July 2014 OFF TO - · PDF fileAs the world pace-setter in grinding technology, Loesche has...

OFF TO NEW HORIZONS

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As the world pace-setter in grinding technology, Loesche has achieved yet another landmark. Having already supplied the world’s largest coal mill, the LM 43.4, to a customer in India, and the largest raw-material mill, the LM 69.6 to Nigeria, the company has now delivered the world’s largest slag mill to one of China’s leading steelmakers.

In September 2011, Loesche received an order from China-based Taigang Group International Trade Co. Ltd for the delivery of an 63.3+3 vertical roller mill for grind-ing granulated blast-furnace slag. Destined from the start to be the largest slag mill in the world, it has been supplied to Shanxi Taigang Stainless Steel Co. Ltd (TISCO) in Taiyuan – the capital city and industrial centre of Shanxi province. Since coming on stream in March, the grinding plant has already set a new production record by achieving a throughput rate of 255 t/h.

The LM 63.3+3 at the TISCO steel works is being used solely for grinding granulated blast-furnace slag. It is powered by a 7.4 MW motor, the most powerful and up-to-date Loesche has ever installed in one of its vertical roller mills. The project guarantees include a capacity of 255 t/h of granulated blast-furnace slag at a fineness of 4,400 Blaine, with the mill having been equipped with a newly developed Loesche LDC classifier – designed for optimum performance with the company’s vertical roller mills.

With the decision for the Loesche Mill Type LM 63.3+3 for this application, the Taigang Group International Trade Co. Ltd can be seen as a trendsetter in the region relying on both tradition and innovative engineering.

LOESCHE GmbHHansaallee 243D-40549 Düsseldorf, Germanywww.loesche.com


LOESCHE DELIVERS WORLD’ S LARGEST SLAG MILL

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As the world pace-setter in grinding technology, Loesche has achieved yet another landmark. Having already supplied the world’s largest coal mill, the LM 43.4, to a customer in India, and the largest raw-material mill, the LM 69.6 to Nigeria, the company has now delivered the world’s largest slag mill to one of China’s leading steelmakers.

In September 2011, Loesche received an order from China-based Taigang Group International Trade Co. Ltd for the delivery of an 63.3+3 vertical roller mill for grind-ing granulated blast-furnace slag. Destined from the start to be the largest slag mill in the world, it has been supplied to Shanxi Taigang Stainless Steel Co. Ltd (TISCO) in Taiyuan – the capital city and industrial centre of Shanxi province. Since coming on stream in March, the grinding plant has already set a new production record by achieving a throughput rate of 255 t/h.

The LM 63.3+3 at the TISCO steel works is being used solely for grinding granulated blast-furnace slag. It is powered by a 7.4 MW motor, the most powerful and up-to-date Loesche has ever installed in one of its vertical roller mills. The project guarantees include a capacity of 255 t/h of granulated blast-furnace slag at a fineness of 4,400 Blaine, with the mill having been equipped with a newly developed Loesche LDC classifier – designed for optimum performance with the company’s vertical roller mills.

With the decision for the Loesche Mill Type LM 63.3+3 for this application, the Taigang Group International Trade Co. Ltd can be seen as a trendsetter in the region relying on both tradition and innovative engineering.

LOESCHE GmbHHansaallee 243D-40549 Düsseldorf, Germanywww.loesche.com


LOESCHE DELIVERS WORLD’ S LARGEST SLAG MILL

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HEKO Ketten GmbHEisenbahnstraße 2 | 58739 Wickede (Ruhr), Germany | Telephone +49(0)2377-9180-0 | Fax +49(0)2377-1028 | E-Mail: [email protected]

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Tel +44 (0)1252 718999 Fax +44 (0)1252 718992 Email: [email protected] Website: www.worldcement.com

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OFF TO NEW HORIZONS


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Volume 45: Number 7July 2014 ISSN 0263 6050

ABOUT THISCOVER

As the world pace-setter in grinding technology, Loesche has achieved yet another landmark. Having already supplied the world’s largest coal mill, the LM 43.4, to a customer in India and the largest raw-material mill, the LM 69.6, to Nigeria, the company has now delivered the world’s largest slag mill to one of China’s leading steelmakers. With the decision for the Loesche mill type LM 63.3+3 for this application, the Taigang Group International Trade Co. Ltd can be seen as a trendsetter in the region, relying on both tradition and innovative engineering.

