months of 2014, to 184,181t in the same period of 2015. According to Agung Wiharto, the surges were not particularly good news as with high transportation costs, cement makers only exported their production when domestic sales were down and the contribution from exports was not significant. Exports, he said, were made to better ensure that its products were absorbed to maintain utilisation and efficiency. Wiharto said that Semen Indonesia was looking to initiate contract-based exports, in comparison to its current spot sales, in the near future if the economy does not show any signs of improvement. By relying on a six-month to one-year contract, the company could ship more cement, ensuring a more certain market.
"We hope to see our exports hit 1Mt in 2015. The prospect is good, given that some of our traditional markets have no cement producers," said Wiharto. Among Semen Indonesia's major export customers are Timor-Leste, Bangladesh and the Maldives.
New RDF plant comes online in Pasig, Manila 25 June 2015
Philippines: According to the Philippine Daily Inquirer, on 24 June 2015 the Pasig City government brought online what it described as, 'The country's largest facility for turning rubbish into fuel, capable of processing 600t/day of trash.'
The plant, which is Pasig City's joint project with the IPM Construction & Development Corp (IPM) and the Metro Manila Development Authority (MMDA), can process almost all of the city's daily waste production into refuse-derived fuel (RDF). Pasig City mayor Maribel Eusebio said that the plant would produce fuel pellets from the waste, which would then be supplied as an alternative fuel to cement plants. The RDF is majority-owned by Basic Environmental Systems & Technologies (BEST), a subsidiary of publicly-listed Minerales Industrias Corp, as well as France-based Lafarge Industrial Ecology International.
The plant mechanically segregates waste, selecting garbage with high thermal value that will be shredded, made into pellets and wrapped into bales. The plant is expected to convert 25 – 35% of the processed waste into alternative fuel for cement kilns. "The plant addresses serious concerns on increasing municipal solid waste and disposal," said Eusebio. "The RDF plant also complies with the waste diversion requirement of Republic Act No 9003 or Ecological Solid Waste Management Act of 2000. It also addresses climate change issues associated with how municipal wastes are managed."
The use of RDF in lieu of coal addresses the twin issues of solid waste management and climate change. "This is the largest RDF plant in the Philippines to date," said Isabelita P Mercado, president of IPM, which operates and manages the plant. "This is also a pioneering endeavour to save the environment by reducing our dependence on fossil fuel."
Slovenia: According to the Slovenian Press Agency, on 24 June 2015 the government adopted a proposal for changes to the environment protection act that remedies shortcomings in provisions governing environmental permits. The problems with the existing legislation had led to the European Commission (EC) taking Slovenia to the EU Court of Justice.
The government said that the key purpose of the amendments was meeting the demands of the EC and that all plants without environmental permits at the time when the changes enter into force will need to stop operations. The step is related to the Lafarge cement plant in Trbovlje, which was instructed to stop operations in March 2015 after lax legislative provisions allowed it to continue to operate for a protracted period even though it did not have an environmental permit.
The EC announced in February 2015 that it was taking Slovenia to the EU Court of Justice for its failure to implement environmental licensing in line with the integrated pollution prevention and control (IPPC) directive of 2007. The EC said that the legal action came because one of the country's major cement producers had continued to operate without the required permit, in reference to Lafarge. The EC was seeking a base fine of Euro1.6m for the country plus Euro9009 for each day that the violation persisted.
Self-sufficiency and exports from every African market…? How is this possible?
Written by Peter Edwards
24 June 2015
The small cement industry of Mozambique, in south west Africa must be an interesting place to make cement. On one side the country's producers, like their more vocal South African counterparts, have been fighting off cheap imports from Iran, Pakistan, China et al. On the other side of the coin though, Mozambique has growing domestic demand and is within striking distance of growing markets further into Africa, like Malawi and the Democratic Republic of Congo (DRC).
With the announcement this week that there will be not one but two new integrated cement plants in the country, bringing over 2Mt/yr of new capacity, everything should be set fair for the coming years then, shouldn't it? Domestic production will rise, the price of local cement will fall as a result, competition from imports will drop off and money will be made from new exports.
Except that might not happen. Before the announcement of these two plants, (one of which does not state a capacity), there was around 5.5Mt/yr of grinding and integrated capacity either currently active in Mozambique or due to come onstream in 2015. With the new projects this rises to over 7.5Mt/yr.
