Rumeli Cement Group Plants
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Rumeli Cement Group Plants
Rumeli Cement Group Plants Preliminary Information September 2004 The present document has been prepared by Rumeli Group, Ernst & Young and Garanti Securities in good faith for information purposes only, but without assuming a duty of care and any other liability. Rumeli Group, Ernst & Young and Garanti Securities or their employees, officers, directors, advisors or counsels give no warranty or representation as to the accuracy and completeness of the information herein contained and shall not be liable for any errors or omissions. The recipients of this document shall make and rely on their own analysis and decisions in taking or no taking any action in connection with this document and a possible transaction. This document shall in no event, imply or otherwise, be deemed, or interpreted as an offer to sell. Rumeli Cement Group plants’ management and control was taken over by Savings Deposit Insurance Fund as of February 2004 Rumeli Group Plants ♦ Lalapasa ♦ Bartin ♦ Ladik ♦ Trabzon ♦ Eskisehir • Lalahan ♦ Van ♦ Ergani ♦Gaziantep ♦Sanliurfa ♦Cement Plant •Grinding Station 3 Cement Plants in Turkey ♦ Lalapasa ♦Pinarhisar ♦Akcansa Bcekmece •Marmara •Ambarlõ Akcansa Canakkale ♦ ♦ Bursa ♦ Balikesir ♦ Bolu •Istaş ♦ Eskisehir ♦ Afyon •YL Samsun ♦ Unye ♦ YL Çorum ♦ Ankara • YL Hasanoğlan ! Lalahan ♦ Askale ♦ YL Sivas • YL Nevsehir ♦ Konya ♦ Goltaş • Ozgur ♦ Kars ♦ Trabzon ♦ YL Yozgat ♦ Bastas ♦ Elazig • Cim Kayseri ♦Denizli ♦Batõsoke ♦ Ladik ♦Aytek • Eregli • Karcimsa ♦Nuh • Bakircay ♦Baticim ♦ Cimentas ♦ Bartõn • İkon ♦Aslan ♦ Adiyaman ♦ Van ♦ Ergani ♦ Kurtalan ♦OYSA Nigde • Ado ♦Cimsa ♦ Adana ♦Gaziantep ♦Sanlõurfa ♦ Mardin ♦OYSA İskenderun ♦ Cement Plant • Grinding Station 4 Capacities* ♦ RUMELI 4,009/7,812 ♦ SABANCI 5,850/9,841 ♦ ITALCEMENTI 2,100/2,800 Afyon Gaziantep 495/1,089 Cimsa Ergani 578/1,162 Cim. Kayseri Lalapasa 578/1,162 Akcansa B.C. 1,850/2,700 Balikesir+P.hisar+ Ambarli+Marmara Sanliurfa 578/581 Akcansa C. 1,900/3,500 Trabzon 356/523 Karcimsa Van 214/559 ♦ LAFARGE Barin 221/376 Ladik Eskisehir Lalahan Nuh 2,100/3,750 1,033/2,700 Denizli 1,815/2,318 ♦ OYAK 5,705/9,514 Goltas 1,320/2,924 Adana 2,260/4,094 Askale 450/600 1,251/2,880 Unye 1,485/1,800 Adiyaman 627/990 Aslan 1,251/2,700 Bolu 1,320/2,600 Kurtalan 644/972 578/1,162 Eregli 0/180 495/1,016 ♦ YLOAC 0/241 1,705/3,597 Ankara 640/1,020 Ikon 0/350 ♦ OYAK SABANCI 415/1,860 Ado 0/240 415/1,200 Ozgur 0/180 Istas 0/250 Aytek 0/288 535/735 OYSA Nigde ♦ CIMENTAS 1,850/3,014 Yozgat 750/798 OYSA Iskenderun Cimentas 1,520/2,500 Samsun 330/475 0/39 2,250/3,744 420/615 Konya 1,500/2,064 Hasanoglan 0/500 Bastas 750/1,680 0/500 Sivas 2,196/2,994 Nevsehir Baticim 1,400/1,800 ♦ OYAK/GAMA 301/953 Elazig 301/953 796/1,194 0/660 ♦ VICAT 0/449 ♦ BATICIM Batõsoke 870/1,510 Mardin Corum Bakircay 8,306/15,762 1,350/2,900 0/600 470/640 ♦ INDEPENDENT Bursa 0/182 Kars 2,373/4,859 5 TOTAL 33,363/66,794 *1,000 tonnes clinker/cement Bartin " Bartin plant was founded in 1962 and privatised in 1993. " Clinker capacity is 220,968 tonnes/year. " Cement capacity is 377,520 tonnes/year. " The plant is located on an open area of 756,022 m2 and covered area of 145,107 m2. " Number of personnel (including operating companies) is 203, of which 49 are white collar and 154 are blue collar. " Distance to Bartin port is 10 km and distance to E5 highway is 