July 2014

CONTENTS

WORLD CEMENT REGULARS07/ Comment09/ News15/ Keynote: Global ViewpointOnce again, Paul Maxwell-Cook introduces this year’s annual World Review with notes and observations on this essential global industry.

173/ Product News176/ Global Fact Sheet

WORLD CEMENT’S WORLD REVIEW 24/ Africa & Middle East52/ Asia & Pacifi c Rim88/ North & Central America104/ South America116/ Europe & CIS

DOMES & SILOS145/ Silo Maintenance and SafetyDennis Blauser, CEO, Marietta Silos, LLC, USA.

149/ Cement Storage SolutionsIsaac Brewer, Ph.D., Tank Connection, USA.

PORTS, TERMINALS & TRANSPORT153/ High Capacity Unloading in HoustonCargotec, Sweden.

157/ Intermodal TransportDean Reilly, InBulk Technologies Ltd, UK.

161/ Malta’s Newest Cement PlayerDaniele Sciuto, Euromecc, Italy.

FANS165/ Energy E� ciency and Cost SavingsErwin Unger, TLT Turbo GmbH, Germany.

WASTE HEAT RECOVERY169/ Waste Heat Recovery in IndiaK. N. Rao and R. Nand Kumar, ACC Limited, India.

/3


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With 130 years of specialist know-how at your disposal, only we can guarantee a fully sustainable and effi cient model that will grow your plant – and profi ts – long after you take over the operation.

To fi nd out how our combined EPC and O&M solution can give you the return without the risk, visit www.flsmidth.com/epc

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with EPC and O&M

Less risk – more return

As the world’s leading supplier of equipment and services for the cement industry, FLSmidth provides a unique 360° solution for the lifecycle of your plant, covering everything from initial raw material investigation and Engineering, Procurement and Construction (EPC) through to ongoing operation and maintenance services. Our combined EPC and O&M solution is a unique offering manged by the most experienced engineers in the business alongside locally recruited staff who are trained and integrated into our expert teams.

With 130 years of specialist know-how at your disposal, only we can guarantee a fully sustainable and effi cient model that will grow your plant – and profi ts – long after you take over the operation.

To fi nd out how our combined EPC and O&M solution can give you the return without the risk, visit www.flsmidth.com/epc

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When it comes to reliability, Jan and Volker have their

minds on a preventative approach. They inspect and test

every component of the system. The hydraulic power

pack is assembled, configured and operated as it will

be in the field. Both normal and extreme conditions are

simulated. Only when Jan and Volker agree that all tests

have been completed to their full satisfaction is the

hydraulic power pack allowed to leave the IKN test

facility for shipment to the client. It is due to the ex-

pertise and experience of IKN Engineers, like Jan and

Volker, that our customers can expect 100% reliability.

“AFTER I HAVE INSPECTED

EVERY PART OF THE

HYDRAULIC POWER PACK

I AM 100% SURE

THAT IT WILL OPERATE

FLAWLESSLY.“

Volker, Electrical Engineer

Systems Design at IKN

IKN Hydraulic Power Packs. The driving force behind our coolers.

E N G I N E E R I N G T H E F U T U R Ewww.ikn.eu

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July 2014

EDITOR’S COMMENT

Katherine Guenioui, Editor [email protected]

The trouble with a material that’s centuries old,reliable, fl exible, resilient and relatively easy to manufacture is that people tend to take it for granted. The myriad benefi ts of cement and

concrete are often swept under the rug in favour of ‘trendier’ discussions about sustainability and climate change. And while the cement industry is busy working out ways to utilise alternative fuels, capture greenhouse gas emissions and create products that offer unparalleled thermal effi ciency (as just one example), we perhaps don’t do enough to shout about our strengths (pun intended).