The desirable chain of events described above starts to break down due to the fact that domestic demand in Mozambique, while rising, is not currently anywhere near as high as domestic supply. The United States Geological Survey estimated that the country produced just 1.2Mt/yr in 2012. Data for 2013 and 2014, though unavailable, is highly unlikely to show a three-fold increase. Indeed Insitec, a minority shareholder in Cimentos de Moçambique, predicted in 2014 that demand for that year would rise to just 1.5Mt, before hitting the dizzying heights of 1.8Mt in 2018 – And that's still three years away!
So what are the options? Option 1: Some or all of the planned and mooted cement plants will fail to come to fruition. Option 2: Some or all of the plants will be built but will operate at reduced capacity and/or on a campaign basis. Option 3: The Mozambican cement industry becomes a regional powerhouse and starts to export to its neighbours.
Option 1 is certainly possible. Limak Group, one of the parties linked to the new projects, is a Turkish cement producer that is inexperienced outside of Turkey. There has also been a lack of information on the progress of projects by Austral Cimentos ('coming on stream in 2015'), Star Cement and Consolidated Building Materials, although a lack of progress reports does not necessarily imply 'no progress.'
Option 2 is more likely, as some producers already operate on a campaign basis. InterCement's plant at Nacala, formerly an integrated plant, currently operates only as a grinding station. Option 3 is also possible, with Malawi particularly lacking in cement production facilities.
In reality a combination of all three 'Options' is the most likely outcome. However, this will lead to Mozambique becoming yet another player in an increasingly busy African cement market. The desire for self-sufficiency in cement production, a common goal for the region's governments, can easily lead to over-estimates of local demand growth, with resultant over-capacity. Of course the expectation that all African countries can get rid of this extra cement capacity via exports will ultimately backfire.
In southern Africa we already have South Africa exporting. Angola declared 'cement self-sufficiency' in October 2014 and banned imports at the start of 2015. Zambia, Botswana, Zimbabwe and DRC all have large-scale Dangote and/or PCC projects near completion or in production that will greatly reduce their need for imports. Meanwhile, further north, Nigeria is already a gigantic producer and significant cement exporter. Cameroon has recently banned imports and Ghana is thinking of doing the same. Over in the east of Africa, Ethiopia's (and the rest of that region's) rapidly-developing situation was covered in this column just two weeks ago.
Finally, in the north of Africa, Algeria has declared its intention to be self-sufficient in cement by 2016. This news must have 'gone down like a lead balloon' in Italy, Spain and Greece, which have been reliant on north African markets after the bottoms fell out of their own economies. In the north east, Egypt has different problems at present, also described previously. It needs fuel not cement!
So where does this all lead for regional cement dynamics in Africa? Well perhaps the situation in India points the way. There, as in Africa, local and regional producers with the desire to expand grew from their local bases and eventually overlapped. Against a backdrop of lower-than-expected demand, the country now has overcapacity. This has resulted in smaller producers being acquired and leaving the market.
Could this eventually happen in Africa? Only time will tell. However one thing is certain: It's just not possible for every country to export to every other country!
US: According to Charlotte Business Journal, Duke Energy has proposed excavating 12 more of its 36 coal ash ponds in North and South Carolina and burying the waste in a fully-lined landfills or structural fill projects.
To date, Duke has proposed closure plans for 24 of the 36 ash ponds. In every case, it has proposed excavation and reburial. However, Garry Miller, head of closure engineering for Duke, said that might not be the case for the remaining 12 ponds. He said that the engineering work that remains to be done at those plants could yet show that a 'cap in place' process, which critics have said would be insufficient to protect against further contamination of groundwater, can effectively close them.
Miller said that none of the waste ash from Duke's 36 ash ponds would undergo beneficial reuse, the process of using the ash for commercial products such as a replacement for Portland cement in concrete and gypsum board. However, he added that Duke does send a portion of the dry ash it is currently producing at its largest plants for reuse. However, the time constraints imposed by North Carolina's Coal Ash Management Act of 2014 make it impossible for the existing ash ponds. "As we close these basins, the quantity in them is such that the market cannot handle it in a timely manner," said Miller.
Duke's current cost estimate for closing the ponds is US$3.4bn, although this is subject to revision.