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The many advantages of P84? bags and P84? blends

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Do cost savings and environmental protection oppose?: The many advantages of P84? bags and P84? blendsThe operation of a bag house results in expenses for fan power, pressurised air and bag material as well as cost for manpower and the loss of production during maintenance. The choice of the bag material influences all of the other above listed costs. Nevertheless typically just the cost for bags and maybe the expected bag life are considered for the purchase decision. What will future developments bring? The emission levels will continue to decrease, for sure. Questions how to reduce the operating costs will arise. Is it possible to reduce emissions and operating costs? Yes, at least in many cases, subsequent examples should give an idea of the performance of common filter media. GEORGE RATHWALLNER and ASHISH BHAIYA on behalf of Evonik Fibres, Austria, report on the use of P84 filter media in kiln dedusting systemIn pulse jet filters for kiln/raw mill dedusting just 2 bag materials are commonly used: woven glass with PTFE-membrane and P84? (polyimide) needle felts. Both are suitable up to peak temperatures of 260?C. The membrane material typically shows an increase of emissions when facing mechanical wear over the bag life whereas P84? bags operate at less than 10 mg/Nm3 typically until the end of life.P84? bags are easy to handle and do not demand special care during installation. The app. 2-3 mm thick needle felt is quite abrasion resistant in comparison to membrane filter media – during installation and during operation. Spare bags can be stored over years without significant influence on the quality of the needle felt.Ambuja Rauri – The first kiln/raw mill filter with P84? in IndiaThe 10.000 TPD kiln of Ambuja near Darlaghat is the first big cement kiln / raw mill dedusting filter with P84? filter bags in India. It went in operation 1.5 years back and operates at a pressure drop of 4.5-11 mbar with emissions below 10 mg/Nm3. This confirms the suitability in Indian kilns which has always been in question. A lab analysis of a used bag is due to be executed in the laboratory of Evonik Fibres and will allow a prediction of the remaining life.An emission of 10 mg/Nm3 corresponds to a loss of cement dust of app. 80 tons per year in a 8.000-10.000 ton per day kiln. Worth to consider a filter media that ensures emissions below legislative limits, especially if also energy can be saved because of a lower operational pressure drop.Comparative tests of kiln filter mediaTo get a direct comparison between P84? bags and glass/membrane bags we have placed both materials in a cement mill filter for 29 months. Then both materials have been evaluated on a test rig according to VDI 3926 regarding filtration efficiency and pressure drop. To get realistic conditions the test was done with cement dust, sampled from the hopper.The membrane media exhibited damage along the supporting cage wires and dust could be found in the cross section of the supporting glass fabric. On the contrary the cross section of the P84? needle felt is free of dust. This resulted in 50% higher emission of the membrane media during evaluation. 29 months can be considered to represent just app. half of the life of the materials. Also the pressure drop of the P84? needle felt is app. 10-20 % lower than that of the membrane media, depending on the set point. This figure can be directly transferred to ID-fan power savings. The pressure drop development of the tested materials during a filtration cycle (which means between two cleaning pulses) is shown in fig. 3.Other applications for P84? fibresP84? has proven to be the fibre with high filtration efficiency because of its irregular cross section and the resulting high specific surface. This advantage can also be utilised in low temperature applications by blending P84? into the dust side of various base materials like polyacrylic, polyester, PPS and PTFE. These blends can solve pressure drop and emission problems as they allow stable operation at higher dust load and a/c-ratio than the base material without P84?.Comparative test of cement mill filter mediaIn fig 4 a comparison of a polyester fine fibre felt and a polyester felt with P84? fibres blended into the filtration side is displayed. Details of felt construction and operating conditions are given in table 2. Both filter materials were used in similar clinker grinding lines under challenging conditions: The blend with the multilobal polyimide fibres exhibits good filtration behaviour for 4-5 years, ensuring a low and stable pressure drop of app. 1500 Pa during the entire period. On the other hand the polyester fine fibre felt shows penetration of dust through the entire cross section after only 7 months operation. Operated at a comparable differential pressure it suffered from more frequent cleaning which lead to dust penetration. Besides emissions as a result of penetration through the felt, cracks occur as a result of increased mechanical burden (abrasion caused by incorporated dust and more frequent pulsing).Even considering the higher investment for the P84? blended bags, this resulted in much lower annual costs for bag material and the additional benefit of higher process stability and less down times.SummaryFor a comparison of the total costs related to filter media more than just bag costs and estimated or warranted life has to be evaluated. Especially the operational pressure drop, which determines the ID-fan power consumption can have even more effect than the costs for bags.Needle felts, especially P84? and P84? blends can outperform membrane materials under realistic conditions, which might be opposite to results from short-term tests on lab scale test rigs.At the end of their life P84? bags and also P84? blends with polyester, acrylic or poly phenylene sulphide (commonly known as ‘Ryton’) do not need to be land filled. They represent an alternative fuel with reasonable heating value and do not produce significant amounts of gaseous pollutants and do not influence the cement quality because of a negligible content of inorganic material.