Enter The Concrete Initiative, a new enterprise formed by CEMBUREAU, together with the European Federation of Precast Concrete and the European Ready-Mixed Concrete Organization. The Concrete Initiative was founded with the aim of engaging stakeholders on the issue of sustainable construction, pointing out the benefi ts of concrete to the economy, to society and to the environment. You can fi nd a launch video on www.worldcement.com, but here are some key facts from The Concrete Initiative:*

For every €1 spent on construction output, a total of €3 is generated in total economic activity.

The concrete used in the Channel Tunnel is guaranteed to last for 120 years. (How’s that for sustainable?)

Existing concrete technology enables energy consumption in buildings of just 50 kWh/m2/year or less.

The concrete industry as a whole employs more than half a million people in the EU.

The Concrete Initiative wants to help stakeholders understand the role of concrete in sustainable construction. It’s important that cement producers also understand their responsibility when it comes to advocacy and education. What is your company doing to promote the use of concrete? Share your stories and ideas on our LinkedIn group, on Facebook and on Twitter.

I hope you enjoy this issue of World Cement, which includes 90 pages of international contract and project news, otherwise known as our annual World Review. It’s a great opportunity to sit down and get some perspective on how – and where – the industry is progressing. Thank you to those companies that submitted entries this year. For those who missed out, do look out for our invitation in February 2015 and make note of the April 2015 deadline. And, of course, you can submit your news all year long for our website and magazine by emailing me at [email protected].

CONTACTDETAILS

EditorialManaging Editor: James Little [email protected]

Editor: Katherine Guenioui [email protected]

Assistant Editor: Louise Fordham [email protected]

Editorial Assistant: Rosalie Starling [email protected]

Contributing Editor: Paul Maxwell-Cook

DesignProduction: Natalie Callow [email protected]

SalesAdvertisement Director: Rod Hardy [email protected]

Advertisement Manager: Ian Lewis [email protected]

Advertisement Executive: Paul Heyworth [email protected]

WebsiteWebsite Editor: Callum O’Reilly [email protected]

Website Manager: Tom Fullerton [email protected]

Digital Editorial Assistant: Katie Woodward [email protected]

MarketingCirculation Manager: Victoria McConnell [email protected]

Subscriptions: Laura Cowell laura.cowell.worldcement.com

Reprints:[email protected]

PublisherNigel Hardy

SUBSCRIPTIONRATES

Annual subscription (published monthly): £160 UK including postage/£175 (E260) overseas (postage airmail)/US$260 USA/Canada (postage airmail).Two year subscription (published monthly): £256 UK including postage/£280 (E416) overseas (postage airmail)/US$416 USA/Canada (postage airmail).Claims for non receipt of issues must be made within 4 months of publication of the issue or they will not be honoured without charge.

Applicable only to USA and CanadaWORLD CEMENT (ISSN No: 0263-6050) is published monthly by Palladian Publications, GBR and is distributed in the USA by Asendia USA, 17B South Middlesex Avenue, Monroe NJ 08831 and additional mailing offices.Periodicals postage paid at New Brunswick NJ. POSTMASTER: send address changes to WORLD CEMENT, 17B South Middlesex Avenue, Monroe NJ 08831.Copyright© Palladian Publications Ltd 2014. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. All views expressed in this journal are those of the respective contributors and are not necessarily the opinions of the publisher, neither do the publishers endorse any of the claims made in the articles or the advertisements.Uncaptioned images courtesy of www.bigstockphoto.com

Printed in the UK. *www.theconcreteinitiative.eu

/7July 2014

World Cement


Something BIG will arrive soon…

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July 2014

WORLD NEWS

/9July 2014

World Cement

NewsHighlightsHighlightsHighlightsHighlightsHighlightsHighlights

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HeidelbergCement introduces Continuous Improvement Program

