Gypsum industry news

Securing sustainable energy sources has been the priority for some of Spain’s gypsum wallboard producers in recent weeks.

In late November 2023 Pladur revealed that it plans to use green hydrogen at its production plants from the second half of 2024 onwards. It will start at its Valdemoro plant near Madrid before rolling usage out elsewhere afterwards. The subsidiary of Belgium-based Etex is also considering trials with biomethane and biogas. Then a few weeks later in early December 2023 Knauf Ibérica announced that it is planning to build a 7.5MW biomass unit at its Guixers plant in Lleida. Commissioning is currently scheduled for late 2024. This follows the installation of solar panels at the site earlier in 2023. Along similar lines, Saint-Gobain Placo signed an 11-year power purchase agreement (PPA) with electricity company Endesa at the end of 2022 to supply 150GWh/yr of renewable energy. Together with a previous renewable energy deal this was expected to cover up to 65% of the group’s electricity requirements in Spain.

Wallboard plants all over the world have been embarking on sustainable energy drives in recent years but the particular drivers in Spain are worth mentioning. The country’s high electricity prices have frequently been raised by large-scale industrial users in the past, often in terms of competitiveness of exports. However, the situation worsened following the start of the war in Ukraine in early 2022 as the wholesale price of coal and gas jumped. The high price of gas in particular pushed the electricity prices up in Spain and wallboard plants typically use both sources of energy. The government eventually capped the price of gas and coal for power generation. It then offered an aid scheme for large-scale gas users but missed the gypsum sector out, much to the chagrin of the Asociación Técnica y Empresarial del Yeso (ATEDY), which complained about it at the end of 2022. The gypsum industry was later included in July 2023 when a funding scheme was announced. It’s unknown how much this initiative has helped wallboard manufacturers but the shift to renewables by the three main companies mentioned above tells its own story.

Despite the energy supply problems a new entrant to the wallboard market in Spain announced itself in March 2023. Italy-based Fassa Bortolo said it was going to spend Euro90m on building a wallboard plant at Tarancón in Cuenca. No commissioning date or main supplier name has been disclosed, but Italy-based Bedeschi did say in late November 2023 that it was providing raw bulk material handling equipment including an apron feeder, stacker, excavator and conveyor belt line. There has also been no word on how the new plant will power itself.

On the topic of exports, Spain has long been one of the world’s larger shippers of natural gypsum. Data from the Geological and Mining Institute of Spain (IGME) shows that the country exported 9.2Mt of gypsum in 2021 with a value of Euro60m. Whether this changed in 2022 when the energy prices increased is unknown at the time of writing. In 2021 Almería was the epicentre of the country, accounting for 70% of the 13Mt total volume of gypsum extracted that year with a quarry at Sorbas, operated by Saint-Gobain Placo, reportedly being the second largest in the world. Most of the gypsum extracted at Sorbas was then driven by truck to the Port of Garrucha, making it the busiest gypsum port in Europe by volume.

Eurogypsum, the European federation of national associations of producers of gypsum products, launched its industry roadmap to net-zero by 2050 on 9 November 2023 at the Global Gypsum Conference 2023, which took place in Chicago, US. Various actions and technologies were unveiled as part of the plan including some of the approaches being taken in Spain such as using ‘green’ electricity, biomass and green hydrogen. All of these suggestions were split into short, mid and final term feasibility categories. So, for example, using renewable sourced electricity is dependent on it being affordable and available. It was placed in the immediate category. Yet, using biofuels or green hydrogen is flagged as requiring investment, so deemed as short-to-mid term.

Spain presents a case where the cost of energy for industrial users may be aligning with sustainability goals. How this translates onto balance sheets remains to be seen though. These kinds of sustainable energy projects may only be slowing the inevitable as raw material and energy costs mount anyway leading to tighter margins, increased competition and potential consolidation. The gypsum sector in Spain may well be testing out slightly earlier than elsewhere how much a more sustainable world will actually cost.

Oman: Oman exported 8.75Mt of gypsum in the first nine months of 2023, a rise of 23% year-on-year from 7.09Mt in the same period in 2022. Data from Oman-based Zawawi Minerals shows that 48% of exports were sent to India.

Oman: Producers and exporters despatched 9.9Mt of gypsum from Oman in 2022. The figure corresponds to year-on-year growth of 13% from 8.74Mt in 2021. The Oman Daily Observer newspaper has reported that India received 4.84Mt (49%) of Omani gypsum exports during the year. This accounts for 87% of the South Asian nation's total gypsum imports, of 5.54Mt, in 2022. The total figure shows a compound annual growth rate (CAGR) of 17% between 2009 and 2022. The market's forecast CAGR up to 2037 is 5.2%.