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Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings

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Region-wise,the southern region comprises 35% of the total cement capacity, followed by thenorthern, eastern, western and central region comprising 20%, 18%, 14% and 13%of the capacity, respectively.

The cement industry is expected to post positive margins on decent price hikes over the months, falling raw material prices and marked drop in overall production costs, said an analysis of Care Ratings.

Wholesale and retail prices of cement have increased 11.9% and 12.4%, respectively, in the current financial year. As whole prices have remained elevated in most of the markets in the months of FY20, against the corresponding period of the previous year.

Similarly, electricity and fuel cost have declined 11.9% during 9M FY20 due to drop in crude oil prices. Logistics costs, the biggest cost for cement industry, has also dropped 7.7% (selling and distribution) as the Railways extended the benefit of exemption from busy season surcharge. Moreover, the cost of raw materials, too, declined 5.1% given the price of limestone had fallen 11.3% in the same aforementioned period, the analysis said.

According to Care Ratings, though the overall sales revenue has increased only 1.3%, against 16% growth in the year-ago period, the overall expenditure has declined 3.2% which has benefited the industry largely given the moderation in sales.

Even though FY20 has been subdued in terms of production and demand, the fall in cost of production has still supported the cement industry by clocking in positive margins, the rating agency said.

Cement demand is closely linked to the overall economic growth, particularly the housing and infrastructure sector. The cement sector will be seeing a sharp growth in volumes mainly due to increasing demand from affordable housing and other government infrastructure projects like roads, metros, airports, irrigation.

The government’s newly introduced National Infrastructure Pipeline (NIP), with its target of becoming a $5-trillion economy by 2025, is a detailed road map focused on economic revival through infrastructure development.

The NIP covers a gamut of sectors; rural and urban infrastructure and entails investments of Rs.102 lakh crore to be undertaken by the central government, state governments and the private sector. Of the total projects of the NIP, 42% are under implementation while 19% are under development, 31% are at the conceptual stage and 8% are yet to be classified.

The sectors that will be of focus will be roads, railways, power (renewable and conventional), irrigation and urban infrastructure. These sectors together account for 79% of the proposed investments in six years to 2025. Given the government’s thrust on infrastructure creation, it is likely to benefit the cement industry going forward.

Similarly, the Pradhan Mantri Awaas Yojana, aimed at providing affordable housing, will be a strong driver to lift cement demand. Prices have started correcting Q4 FY20 onwards due to revival in demand of the commodity, the agency said in its analysis.

Industry’s sales revenue has grown at a CAGR of 7.3% during FY15-19 but has grown only 1.3% in the current financial year. Tepid demand throughout the country in the first half of the year has led to the contraction of sales revenue. Fall in the total expenditure of cement firms had aided in improving the operating profit and net profit margins of the industry (OPM was 15.2 during 9M FY19 and NPM was 3.1 during 9M FY19). Interest coverage ratio, too, has improved on an overall basis (ICR was 3.3 during 9M FY19).

According to Cement Manufacturers Association, India accounts for over 8% of the overall global installed capacity. Region-wise, the southern region comprises 35% of the total cement capacity, followed by the northern, eastern, western and central region comprising 20%, 18%, 14% and 13% of the capacity, respectively.

Installed capacity of domestic cement makers has increased at a CAGR of 4.9% during FY16-20. Manufacturers have been able to maintain a capacity utilisation rate above 65% in the past quinquennium. In the current financial year due to the prolonged rains in many parts of the country, the capacity utilisation rate has fallen from 70% during FY19 to 66% currently (YTD).

Source:moneycontrol.com

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Wonder Cement shows journey of cement with new campaign

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The campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV…

ETBrandEquity

Cement manufacturing company Wonder Cement, has announced the launch of a digital campaign ‘Har Raah Mein Wonder Hai’. The campaign has been designed specifically to run on platforms such as Instagram, Facebook and YouTube.