Pikalevsky Cement records 8% increase in production levels

Signs of recovery in the Saudi cement sector

Worldwide Gebr. Pfeiffer SE receives a number of new orders

Bilim Makina Insaat Sanayi ve Tic. a.s. has ordered further grinding technology from Gebr. Pfeiffer SE. Four mills will be delivered to the Elazig cement plant to the east of Ankara, Turkey, in spring 2015. This includes a coal grinding mill with a 500 kW drive and two safety shut-off dampers. The MPS 250 BK roller mill will have a grinding rate of 35 tph at a fi neness of 3.5% R 90 µm. Two MPS 5000 BC mills will be provided for cement grinding. These will each have a capacity of 200 tph and an installed drive power of 4400 kW. These mills will grind OPC with a specifi c surface of 3400 cm2/g acc. to Blaine. The fi nal mill for this order is an MPS 5000 B with a drive power of 3800 kW. This will grind cement raw material at a rate of 470 tph to a fi neness of 12% R 90 µm.

Also in Turkey, Gebr. Pfeiffer has received an order from Bolu Cimento for an MPS 4500 BC mill for granulated blastfurnace slag. The mill will be installed at the Bolu plant, and will have a drive power of 3300 kW. It will grind slag to a fi neness of 4500 – 4750 cm2/g at a rate of 85 tph.

Meanwhile, general contractor TCDRI has awarded Gebr. Pfeiffer SE a contract to supply a coal mill to a YTL cement plant in Malaysia. The MPS 2800 BK will have the capacity to grind 35 tph of sub-bituminous coal with a total moisture content of 25% to a product fi neness of ≤10% R 90 µm. The coal mill, which has a drive power of 700 kW, is scheduled to be delivered at the end of this year.

The company has also won a contract with general contractor Sinoma Suzhou Construction for cement grinding technology for a plant in Sulaymaniyah, Iraq. This comes on the heels of an order placed in summer 2013 for a raw mill for the same plant. Gebr. Pfeiffer SE will provide two MVR 6000 C-6 cement plants, which are due to be delivered to the plant at the end of 2014. The mills will grind different cement qualities to their required fi neness of between 3600 and 5500 cm2/g depending on the product type. Their grinding capacities will lie in the 132 – 210 tph range.

Russia Lafarge Russia inaugarates a new state-of-the-art cement plant

Lafarge Russia has inaugurated a new cement plant in Ferzikovo village, Kaluga region. Guests at the ceremony included First Deputy Prime Minister, Igor Shuvalov, Kaluga Region Governor, Anatoly Artamonov, Chairman and Chief Executive Offi cer of Lafarge Group, Bruno Lafont, and André Martin, Chief Executive Offi cer, Lafarge Russia.

The plant, built by Lafarge and the European Bank for Reconstruction and Development, the company’s co-shareholder in Russia, has a designed capacity of 2 million tpa and is the fi rst cement production facility to be set up in the region. The facility will enhance Lafarge’s presence in Russia and will provide a unique

value proposition to customers in a region with high construction needs.The Ferzikovo facility is a dry line cement plant, which means it comsumes 2.5 times less energy than conventional technology. The use of alternative fuels in the future, which should reach up to 45% by 2020, will help the plant to contribute to the preservation of non-renewable natural resources and a decrease in CO2 emissions. The plant’s product portfolio comprises CEM I 42.5 B (bulk and bagged) and CEM I 42.5 N (bulk). In 2015, the company intends to start production of a new cement type, CEM II 42.5 with additives. Today, the facility employs over 200 people, most of whom are residents of the Kaluga region.


July 2014

WORLD NEWS

10\July 2014World Cement

8 – 11 September 2014XXXI Technical Congress FICEM

Santo Domingo, Dominican Republicwww.congresotecnico2014.fi cem.org

30 September – 2 October 2014 POWTECH 2014

Nuremberg, Germanywww.powtech.de/en

8 – 10 October 2014ILA General Assembly & Information

Exchange ForumVancouver, Canada

[email protected]

13 – 14 October 201416th Asia CemenTrade

Jakarta, Indonesiawww.cmtevents.com

11 – 13 November 201419th Arab International Cement

Conference and ExhibitionMarrakech, Morocco

www.aucbm.org

11 – 14 November 2014Moscow International Lubricants

WeekMoscow, Russia

www.rpi-conferences.com

Ecuador UNACEM to acquire Lafarge’s operations in Ecuador

Lafarge’s operations in Ecuador, Lafarge Cementos SA, are to be sold to Peru’s Unión Andina de Cementos S.A.A. (UNACEM) for an enterprise value of US$553 million. The acquisition comprises a 1.4 million tpa integrated cement plant in Otavalo, in the north of the country.