The Indian cement industry, which reportedly relies on the dwindling domestic stock of phosphogypsum, is anticipated an anticipated source of continued growth in demand.

US: The US gypsum wallboard industry produced 623Mm² of gypsum wallboard during the first quarter of 2023, down by 1% year-on-year and by 1.2% quarter-on-quarter. The industry exported 20.1Mm² of gypsum wallboard in the quarter under review, corresponding to 19% year-on-year growth. Canada received 19Mm² of the product, 94% of total exports for the quarter.

United States Geological Survey (USGS) data show 4% year-on-year growth in US gypsum wallboard imports. The country imported 23Mm² during the year, 20.9Mm² (91%) of it from Mexico and 1.84Mm² (8%) from Canada. Total calcined gypsum consumption was 4.66Mt in the US in the first quarter of 2023, up by 9.9% year-on-year from 4.24Mt in the first quarter of 2022.

Canada: USG Corporation subsidiary Canadian Gypsum Company (CGC) plants to restart operations at its 2Mt/yr-capacity Little Narrows gypsum quarry in Nova Scotia. Construction Canada News has reported that the company expects the commissioning to take until early-mid 2026. Work includes the construction of a new crusher and conveyor systems, as well as a dock and ship loader, and the purchase of new mining equipment, including drills, loaders, excavators and haul trucks. When operational, the quarry will ship gypsum to markets along the east coast of North America, including Montréal, Québec.

USG Corporation CEO Chris Griffin said “This investment will cement our long-term commitment to the Canadian market and our dedication to providing the best experience for our customers across North America. CGC has a proud history of operations at the Little Narrows gypsum quarry, which was active from 1954 to 2016. We are deeply connected to Little Narrows and Cape Breton, and thrilled to return to drive economic growth and support the local community as a neighbour and partner.”

Philippines: Knauf Gypsum Philippines has petitioned the Philippines Tariff Commission to reduce the import duty on imports of Omani gypsum to 0% of value. Currently, Oman’s gypsum enjoys a most favoured nation (MFN) reduced tariff rate of 3%. The Oman Daily Observer newspaper has reported that high gypsum wallboard demand has created short supply of gypsum in the Philippines, according to Knauf Gypsum Philippines. Beside the company’s wallboard operations, the raw material is also critical to cement production in the country.

The Philippines receives a minor share of Oman’s 8.74Mt/yr of natural gypsum exports. The Southeast Asian country has a housing backlog of 6m units.

Tanzania: Knauf Gypsum Tanzania says that it plans to more than double the production capacity of its 15Mm²/yr gypsum wallboard plant in Mkuranga, Pwani Region, to 43Mm²/yr. IPP Media News has reported that the company's planned investment in the project as US$49.3m. The producer expects that the expanded Mkuranga gypsum wallboard plant will increase its annual gypsum wallboard exports by 170%. When commissioned in 2025, the plant will be the largest in East and Sub-Saharan Africa.

US: Gypsum wallboard companies sold 629Mm² of gypsum wallboard in the first quarter of 2022, in line with first-quarter 2021 sales, according to US Geological Survey (USGS) figures. They exported 16.9Mm², up by 6% year-on-year from first-quarter 2021 volumes. Canada received 15Mm², 94% of exports. The US Census Bureau recorded gypsum wallboard imports of 22.2Mm², up by 28% year-on-year. Mexico supplied 19.1Mm² (86%), while Canada supplied 2.89Mm² (13%).

In the first quarter of 2022, national natural gypsum production was 5.33Mt, up by 2.1% year-on-year from 5.22Mt in the first quarter of 2021.

Oman: A geological survey undertaken by Minerals Development Oman (MDO) in Shaleem has uncovered ‘large’ local gypsum reserves. The Muscat Daily newspaper has reported that MDO CEO Nasser al Maqbali said that the reserves would contribute to the continued steady growth of Omani crude gypsum’s stake in the global gypsum market. Maqbali added that the resource is characterised by high purity, competitive prices and proximity to consumer markets.

MDO previously discovered 15Mt-worth of gypsum reserves in Wadi Al Jizi, from which it will supply 1Mt/yr of gypsum to the local steel industry. Uses of limestone in the steel sector include flue gas desulphurisation (FGD), which produces synthetic gypsum.

US: The United States Geological Survey (USGS) reports that total gypsum board product sales grew by 4% year-on-year to 2.54Bnm² in 2021 from 2.43Bnm² in 2020. 22.4Mt of gypsum was mined in 2021, a 1% rise from 21. Synthetic gypsum supply decreased by 10% to 13Mt from 14.4Mt. Imports declined by 11% to 25,700t from 29,000t but exports grew by 11% to 98,800t from 89,300t.