180 km. " Distance to Kokaksu train station is 40 km. " The plant’s proximity to an iron and steel producer is an advantage in the supply of slag. 6 Bartin " Type of cement produced is KC 32.5. " The plant operates with wet process. " Grinding mills consist of 2 KRUPP (2x14 tonnes/hr) and 1 F LILLE (24 tonnes/hr). " Bartõn plant’s share in Black Sea Region cement capacity is 5%. " In 2003 Bartõn plant produced 208,000 tonnes of cement (2002: 170,479) " 1H04 cement sales was 66,177 tonnes (1H03: 63,497). " The plant has ISO 9001:2000 certificate. Licenses Furnace Type Marl Marl Limestone Trass Area (m2) Reserves (tonnes) Type of License Termination date 15,000 400,000 Stone quarry 31/12/2004 100,188 3,000,000 Stone quarry 02/05/2006 68,500 3,425,000 Mine 15/03/2005 20,000 900,000 Stone quarry 01/09/2004 7 Owner of property Forest/Rent Plant Forest/Rent Forest/Rent Ladik " Ladik plant was founded in 1983 and privatised in 1993. " Clinker capacity is 577,500 tonnes/year. " Cement capacity is 1,161,600 tonnes/year. " The plant is located on an open area of 482,248 m2 and covered area of 25,941 m2. " Premises of Merkez Kagit Torba are located in the land. " Number of personnel (including operating companies) is 237, 51 of which are white collar, 186 of which are blue collar. " Distance to Samsun port is 100 km and distance to highway is 13 km. " Distance to Toptepe train station is 13 km. 8 Ladik " Type of cement produced is PCC/B-32.5 and PCC/A-42.5. " Clinker technology used is dry process. " Grinding mills consist of 2 FLS (80 tonnes/hr). " Ladik plant’s share in Black Sea Region cement capacity is 14%. " In 2003 Ladik plant produced 372,710 tonnes of cement (2002: 435,580) " 1H04 cement sales was 208,053 tonnes (1H03: 166,362). " The plant has ISO 9001:2000 certificate. Licenses Furnace Type Limestone-1 Limestone-2 Clay Area (m2) Reserves (tonnes) Type of License Termination date 2,470,000 61,937,500 Mine 29/05/2011 2,500,000 62,000,000 Mine 10/07/2012 365,565 6,000,000 Mine 04/09/2012 9 Owner of property Treasury Treasury Plant Trabzon " Trabzon plant was founded in 1967 and sold to Rumeli group in 1992 through privatisation. " Clinker capacity is 356,400 tonnes/year. " Cement capacity is 522,720 tonnes/year. " The plant is located on an open area of 79,212 m2 and covered area of 15,129 m2. " Number of personnel (including operating companies) is 184, 34 of which are white collar, 150 of which are blue collar. " Distance to Trabzon port is 1 km and distance to state highway is 100m. " Raw material furnace is at a distance of 30km. " The plant is located inside the city. " The plant’s raw material quarries are operated by subcontractor. 10 Trabzon " Type of cement produced is CC-32.5. " Clinker technology used is dry process. " Grinding mills consist of 1 HUMBOLD (55 tonnes/hr), 1 KRUPP (17 tonnes/hr). " Trabzon plant’s share in Black Sea Region cement capacity is 6%. " In 2003 Ladik plant produced 179,804 tonnes of cement (2002: 241,358) " 1H04 cement sales was 134,932 tonnes (1H03: 105,088). " The plant has ISO 9001:2000 certificate. Licenses Furnace Type Limestone Marl Area (m2) Reserves (tonnes) Type of License Termination date 338,400 8,870,708 Mine 15/01/2012 27,600 1,922,500 Stone quarry 17/04/2005 11 Owner of property Plant Plant Black Sea Cement Market Local Producers PLANT GROUP LOCATION TYPE CAPACITY ('000 Tonnes) Clinker Cement - 180 221 378 Lafarge Eregli Lafarge+Aslan+Aurelius