The purchase is in line with UNACEM’s expansion plans in the region, while synergies with its current cement operations will help to enhance effi ciency. For Lafarge, the divestment will contribute to its target of reducing net debt to less than €9 billion in 2014.

Brazil 6th Brazilian Cement Congress round-up

On 19 – 21 May, some 300 delegates from the Brazilian and international cement industry gathered in São Paulo for the 6th Brazilian Cement Congress (CBC). After a gap of 15 years, the congress returned to deliver a strong technical programme and an engaging exhibition.

The three-day conference programme was opened by Renato José Giusti, Chief Executive of ABCP (Brazilian Portland Cement Association), and José Otávio de Carvalho, Chief Executive of SNIC (National Union of the Cement Industry), both of whom outlined the continuing demand for cement driven by the country’s housing and infrastructure requirements. Although growth is projected at a more modest rate than in previous years, the industry is still investing in capacity expansion to meet consumption needs. Sustainability, energy effi ciency and emissions reduction were prominent points of discussion at the event. ABCP Technology Director, Yushiro Kihara, looked at areas that the Brazilian cement sector could improve on in order to lower its greenhouse gas emissions further, while also highlighting its achievements so far. In 2013, the domestic cement industry coprocessed approximately 1.2 million t of waste, had an impressive biomass utilisation rate and coprocessed enough tyres to go around the world 1.2 times.

Each conference session kicked off with a presentation from a keynote speaker, including the CSI’s Philippe Fonta, CEMBUREAU’s Vagner Mariongolo,

the VDZ’s Martin Schneider, USP Associate Professor John Vanderley, and the PCA’s Cary Cohrs. These speakers provided an insight into some of the principal issues affecting the industry, both in Brazil and elsewhere in the world, from environmental goals and innovations to disaster-resilient buildings.

Technology and service specialists also delivered papers on the latest equipment and process developments. Several speakers discussed recent projects; for example, Densit do Brasil Ltda talked through the results of implementing a new system to optimise grinding for Ciplan Cimento Planalto, IKN outlined a clinker cooler upgrade project for Holcim Brazil’s Cantagalo plant, while Dynamis explained the development process for its new generation of burners.

Academics and cement producers also featured in the conference programme. This included an interesting presentation on carbon nanotubes, currently being researched by the Federal University of Minas Gerias with the support of InterCement, as well as an overview of Votorantim Cimentos’ sustainability initiatives and growth strategy by Edvaldo Araújo Rabelo.

While the conference programme remained well attended throughout the event, participants also had the opportunity to visit the exhibition, which comprised a number of key equipment and service providers.

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July 2014

WORLD NEWS

12\July 2014World Cement

The European Commission has unconditionally cleared Holcim’s planned acquisition of Cemex West, Germany. The purchase forms part of a range of transactions between Holcim and Cemex that will enable them to optimise their portfolio of operations in Europe.

US carbon capture technology company, Skyonic Corporation, has received an additional US$12.5 million in funding from new investor Enbridge and existing investor ConocoPhillips. This will enable it to continue to develop its SkyCycle™ technology towards a commercial level.

AUMUND Fördertechnik acquired BESTA & MEYER’s spare parts services, strengthening its sales and service activities.

Mapei Americas will expand into the US concrete admixtures market with the acquisition of General Resource Technology, Inc.

Holcim New Zealand Limited has received approval to build two new 30 000 t cement import terminals and plans to close the Westport plant once they are operational in 2016.

Africa Lafarge combines Nigerian and South African businesses to form Lafarge Africa Plc

Lafarge plans to consolidate its African portfolio by combining its operations in Nigeria and South Africa. Shares in Lafarge’s Nigerian and South African businesses will be transferred to Lafarge Cement WAPCO Nigeria Plc, which will be renamed Lafarge Africa Plc. This will have a total cement production capacity of 12 million tpa, in addition to fl yash, ready-mix and aggregates operations.