#HarRaahMeinWonderHai is a one-minute video, designed and conceptualised by its digital media partner Triature Digital Marketing and Technologies Pvt Ltd. The entire journey of the cement brand from leaving the factory, going through various weather conditions and witnessing the beauty of nature and wonders through the way until it reaches the destination i.e., to the consumer is very intriguing and the brand has tried to showcase the same with the film.

Sanjay Joshi, executive director, Wonder Cement, said, "Cement as a product poses a unique marketing challenge. Most consumers will build their homes once and therefore buy cement once in a lifetime. It is critical for a cement company to connect with their consumers emotionally. As a part of our communication strategy, it is our endeavor to reach out to a large audience of this country through digital. Wonder Cement always a pioneer in digital, with the launch of our IGTV campaign #HarRahMeinWonderHai, is the first brand in the cement category to venture into this space. Through this campaign, we have captured the emotional journey of a cement bag through its own perspective and depicted what it takes to lay the foundation of one’s dreams and turn them into reality."

The story begins with a family performing the bhoomi poojan of their new plot. It is the place where they are investing their life-long earnings; and planning to build a dream house for the family and children. The family believes in the tradition of having a ‘perfect shuruaat’ (perfect beginning) for their future dream house. The video later highlights the process of construction and in sequence it is emphasising the value of ‘Perfect Shuruaat’ through the eyes of a cement bag.

Tarun Singh Chauhan, management advisor and brand consultant, Wonder Cement, said, "Our objective with this campaign was to show that the cement produced at the Wonder Cement plant speaks for itself, its quality, trust and most of all perfection. The only way this was possible was to take the perspective of a cement bag and showing its journey of perfection from beginning till the end."

According to the company, the campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV. No other brand in this category has created content specific to the platform.

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In spite of company’s optimism, demand weakness in cement is seen in the 4% y-o-y drop in sales volume. (Reuters)

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Cost cuts and better realizations save? the ?day ?for ?UltraTech Cement, Updated: 27 Jan 2020, Vatsala Kamat from Live Mint

Lower cost of energy and logistics helped Ebitda per tonne rise by about 29% in Q3
Premiumization of acquired brands, synergistic?operations hold promise for future profit growth Topics

UltraTech Cement
India’s largest cement producer UltraTech Cement Ltd turned out a bittersweet show in the December quarter. A sharp drop in fuel costs and higher realizations helped drive profit growth. But the inherent demand weakness was evident in the sales volumes drop during the quarter.

Better realizations during the December quarter, in spite of the 4% year-on-year volume decline, minimized the pain. Net stand-alone revenue fell by 2.6% to ?9,981.8 crore.

But as pointed out earlier, lower costs on most fronts helped profitability. The chart alongside shows the sharp drop in energy costs led by lower petcoke prices, lower fuel consumption and higher use of green power. Logistics costs, too, fell due to lower railway freight charges and synergies from the acquired assets. These savings helped offset the increase in raw material costs.

The upshot: Q3 Ebitda (earnings before interest, tax, depreciation and amortization) of about ?990 per tonne was 29% higher from a year ago. The jump in profit on a per tonne basis was more or less along expected lines, given the increase in realizations. "Besides, the reduction in net debt by about ?2,000 crore is a key positive," said Binod Modi, analyst at Reliance Securities Ltd.

Graphic by Santosh Sharma/Mint
What also impressed analysts is the nimble-footed integration of the recently merged cement assets of Nathdwara and Century, which was a concern on the Street.

Kunal Shah, analyst (institutional equities) at Yes Securities (India) Ltd, said: "The company has proved its ability of asset integration. Century’s cement assets were ramped up to 79% capacity utilization in December, even as they operated Nathdwara generating an Ebitda of ?1,500 per tonne."

Looks like the demand weakness mirrored in weak sales during the quarter was masked by the deft integration and synergies derived from these acquired assets. This drove UltraTech’s stock up by 2.6% to ?4,643 after the Q3 results were declared on Friday.

Brand transition from Century to UltraTech, which is 55% complete, is likely to touch 80% by September 2020. A report by Jefferies India Pvt. Ltd highlights that the Ebitda per tonne for premium brands is about ?5-10 higher per bag than the average (A cement bag weighs 50kg). Of course, with competition increasing in the arena, it remains to be seen how brand premiumization in the cement industry will pan out. UltraTech Cement scores well among peers here.

However, there are road bumps ahead for the cement sector and for UltraTech. Falling gross domestic product growth, fiscal slippages and lower budgetary allocation to infrastructure sector are making industry houses jittery on growth. Although UltraTech’s management is confident that cement demand is looking up, sustainability and pricing power remains a worry for the near term.

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