Eregli Grinding Bartin Rumeli Bartin Integrated Bolu Cimento Oyak Bolu Integrated 1,320 2,600 Corum Yibitas+Lafarge Corum Integrated 535 735 Ladik Rumeli Ladik Integrated 578 1,162 Samsun YLOAC Samsun Samsun - 450 Unye Cimento Oyak Unye Integrated 1,485 1,800 Trabzon Rumeli Trabzon Integrated 356 523 Aytek Independent Kocaeli Grinding - 288 Karcimsa Sabanci Karabuk Grinding - 241 Grinding 12 Black Sea Cement Market " The Black Sea Region has a 12% share in clinker capacity, 12% in cement capacity and 14% in cement consumption. " The region accounts for 13% of the total population and contributes 9% to Turkey’s GNP. " " " Cement Capacity by Group Lafarge-Yibitas 16% Three groups are active in the region, namely Oyak, Rumeli and YLOAC (Yibitas Lafarge). Oyak is the market leader with a 53% share. Production at Rumeli plants fell sharply after 1997 at the gain of Oyak companies. Other 3% Oyak 53% Rumeli 25% Sabanci 3% Rumeli is the second largest producer in the region with 25% share in cement capacity. 13 Lalapasa " Lalapasa plant was founded in 1991 and sold to Rumeli group in 1996 through privatisation. " Clinker capacity is 577,500 tonnes/year. " Cement capacity is 1,161,600 tonnes/year. " The plant is located on an open area of 571,313 m2 and covered area of 39,868 m2. " Number of personnel (including operating companies) is 173, 55 of which are white collar, 118 of which are blue collar. " Distance to Tekirdag port is 157 km, to TEM highway 20 km and Edirne train station 25 km. 14 Lalapasa " Type of cement produced is PCC/A-32.5R, PCC/B-32.5R and PC-42.5. " Clinker technology used is dry process. " Grinding stations consist of 2 FLS (80 tonnes/hr). " Lalapasa plant’s share in Marmara Region cement capacity is 6%. " Possibility to export to neighboring countries Greece and Bugaria. " In 2003 Lalapasa plant produced 356,170 tonnes of cement (2002: 415,015) " 1H04 cement sales was 227,079 tonnes (1H03: 114,288). " The plant has ISO 9001:2000 certificate. Licenses Furnace Type Limestone Clay Area (m2) Reserves (tonnes) Type of License Termination date 1,402,300 20,700,000 Mine 06/04/2009 9,950 167,160 Stone quarry 18/05/2005 15 Owner of property Treasury Plant Marmara Region Cement Market Local Producers PLANT GROUP LOCATION TYPE Lalapasa Set (Trakya) Akcansa Set (Ambarli) Aslan Cimento Ikon Nuh Cimento Set (Balikesir) Bursa Cimento Set (Marmara) Rumeli Set+Italcementi Sabanci Holding+CBR Set+Italcementi Lafarge Independent Independent Set+Italcementi Independent Set+Italcementi Edirne Pinarhisar Canakkale and Buyukcekmece Ambarli/Ist Darica/Kocaeli Izmit Hereke/Kocaeli Balikesir Bursa Istanbul 16 Integrated Integrated Integrated Grinding Integrated Grinding Integrated Integrated Integrated Grinding CAPACITY ('000 Tonnes) Clinker Cement 578 1162 700 1000 3750 6200 500 1250 2700 350 2100 3750 350 500 1350 2924 710 Marmara Region Cement Market " Marmara is the leading region in terms of cement production (28%), consumption (25%) and exports (41%). " The region accounts for 27% of Turkey’s total population and makes the largest contribution to GNP with 37%. " There are 7 players in the Marmara Region with 8 integrated plants and 3 grinding facilities. " Regional leader Akcansa is also Turkey’s biggest producer. " Due to its rapid urbanisation and industrialisation, Marmara Region has also attracted foreign investors, namely CBR, Lafarge and Italcementi, which together control 60% of capacity and a similar percentage of cement sales in the region. " Cement Capacity by Group Sabanci 31% Other 35% LafargeYibitas 14% Rumeli’s share in regional cement capacity is 6%. 