Lafarge Africa will strengthen the Group’s position in the region, enabling it to offer a greater range of products and services to the growing Sub-Saharan market.

Lafarge Africa will continue to be listed on the Nigerian Stock Exchange. The transaction, which is subject to approval by Lafarge WAPCO shareholders and regulatory bodies, is expected to close in 2H14.

Germany Pfeiffer Convention 2014

Gebr. Pfeiffer held its two-yearly Pfeiffer Convention on 8 – 9 May 2014 at Gartenschau Convention Centre in Kaiserslautern, Germany. This year’s event was particularly pertinent for the company as it celebrated a signifi cant milestone: its 150th anniversary.

Gerold Keune, Commercial Director, opened the convention with an overview of Gebr. Pfeiffer’s fascinating 150-year history, followed by Dr Robert Schnatz, who treated delegates to an informative presentation on VRMs in the global cement industry. Dr Schnatz highlighted the increasing market share of VRMs in the sector, noting that mills with more than 6000 kW and split grinding plants are becoming progressively common. Furthermore, in his lecture on new trends in the cement industry, Dr Joe Harder emphasised the surge in global demand, which increased by 6.8% to 3.99 billion t in 2013 and is projected to grow by 4.5% in 2014.

The two-day conference, which was attended by some 200 delegates from countries all over the world, featured a number of presentations, covering a wide range of topics. Bernd Henrich, Patrick Heyd and Eckhard Sander gave lectures on the operation of an MVR mill, solid fuel grinding and grinding/calcining of gypsum, respectively, while Axel Auerbach and Jens Reimers spoke about Pfeiffer’s after sales service and approach to business. In addition, Dr Caroline Woywadt and Sascha Hamm spoke about Pfeiffer projects in Turkey (Limak Cimento) and Australia (Cemengal), and Shree Cement’s H.M. Bangur gave a talk on MVR mills at the company’s RAS, Raipur and Bihar plants in India.

The lectures were punctuated by short breaks, providing an opportunity for delegates to network, share ideas and pose questions to Gebr. Pfeiffer employees. Outside of conference hours, the company put on a range of entertainment including welcome drinks, buffet lunches and a gala dinner at the Fruchthalle in Kaiserslautern. The entire event was incredibly well organised, and enjoyed by all.

Indonesia Holcim inaugurates Tuban 1 line

On 17 June 2014, PT Holcim Indonesia Tbk offi cially commenced cement production from the Tuban 1 line at its Tuban cement plant in East Java. The inauguration ceremony was attended by the cement manufacturer’s customers and distributors, as well as the Board of Directors.

The line will increase the company’s total cement production capacity by 20% to 1.7 million tpa. The Tuban 2 line is scheduled for completion early next year, adding an additional 20% capacity. The Tuban plant will increase Holcim Indonesia’s market share in the region, ensure product supply and greater proximity to customers.

PFEIFFER. SETTING BENCHMARKS. SINCE 1864.

From one man’s idea to the largest mill in the world

When industrialization began in Europe, Jacob Pfeiffer had a vision: the grinding of

mineral raw materials on a large scale. As a family-owned company, inspired by his

energy and enthusiasm, we carry on his idea and have been doing so for 150 years.

And still today, as a technology leader operating worldwide, we continue to set bench-

marks for the industry. Behind all this, lies state-of-the-art engineering work „made

in Germany“ and the special quality of a manufacturer with his own manufacturing

facilities guaranteeing highest durability and reliability. Jacob Pfeiffer would be proud.

www.gpse.de

1864Jacob and Karl Pfeiffer founded the Pfeiffer machine factory and foundry

1890The fi rst air separator in the cement industry

1894The fi rst cement grinding operation in a Pfeiffer mill

1925The largest cement mill in the world

1956The fi rst MPS mills for raw material and coal grinding

1979The fi rst vertical mill for cement grinding

1994Launch of MPS B series with improved performance

2006The fi rst MVR mill for cement grinding

2007The fi rst vertical mill with MultiDrive®

2014The world’s largest vertical mill for cement, under erection

GERGERGE MAN ENNGINGINGINEERINGNGG

SINCE 186866444

YEARS

6856-004 GP JubiläumsAnzeige_RZ_A4_GB.indd 1 24.03.14 11:13WCT_July14-part 1.indb 12 30/06/2014 08:30

PFEIFFER. SETTING BENCHMARKS. SINCE 1864.

