Cement production faces strain amid Iran’s widening energy crisis

Iran's cement industry is grappling with the dual challenges of restricted natural gas supplies and reliance on environmentally harmful mazut as a backup fuel, exposing vulnerabilities in the country’s energy infrastructure.

Cement plants near metropolitan areas, barred from using mazut due to pollution concerns, have slashed production by 50%, while those in remote regions are navigating logistical hurdles to secure alternative fuels.

The disruptions come against the backdrop of a worsening energy deficit that has deeply impacted multiple industries.

Ali Akbar Alvandian, Secretary of the Cement Industry Employers' Association, highlighted the strain during a recent interview with ILNA news agency.

"Gas supplies to cement factories are limited, forcing some plants far from cities to use mazut. Those near urban centers, unable to utilize mazut, have had to halve their production," he explained.

Despite the setbacks, Alvandian claimed that the market remains stable, with October’s production levels surpassing those of the same period last year. Producers, he said, are striving to ensure consistent supply despite the energy challenges​​.

Iran's energy deficit is not new, but its scale has become more pronounced. The country’s natural gas production growth has slowed significantly, particularly from its South Pars gas field, which accounts for 75% of output and is now in decline. Sanctions have prevented Iran from attracting the foreign investment and technology needed to offset this decline. Furthermore, inefficiencies in production and distribution contribute to an annual loss of 28 billion cubic meters of gas—equivalent to one-tenth of the nation’s annual production​​.

The result has been a chronic shortage of power, with blackouts impacting residential, commercial, and industrial sectors. Summer months saw electricity rationing that halted operations at 70% of cement kilns, causing supply chain disruptions.

As winter approaches, the focus has shifted to natural gas, with cuts already affecting the steel and petrochemical sectors. This has compounded existing challenges for industries reliant on consistent energy supplies​​.

For factories located far from urban centers, mazut has become a critical alternative to natural gas. Yet, even this stopgap measure is fraught with difficulties. According to Alvandian, plants are required to source mazut from ports on the Persian Gulf, incurring steep transportation costs exacerbated by a shortage of tanker fleets.

"If these challenges persist, production could be halted entirely," he warned.

The cement industry’s struggles mirror the broader economic pressures facing Iran. Inflation has remained above 40% for five years, while the national currency has lost half its value in just two years. With at least 30 million citizens living below the poverty line, energy disruptions further strain an already fragile economy. Industrial sectors, including steel and petrochemicals—key contributors to non-oil exports—have faced severe production losses due to energy shortages.

Cement exports have also declined, with clinker exports dropping by 17% in the first seven months of the Iranian year (starting in mid-March) compared to the same period last year. Domestic markets are now being prioritized, but reduced production levels could still lead to local shortages​​.

The government faces difficult choices as winter intensifies. Domestic gas consumption is expected to surge to 650 million cubic meters per day, exacerbating an existing deficit of 90 million cubic meters. Planned price increases for gas might bolster state revenues but are unlikely to curb household consumption significantly due to low base rates. Meanwhile, industrial users remain at the mercy of unpredictable energy supplies, jeopardizing output and employment​​.

Alvandian suggested shared power outages between households and industries as a potential stopgap, though he cautioned against extending such measures into winter.

"Further electricity disruptions would affect not only industries but also residential areas, leading to broader economic and social challenges," he added.

Iran’s energy crisis, rooted in years of underinvestment, inefficiencies, and sanctions, presents a formidable barrier to economic recovery. The cement industry’s struggles are emblematic of the larger pressures facing the country.