17 Rumeli Italcementi 6% (Set) 14% Eskisehir " Eskisehir plant was founded in 1957 and acquired by Rumeli Group in 2002. " In 1976 a precalcination modernisation investment was made. " Clinker capacity is 495,000 tonnes/year. " Cement capacity is 1,016,400 tonnes/year. " The plant is located on an open area of 1,944,991 m2 and covered area of 84,403 m2. " Number of personnel (including operating companies) is 126, 53 of which are white collar, 73 of which are blue collar. " The plant is located at the conjunction of Istanbul-Eskisehir highway and at a close distance to coal mines. " Railway passes through the premises, where loading and unloading can be achieved. 18 Eskisehir " Type of cement produced is PC-42.5; PC/B 32.5R and MC-12.5X. " Clinker technology used is dry process. " Grinding mills consist of 2 MIAG’s (45 tonnes/hr and 95 tonnes/hr). " Eskisehir plant’s share in Central Anatolian Region cement capacity is 6%. " In 2003 production of cement reached 529,711 tonnes (2002: 26,000) " 1H04 cement sales was 223,558 tonnes (1H03: 212,202). " The plant’s raw material quarries are operated by subcontractor. " The plant has ISO 9001:2000 certificate. Licenses Furnace Type Limestone+Clay Limestone+Clay Area (m2) Reserves (tonnes) Type of License Termination date 1,230,400 7,290,426,150 Mine 13/11/2009 3,313,600 96,200,000 Mine 19 Owner of property plant/individual/treasury individual Lalahan " Lalahan grinding station was founded in 2002. " Cement capacity is 181,500 tonnes/year. " The plant is located on an open area of 85,806 m2 and covered area of 5,009 m2. " Number of personnel (including operating companies) is 47, 21 of which are white collar, 26 of which are blue collar. " Distance to Samsun highway is 600m and to Lalabel train station 6 km. " Type of cement produced is PZC/A-32.5. " Grinding mill is a KRUPP (25 tonnes/hr). " The plant has automated system. " There is a covered clinker silo. " Lalahan’s share in regional cement capacity is 2%. " In 2003 142,562 tonnes of cement was produced. " 1H04 cement sales was 60,218 tonnes (1H03: 67,614). " The plant has ISO 9001:2000 certificate. 20 Central Anatolian Region Cement Market Local Producers PLANT GROUP LOCATION Bastas Baskent Cim Hasanoglan Set (Ankara Cim) Eskisehir Cimento Lalahan Yibitas Yozgat Konya Cimento Nevsehir Cimento Oysa Cimento Sanayi Cimsa Kayseri Yibitas Lafarge Sivas Afyon Cimento İstaş Vicat Yibitas+Lafarge Set+Italcementi Rumeli Rumeli Yibitas+Lafarge Vicat Yibitas+Lafarge Oyak+Sabanci Sabanci Yibitas+Lafarge Set+Italcementi Independent Ankara Ankara Ankara Eskisehir Ankara Yozgat Konya Nevsehir Nigde Kayseri Sivas Afyon Ankara 21 TYPE Integrated Grinding Integrated Integrated Grinding Integrated Integrated Grinding Integrated Grinding Integrated Integrated Grinding CAPACITY ('000 Tonnes) Clinker Cement 750 1650 376 870 1,500 495 1,016 182 725 832 1,500 2,073 372 420 1,200 600 410 810 470 650 250 Central Anatolian Region Cement Market " " " " This is the third largest region in terms of clinker capacity, accounting for 16% of clinker, 17% of cement capacity and 21% of cement consumption. Cement Capacity by Group The region accounts for 17% of Turkey’s population and contributes 16% to Turkey’s GNP. There are three