From one man’s idea to the largest mill in the world

When industrialization began in Europe, Jacob Pfeiffer had a vision: the grinding of

mineral raw materials on a large scale. As a family-owned company, inspired by his

energy and enthusiasm, we carry on his idea and have been doing so for 150 years.

And still today, as a technology leader operating worldwide, we continue to set bench-

marks for the industry. Behind all this, lies state-of-the-art engineering work „made

in Germany“ and the special quality of a manufacturer with his own manufacturing

facilities guaranteeing highest durability and reliability. Jacob Pfeiffer would be proud.

www.gpse.de

1864Jacob and Karl Pfeiffer founded the Pfeiffer machine factory and foundry

1890The fi rst air separator in the cement industry

1894The fi rst cement grinding operation in a Pfeiffer mill

1925The largest cement mill in the world

1956The fi rst MPS mills for raw material and coal grinding

1979The fi rst vertical mill for cement grinding

1994Launch of MPS B series with improved performance

2006The fi rst MVR mill for cement grinding

2007The fi rst vertical mill with MultiDrive®

2014The world’s largest vertical mill for cement, under erection

GERGERGE MAN ENNGINGINGINEERINGNGG

SINCE 186866444

YEARS

6856-004 GP JubiläumsAnzeige_RZ_A4_GB.indd 1 24.03.14 11:13WCT_July14-part 1.indb 13 30/06/2014 08:30

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IntroductionEarlier this year, Nariman Behravesh of IHS said, “We expect world growth will accelerate slowly, mostly in the developed countries. But as they start to recover, so they will pull along the emerging markets, and they in turn will begin to enjoy export-led growth.” The cement analysts have been at it again with their predictions for growth in the cement industry. Global consumption in 2014, excluding China, could improve 3 – 5%, says IA Cement. Others suggest a growth of 3.9%, while at least one group is suggesting an annual fi gure of 5.3% to give a worldwide sales fi gure of 4.7 billion t by 2017.

The main news now is the Holcim-Lafarge merger. This has implications for their operations in 90 countries. Reuters estimates that the pair may have to sell €5 billion of assets to persuade competition regulators to allow the marriage of the two major players.

Africa Some of the key facts emerging at the World Economic Forum in January were: Africa’s population is projected to grow to 2 billion by 2050; the continent has a US$2 trillion economy with about a third of its 54 countries seeing annual GDP growth of more than 6%; of the top ten fastest growing economies in the world, six are in Africa.

In April of this year, Nigeria finally completed a rebasing of its GDP data to confirm that the continent’s top oil-producing nation had overtaken South Africa to become Africa’s largest economy in terms of its GDP size. One important African business leader who has seen his country’s economy expanding by an average of 7% per annum over the past decade is, of course, Aliko Dangote. Dangote Cement has been the driving force of the country’s cement industry, as you can see across pages 24 to 50.

Once again, Paul Maxwell-Cook introduces this year’s annual World Review with notes and

observations on this essential global industry.

15

GLOBAL VIEWPOINTKeynote


Not all the cement in Nigeria is produced in Dangote’s plants. Lafarge Cement Wapco plc has said it plans to invest an additional €1 billion over the next three to fi ve years on expanding its plants in Calabar and Ashaka. Lafarge is also reported to be looking at investing about US$20 million in the refurbishment of its existing plant in Zimbabwe, increasing production capacity by 20%. Demand for cement is expected to increase in the medium to long-term as a result of an infrastructure backlog of approximately US$14 billion.

