ETHIOPIA: Ethiopia's Biggest Cement Plant to Start Output This Month

Derba MIDROC Cement Plc, Ethiopia’s biggest cement factory, said it will start production within the “next 10 days,” helping end a shortage of the building material in Africa’s fourth-largest economy.

The $351 million plant, about 70 kilometers (44 miles) northwest of the capital, Addis Ababa, will produce 8,000 metric tons of the building material daily by February, said Chief Executive Officer Haile Assegide. Derba is part of the MIDROC Ethiopia group owned by Mohammed al-Amoudi, an Ethiopian-born Saudi Arabian billionaire who is one of the biggest investors in the Horn of Africa nation.

Once output begins, Ethiopia “will be self-sufficient for the coming two to three years” in cement, Haile said in an interview at the site on Dec. 1.

Ethiopia, a net importer of cement, plans to boost output ten-fold by mid-2015 to 27 million tons, according to the government. The Derba plant will add 2.5 million tons per year, while expansions to Mesobo Building Materials Production Plc, owned by the country’s ruling party, and state-owned Mugher Cement Enterprise will add another 1 million, it said.

Dangote Cement Plc, Nigeria’s biggest company by market value, said in October it plans to invest $400 million in an Ethiopian factory with the capacity to produce 1.5 million tons per year.

Derba Cement, built by China National Building Material Co., may earn more than 2 billion birr ($115.9 million) annually, Project Manager Tadesse Kebede said in an interview at the site. “If everything goes well it will be a cash cow,” he said.

Loans

Al-Amoudi’s company invested $100 million in the operation, with the European Investment Bank, the African Development Bank, the International Finance Corp. and the Development Bank of Ethiopia providing the rest of the funds.

The project was delayed for “almost one year” because obtaining the loans took longer than expected, Tadesse said. “To work with multilateral banks is very difficult,” he said.

The factory, which took 3 1/2 years to complete, will require as much as 60 megawatts of electricity from the national grid, Haile said. The company paid for transmission lines and a sub-station to power the plant, according to Haile.

AFRICA: NIGERIA: Dangote provides 70% of Nigeria ’s cement as producers target 20million MT by 2012

With the addition of six million metric tons (MT) of cement to be generated from the new Ibese Cement Plant in Ogun State , the Dangote Group is expected to provide 70% of the total target of 20 million metric tons from all cement producing companies in Nigeria.

Aliko Dangote, President of Dangote Group, while conducting the Ogun State governor, Ibikunle Amosun round the six million tons per annum capacity facility, said the Ibese new cement plant is expected to provide over 7,000 jobs.

“The national consumption hovers around 18 million tons per annum and by the first quarter of next year, all the cement companies in the country would have been producing up to 20million tons per annum, with the Dangote Cement accounting for over 70 per cent of it,” Dangote noted.

Dangote said the opportunities would come both through direct and indirect jobs, while also promising to continue to lead other investors to ensure Nigeria becomes an industrial giant nation that is self-sufficient in production, rather than being a leader in importation.

He assured that with his Group’s massive investments in cement production would enable Nigerians enjoy reduced prices, while the nation would become exporter of the commodity to other countries.

Business Day gathered that the firm’s expansion project in Obajana, Kogi State , and the construction of Ibese Cement Plant would inject about 17 million tons into the market annually. The company has already commenced the construction of some facilities to actualise the export dream.

But by first quarter of 2012, with expansion projects going on in both Dangote Group and Lafarge, which are major cement manufacturers in the country, production is expected to reach 20 metric tones.

He further observed that his continuous investment in Nigeria and the rest of Africa was borne out of the fact that the country was a fertile ground for investment and that no one outside Africa would be genuinely determined to develop Africa except Africans themselves.

He explained the efforts put into the multi- million dollar plant as worthy when perceived from the standpoint of the fact that there is the need for job and wealth creation in the country adding that these two critical necessities could only be achieved through manufacturing.

The Dangote President pledged that he would look into other areas where the group could further create jobs and wealth for the citizenry and that agriculture holds the ace. He further stated that he has invested in some other areas in agriculture like fertiliser, to help the farmers and to provide jobs, while striving to create an industrial giant nation through investments in manufacturing.

He appealed to the Ogun State government to help in the provision of security for the investments, saying though the host community of Ibese and others have been very cooperative, government should help in putting in place security arrangements for the business to thrive.

Joseph Makoju, Chairman of the Cement Manufacturers Association of Nigeria had earlier told Business Day that the manufacturers do not expect less that 60% performance from most of the new plants in 2012. “Investments in the industry are ongoing and if the government continues with the strict implementation of the backward integration policy, our expectation is that more new entrants will come into the business of cement manufacturing and the present tempo of growth in the cement industry will be sustained”.

CHINA: Conch Cement Ups Stake In Jidong Cement

Anhui Conch Cement (600585,0914.HK) upped its stake in Tangshan Jidong Cement (000401) during the September-December period, purchasing a total of 60.69 million shares, or five percent of the latter's total equity, reports China Securities Journal, citing a company filing.