main groups in the region with a combined market share of 67%: Vicat-Bastas, Italcementi and Lafarge Yibitas. Other 7% LafargeYibitas 20% 22 Sabanci 10% Rumeli 10% Vicat 30% Rumeli’s share in the region’s cement capacity is 10%, including Lalahan grinding station. Oyak 5% Italcementi (Set) 18% Gaziantep " Gaziantep plant was founded in 1961 and sold to Rumeli group through privatisation in 1992. " Clinker capacity is 495,000 tonnes/year. " Cement capacity is 1,089,000 tonnes/year. " The plant is located on an open area of 1,952,977 m2 and covered area of 35,915 m2. " Number of personnel (including operating companies) is 62 white collar and 149 blue collar. " Distance to Antep-Sanliurfa road is 500 m and to Antep-Adana highway 20 km. " Railway passes through the premisses. 23 Gaziantep " Type of cement produced is PCC-32.5, PC42.5 and CC-32.5. " Clinker is produced through one dry process kiln and one Lepol kiln. " Grinding mills consist of 1 HUMBOLD (70 tonnes/hr) and 1 FLS (80 tonnes/hr) " Gaziantep plant’s share in South East Anatolian Region cement capacity is 19%. " In 2003 Gaziantep plant produced 339,674 tonnes of cement (2002: 330,872) " 1H04 cement sales was 147,372 tonnes (1H03: 141,718). " The plant has ISO 9001:2000 certificate. Licenses Furnace Type Limestone Clay Trass Area (m2) 485,300 146,730 168,000 Reserves (tonnes) Type of License Termination date Owner of property 12,600,000 Mine 20/10/2009 Plant 340,809 Stone quarry 19/09/2004 Plant 1,900,000 Stone quarry 17/07/2004 Plant 24 Sanliurfa " Sanliurfa plant was founded in 1986 and sold to Rumeli group through privatisation in 1993. " Clinker capacity is 577,500 tonnes/year. " Cement capacity is 580,800 tonnes/year. " The plant is located on an open area of 1,386,844 m2 and covered area of 33,472 m2 " Number of personnel (including operating companies) is 49 white collar and 140 blue collar. " Distance to TEM highway is 1 km and to Akcakale train station 70 km. 25 Sanliurfa " Type of cement produced is PCC/B-32.5R and PC-42.5. " Clinker technology used is dry process. " Grinding mill is FLS (80 tonnes/hr). " There is one mill in the plant, but there is spare space for a second mill and bunker. " Sanliurfa plant’s share in South East Anatolian cement capacity is 10%. " In 2003 Sanliurfa plant produced 292,375 tonnes of cement (2002: 217,633) " 1H04 cement sales was 170,321 tonnes (1H03: 122,853). " The plant has ISO 9001:2000 certificate. Licenses Furnace Type Limestone Clay Clay Marl Area (m2) 1,223,400 198,750 173,250 350,575 Reserves (tonnes) Type of License Termination date Owner of property 146,832,028 Mine 21/11/2004 Treasury 2,385,000 Stone quarry 31/12/2004 Plant Stone quarry 31/12/2004 Plant 3,856,325 Stone quarry 31/12/2004 Plant 26 Ergani " Ergani plant was founded in 1984 and sold to Rumeli group through privatisation in 1996. " Clinker capacity is 577,500 tonnes/year. " Cement capacity is 1,161,600 tonnes/year. " The plant is located on an open area of 392,101 m2 and covered area of 35,337 m2. " Number of personnel (including operating companies) is 225. " The plant is located on Elazig highway. " The distance to Ergani train station is 4 km. 27 Ergani " Type of cement produced is PZC/A-32.5 and PC-42.5. " Clinker technology used is dry process. " Grinding mills consist of 2 FLS (80 tonnes/hr). " Ergani plant’s share in South East Anatolian cement capacity is 20%. " In 2003 Ergani plant produced 289,650 