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Alternative Fuels: Advantages for the cement industry

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The most significant alternative fuel energy contributors to the India cement industry are agro-wastes and bio-mass fuels. A solution for alternative fuel should ensure the maximum availability of the kiln alongwith the alternative fuel feeding system and shall have minimum detrimental effect to the clinket production, say Avinash Karrahe and Venkatesh Sheshadri of FL SmidthThere is a tremendous interest in alternative fuels on a global level which holds many advantages for the cement industry.Different types of alternative fuels find their applications in different forms, ranging from hazardous to non-hazardous and they may be in the gaseous, liquid or solid state. Currently, solid fuels account for the largest part of the forms. The most significant alternative fuel energy contributors to the Indian cement industry, in particular are agro-waste and biomass fuels.The firing of alternative fuels can take place in the Rotary Kiln Burner, Calciner system or in extensional equipment, specially designed for large solid fuel particles. It is imperative that the fuels are burnt sufficiently in order to preserve the quality of the cement as well as stabilize kiln system operations. It has been observed that gaseous and liquid alternative fuels are more easily combustible than solid fuels.Distinct alternative fuels have different physical and chemical properties. Hence the mode of receiving, storage, transport and feeding system varies for each kind of fuel. A solution for alternative fuel should ensure the maximum availability of the kiln alongwith the alternative fuel feeding system and shall have minimum detrimental effect to the clinker production. Utilization of alternative fuels may result in cement plants losing production capacity for different reasons. In addition to having an appropriate design of the pyro process, it is particularly important to ensure that the alternative fuel is dosed and admitted to the kiln system in a very consistent and well controlled flow. This is strongly affected by the selected main equipments, the detailed engineering of the whole solution as well as the integration with the pyro process.Integration of Alternative Fuels in the Cement Industry :Even though utilisation of alternative fuels in the cement industry has major advantages, the introduction of alternative fuels , especially at higher substitution rates, has led to the following issues:1) What are the combustion kinetics of the various alternative fuels and how should existing/new combustion equipment be altered/ developed to obtain the desired fuel conversion?2) Will the reactivity/and or heating value of the alternative fuels cause problems with the desired flame formation in the rotary kiln?3) Will the use of alternative fuels affect emissions?4) How is the quality of the cement clinker affected by using alternative fuels?5) How does the use of alternative fuels influence kiln process stability?6) Will the water content reduce cement clinker production capacity?7) How are the alternative fuels, transported, stored, handled and delivered?The devolatilization stage in the combustion process of the alternative fuels is responsible for a large part of the fuel heating value. Kiln process stability, in particular, is influenced by insufficient carbon burnout in the calciner system, which results in reducing conditions in the material inlet of the rotary kiln and consequently an increased tendency to form deposits. Clinker quality is mainly affected by minor components from the fuel ashes or from carbon dropping into the material charge of the rotary kiln. The emissions seem not to have been affected by the alternative fuels used until now. However, caution should be taken with regard to emission of carbon monoxide while using alternative fuels.While embarking upon a change from conventional fuels to alternate fuels, it is highly recommended of cement makers to seek assistance from professional solution providers in the assessment of different options. In this regard, it can be mentioned that FLSmidth has developed a broad range of products and solutions to handle both solid and liquid alternative fuels available in the Indian industry.Alternative fuel technology is becoming a more integral part of the cement production process. No standard solutions for alternative fuel requirements are available and it is often challenging to replace traditional fuel with waste fuel, as it may influence the process in the kiln and the clinker quality, when considering a shift from fossil fuels to alternative fuels.(Courtesy: Avinash Karrahe and Venkatesh Sheshadri FLSmidth Private Limited India)

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Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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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…

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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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