Through December 7, Conch Cement held a a total of 183 million shares, or a 15.05 percent stake, in Jidong Cement.

Conch Cement had purchased 9.34 million shares in September at prices ranging from between 14.88 yuan and 16.5 yuan per share, before acquiring another 13.35 million shares in October at 15.26 -16.5 yuan per share.

Conch Cement bought 17.95 million shares at 15-16.51 yuan per share in November, and bought 5.1 million shares at between 15 yuan and 15.9 yuan per share during the first five trading sessions in December.

Conch Cement had previously acquired shares of Jidong Cement in August 2008 and April 2010.

According to Anhui Conch Cement, the stake purchases were a commercial decision, and whether it will further up its stake in Jidong Cement in future will depend on the company's future development and the level of its share price.

Separately, Conch Cement had purchased equity stakes in Gansu Qilianshan Cement Group (600720), Fujian Cement(600802), Henan Tongli Cement (000885), Huaxin Cement (600801,900933) and Jiangxi Wannianqing Cement (000789) in 2008.

PAKISTAN: Cement industry may be allowed to use 'tyre-derived fuel'

The government is likely to allow the cement industry to use 'Tyre Derived Fuel' (TDF), which is a mix of about 80-88 percent carbon and oxygen, official sources told Business Recorder.

Pakistan has 29 cement plants with total installed capacity of 44 million tons. The shortage of natural gas and increasing cost of oil and coal has adversely affected cement production in the country.

The cement entrepreneurs are exploring different venues to supplement their fuel requirement for bringing down their cost of production. One of the options for them is to use certain percentage of old tyres, in shredded form, as fuel, as being practised in other countries. A number of cement units have approached the federal and provincial environmental protection agencies for issuance of consent under local, national and international obligations for import, processing and use of TDF.

Sources said that the objective of these guidelines is how to use TDF as supplementary fuel in cement manufacturing and prescribed procedures for monitoring of emissions.

These guidelines are reference document for using TDF in cement industry whether imported or local and owned by public or private sectors. These guidelines provide the minimum requirements that a cement industry should meet.

The following definitions shall be based in these guidelines, unless there is anything repugnant in subject context or contrary to the Pakistan Environmental Protection Act, 1997, rules, regulation and standards made thereunder.

A) "Authorised officer" means an officer authorised by the Federal or Provincial Government for the purposes of these Guidelines.

b) "certified laboratory" means any laboratory certified under the National Environmental Quality Standards (Certification of Environmental Laboratories) Regulations, 2000.

c) "consignment" means a batch of TDF procured under a purchase order;

d) DNA means 'designated national authority'.

e) "pollution control device" means a device installed at cement kiln to filter or remove particulate matter and 'other emissions' which may include electrostatic precipitator or a bag-house filter.

f) "storage area" means a site where TDF is accumulated within a structure that is not completely enclosed; and which comply with guidelines and relevant local/national laws.

g) 'TDF'means a fuel that is derived from end of life scrap tyres by completely shredding/cutting them into pieces for use as supplemental fuel.

The import in the country is governed by the Import Policy as announced by the Federal Government from time to time and 'the international conventions and protocols to which Pakistan is a party'.

No cement unit is allowed to import, or use, TDF without obtaining consent from the concerned Environmental Protection Agency (EPA) and the Designated National Authority (DNA) of the related international convention/protocol. The following criteria and standards will apply to award consent to the cement unit desirous to import or use TDF in the country:

A clean TDF is composed of about 80-88 percent of carbon and oxygen, which accounts for its rapid combustion and relatively high heating value in the range of 7000-8000 kcal/kg. Cement unit will procure clean, properly sized (2 inches), high-energy-content tyre derived fuel as far as possible. Each consignment of TDF will be accompanied by a certificate from DNA of the exporting country, verifying that the consignment of TDF does not contain or is contaminated with hazardous substances or wastes as defined in Annexure IX of the Basel Convention. The procedures laid down in the Basel Convention will be followed in the import of TDF. The Authorised Officer of EPA will check quality of TDF as and when deems necessary.

The transportation and storage arrangements for TDF will be done in accordance with the Environment Management Plan. In addition, the cement industry should modify its fire fighting plan and procedure to include and respond to the potential fire risks and hazards associated with transportation storage, and usage of TDF. Special attention should be given to the fire protection measures on the feeding end of the cement kiln.

Normally, a cement unit utilises 15-30 percent TDF of the total heat input. The exact maximum quantity shall be determined after carrying out emission tests at individual unit through third party under supervision of concerned EPA. No cement unit will be allowed to use TDF quantity beyond the limit set out. However, cement units can be allowed to use a greater proportion of TDF provided they improve performance of pollution control system and after re-checking emission levels by concerned EPA.

Each cement factory will get its feeding system and pollution control technologies/equipment inspected before the use of TDF as fuel. For this purpose, a joint team comprising of the representatives of DNA and concerned EPA, within 15 working days from the receipt of inspection request, will assess the facilities of the cement unit and will witness the test trial of use of TDF.