tonnes of cement (2002: 196,967) " 1H04 cement sales was 117,967 tonnes (1H03: 121,377). " The plant has ISO 9001:2000 certificate. Licenses Furnace Type Limestone Marl with clay Cender Area (m2) Reserves (tonnes) Type of License Termination date Owner of property 1,392,600 87,647,937 Mine 23/03/2014 Treasury 765,000 25,111,200 Stone quarry 02/02/2009 Teasury 943,700 5,775,000 Mine 02/09/2007 Treasury/plant 28 South East Anatolian Cement Market Local Producers PLANT GROUP LOCATION TYPE CAPACITY '000 Tonnes) Clinker Cement Adiyaman Sanko Adiyaman Integrated 630 990 Gaziantep Rumeli Gaziantep Integrated 495 1,089 Sanliurfa Rumeli Sanliurfa Integrated 578 581 Ergani Rumeli Ergani Integrated 578 1,162 Oyak Mardin Oyak Mardin Integrated 640 1,020 Kurtalan Limak Kurtalan Integrated 644 972 29 South East Anatolian Cement Market " South East Anatolia has a 10% share in total clinker capacity, 8% in cement capacity and 10% in cement consumption. " The region accounts for 13% of Turkey’s total population and contributes 5% to total GNP. " The ongoing South East Anatolian (GAP) Project, a US$20bn worth project involving building of dams and irrigation systems, is the major driver of cement demand in the region. " The region’s proximity to Iraq represents an important opportunity as cement exports to Iraq are expected to surge with further stabilisation in the region. " With a 49% share in the region’s cement capacity, Rumeli group has an important advantage and should strongly benefit from increased exports to Iraq. 30 Cement Capacity by Group Other 33% Oyak 18% Rumeli 49% Van " Van plant was founded in 1969 and sold to Rumeli group through privatisation in 1996. " Clinker capacity is 213,840 tonnes/year. " Cement capacity is 559,020 tonnes/year. " The plant is located on an open area of 280,050 m2 and covered area of 16,027 m2. " Number of personnel (including operating companies) is 144, 38 of which are white collar and 106 are blue collar. " The distance to Van-Diyarbakir railway is 22 km. 31 Van " Type of cement produced is PZC/A-32.5. " Clinker technology used is dry process. " Grinding mills consist of 1 HUMBOLD (27 tonnes/hr) and 1 FLS (50 tonnes/hr). " Van plant’s share in South East Anatolian Region cement capacity is 22%. " In 2003 Van plant produced 199,626 tonnes of cement (2002: 137,517) " 1H04 cement sales was 80,317 tonnes (1H03: 70,812). " The plant has ISO 9001:2000 certificate. Licenses Furnace Type Limestone Clay Pomza Area (m2) 549,800 5,000 16,873,400 Reserves (tonnes) Type of License Termination date Owner of property 48,000,000 Mine 01/12/2004 Treasury 500,000 Stone quarry 17/07/2003 Treasury 3,547,500 Mine 09/04/2009 Individual/Treasury 32 East Anatolian Region Cement Market Local Producers PLANT GROUP LOCATION Kars Cimento Askale Cimento Van Elazig Cementir Er-Cimsan Rumeli Oyak+Gama Kars Erzurum Van Elazig TYPE Integrated Integrated Integrated Integrated 33 CAPACITY ('000 Tonnes) Clinker Cement 330 475 450 600 214 559 301 953 East Anatolian Region Cement Market " " East Anatolia, the least developed region of Turkey contributes 3.3% to Turkey’s GNP and has 9% of the total population. Cement Capacity by Group The region has a 3% share in cement capacity and 6% in cement consumption. " There are four plants in the region owned by different groups. " Rumeli is the second largest group with a 22% share in local cement capacity. Other 23% Cementir 18% 34 Oyak 37% Rumeli 22%