The Dangote Group has said it plans to complete ongoing projects in Zambia, Tanzania, South Africa, Republic of Congo and Gabon this year, adding some 13.5 million tpa to the Group’s existing capacity. Also in Zambia, Lafarge is constructing the fi rst cement depot in Chipata district in Eastern province. There is growing demand for cement in East Africa due to rapid infrastructure development. At present, the region imports some 50% of its cement.

A report from Business Monitor International predicts that Ghana will benefi t from signifi cant investment over the next fi ve years as the government increases efforts to address transport, housing and utility shortages. Half of the country’s 25 million inhabitants now live in urban areas and suburban sprawl has subsumed towns near the major cities. CIMAF announced that it will invest €60 million in a 1 million tpa cement plant in Tema.

Bloomberg reports that Saudi billionaire Mohammed al-Amoudi, the biggest investor in Ethiopia, plans to build two more plants in the Horn of Africa. These will add to the existing facility at Derba Midroc. The country’s economy is projected to expand 7.5% this year. The Development Bank of Ethiopia (DBE) has signed a loan agreement with Habesha Cement for US$33 million towards the construction of a 1.4 million tpa plant at Holeta, Oramia state.

In South Africa, Sephaku Cement began operating its Delmas grinding plant in January. PPC is expanding into other areas of Africa, investing US$230 million in building a 1 million tpa plant in the Democratic Republic of Congo (DRC) in partnership with Habesha Cement, and it has plants under construction in Ethiopia, Zimbabwe and Rwanda. Meanwhile in Mali, Ciments de l’Afrique is establishing a 500 000 tpa cement grinding plant that will process imported clinker from Morocco.

In North Africa, revenues from oil and gas resources and energy exports have allowed the government in Algeria to assign US$286 billion for investment in infrastructure over the next fi ve years. Demand for cement is particularly high, currently running at 21 million tpa against a domestic production fi gure of about 18 million t. The defi cit has

to be imported. The Minister of Industrial Development and National Production, Amara Benyounes, is quoted as saying that cement imports will cease by 2017. New plants are planned for the northern province of Relizane and the southern provinces of Bechar, Adrar and Tamanrasset. Work is due to begin shortly on a new 2.2 million tpa cement plant in the region of Maghra (M’sila). Algerian private company Hodna Cement and its South African partner PPC have signed an investment agreement for the project, which is expected to be completed in June 2016.

For the past three years, economic growth in Egypt averaged 2% pa, infl ation was in double digits and the unemployment rate went from 9% in 2010 to over 13% in 2013. Online media reports suggest that the main reason for the economic disarray is the failure of previous governments to develop an economic plan. The administration that gained power in August 2013 has committed itself to tackling the energy and input shortages that have seriously constrained industrial production. Last year, as the country faced a fuel crisis, some plants saw a drop of almost 20% in production. The alternative is for cement plants to switch to coal, but this comes up against the minister for environmental affairs and NGOs who support ‘Egyptians Against Coal’. As this debate continues, the Suez Cement Group (Italcementi) inaugurated its fi rst waste treatment plant in February 2014. The project uses 45 000 tpa of household waste to produce 35 000 tpa of alternative fuel.

Market conditions in Morocco are poor. Holcim’s Dominique Drouet is reported as saying that there was a 12% drop in activity in the cement industry at the end of December 2013 and the decline is expected to continue this year. Ciments du Maroc, however, plans to open a new plant in Tetouan, while Lafarge Ciments is pursuing a project to install a new plant in Taroudant. The Awka Group plans to open its fi rst facility in Sidi Bibi near Agadir, but Ynna Asment has delayed opening its fi rst plant.

Middle East In February, a report by Gulf Investment House commented that the uptrend in cement demand in the region is supported by forthcoming major events, such as the 2022 FIFA World Cup in Qatar and the World Expo in 2020. Demand remains high for affordable housing. Saudi Arabia is expected to require some 150 000 units every year to meet its housing shortage. Global Research mentions that the Kingdom continues to enjoy hefty cement demand due to the large numbers of major projects recently announced by developers.

World Cement 2014 World Review16

GLOBAL VIEWPOINTKeynote


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