Uncontrolled and disproportionate feeding of TDF could lead to toxic emission of gases from kiln stack. There is need to properly install automatic TDF feeding/weighing system and maintain record. In case of higher concentrations than the emission limits mentioned in the Guidelines are observed due to tripping or malfunctioning of pollution control device of the kiln, the TDF feeding system should automatically stop immediately.

Two operating conditions viz, operating temperature and retention time, are of utmost importance for avoiding production of dioxin and furan. Operating temperature in cement kiln, which is over 1550°C, and retention time of 3 to 6 seconds in above 1200°C, is well suited for the safe and efficient consumption of TDF.

The level of emissions from any furnace / kiln is highly dependent on the way it is operated and process is controlled. In general, emissions are likely to increase when operated in unstable conditions. Emissions being released from the burning of TDF in uncontrolled and controlled conditions are different. In the former case, TDF burning, especially at low temperatures, causes generation of highly toxic gases and compounds like Poly-aromatic hydrocarbons, dioxin/furan, hydrogen chloride, benzene, polychlorinated biphenyls (PCBs). Metals such as arsenic, cadmium, nickel, zinc, mercury, chromium, and vanadium are also emitted. Exposure to emissions from tyre burning in uncontrolled conditions could cause irritation of skin, eyes, and, mucous membrane, central nervous system, depression, respiratory disorders and cancer.

In Pakistan, almost all cement units are equipped with some kind of anti-pollution devices to control emission of gases and particulate matter. The majority of the cement units are fitted with electrostatic precipitators (EPs). Some units frequently come across tripping or breakdown of Eps, causing "excessive emission of kiln flue gases and particles. Under this condition, use of TDF as fuel would allow free emission of toxic gases. Much emphasis, therefore, should be given on performance of pollution control devices while using TDF as fuel. Besides, electrostatic precipitators, scrubbers should be used where required to clean out hazardous gases--Benzene, Polycyclic Aromatic Hydrocarbons (PAHs) or Ploy Chlorinate Biphenyl (PCB). All anti-pollution devices should be kept in good operating condition.

It is desirable that cement industry using TDF should have in-house capacity for measuring levels of conventional pollutants like PM, CO, NOx, SO2, THC using reliable emission analysers. The staff should be trained to independently check emission of heavy metals as prescribed in the above standards. In absence of the facility, the services of EPAs or approved/laboratories certified under Certification of Environmental Laboratories Regulations 2000 should be acquired for monitoring the emission, including heavy metals.

Every cement unit burning TDF will be registered under self-monitoring and reporting tool (SMART) with concerned EPA. Cement industry will monitor the level of PM, CO, NOx, SO2 and THC using own reliable online emission analysers and maintain record and also report the same to the concerned EPA in accordance with the frequency mention in the table under heading "emission limits".

Cement industry will also include the following information and report to the concerned EPA on monthly basis; (i) quantity of TDF imported; (ii) quantity of TDF used; (iii) quantity of local TDF used[ and (iii) amount of coal/fuel used.

Cement industry desiring utilidation of TDF will prepare a detailed EMP and submit to the concerned EPA. The EMP will be prepared considering these Guidelines as well as the obligations under the prevailing environmental laws.

The management may invite public representatives and duly brief them about their plan for using TDF. The community should be educated on the pollution control measures while using TDF

CUBA: Cementos Cienfuegos SA: Eficiencia sin daños al medio Ambiente

Unas 15 mil toneladas de Dióxido de Carbono (CO2), ha dejado de emitir a la atmósfera durante el 2011 la Empresa Cementos CienfuegosSA, la cifra representa además, el ahorro de 468 mil pesos convertibles al país por el uso adecuado de portadores energéticos y una mayor eficacia operacional.

Durante la etapa que cierra, la empresa líder en la fabricación de cemento enCuba, ratificó su estabilidad en el mejoramiento continuo de la eficiencia y calidad ambiental, al consumir un uno por ciento menos de energía eléctrica y de combustible pet coke, en comparación con el 2010. Resultados que se derivan del acomodamiento de las cargas y también de la automatización y optimización del proceso productivo.

“Con la reducción del consumo de energía eléctrica durante el 2011 se dejaron de emitir a la atmósfera 360 toneladas de Dióxido de carbono y se ahorraron al país, por esta vía unos 68 mil CUC. Asimismo con la eficiencia en las operaciones productivas dejamos de utilizar 4000 toneladas de combustible pet coke, evitando la emisión de 14 666 toneladas de Dióxido de carbono a la atmósfera y ahorrando 400 mil CUC,” comentó Leonardo Cabrera, Gerente de Planta.

La instalación de 90 filtros, es otra de las acciones realizadas también por la empresa a favor del medio ambiente: “Estos sistemas tienen una elevada efectividad y devuelven al ciclo productivo el 25 por ciento de la materia prima, además de que permiten la emisión de un aire mucho más limpio a la atmósfera”, explicó José Luis Romero, Especialista en Medioambiente de la entidad cienfueguera.

Contribución por varios años de Cementos Cienfuegos SA en la reducción de emisiones de gases de efecto invernadero, una de las demandas del protocolo de Kyoto, cuya posible ratificación permanece aún en suspenso en la cumbre de Durban.