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Co-processing plastic waste

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With emerging prices of raw materials for cement production, there arises a need for an alternative resource. RK Shrivastava, Madhya Pradesh Pollution Control Board, Dr BN Mohapatra, Dr Anand Rai, Sunil Kumar Vyas and Chander Shekhar co-process plastic waste in the cement kiln without affecting the quality.

Never would have one imagined waste to be an integral part of the construction industry. However, it has been more than 20 years now, and cement companies world over continue to utilise waste as an alternative fuel in cement kiln. Though, the alternative fuel movement in India is at a nascent stage, a few cement companies have started utilising waste from cement manufacturing process as alternate fuel and raw material to reinforce its competitiveness and contributing to solutions of waste and benefitting the environment. Waste generation has increased considerably particularly in the developing economies. Interest in co-processing municipal solid waste and sewage sludge is rising.The energy intensiveness of cement production processes and increasing fuel prices, combined with fuel deficit, forced the cement industries to search for technologies based on waste derived alternate fuels. Coal and pet coke are the primary fuels for the cement industries. Alternative fuels contribute towards lowering the emission of green house gases by replacing the use of fossil fuels with materials that would otherwise have to be incinerated with corresponding emissions and final residue. Incineration of any waste in dedicated incinerator results in non-utilisation of energy from this valuable waste rather it requires additional energy for incineration and increments the green house gas emissions. Thus, the cement industry can use part of this waste as alternative fuel and raw material, which reduces usage of fossil fuels.

Established in the year 1985, Vikram Cement Works (VCW), a unit of UltraTech, is flagship unit of cement business of Aditya Birla Group Company. Located at Khor, a village in Neemuch, Madhya Pradesh, the unit started with a single manufacturing line of 1500 TPD capacity in the year of its inception. The journey of excellence with technological up gradation such as retrofitting of coolers, continual improvements anf optimisation projects resulted in three units (Line-I, II and III) with ultimate capacity of 4.0 MTPA cement production. The unit is producing Gray Cement and Clinker.

Plastic waste generated from different cities and towns is a part of Municipal Solid Waste. The disposal of polythene bags and other non-recyclable plastic wastes generates serious problems for the municipalities and corporations. Being non-biodegradable, gives an ugly appearance as well as impacts by leaving the land infertile, and chokes the drain. Indiscriminate burning of the same causes environmental hazards.

To overcome the above problem, VCW had taken an initiative to dispose plastic and polythene waste for energy recovery in cement kiln thereby replacing fossil fuel to conserve the natural resources under the mega drive of Madhya Pradesh Pollution Control Board, Bhopal.

Co-processing of plastic and polythene waste has following environmental benefits

  • High flame temperature of 2000 0C, material temperatures up to 14500C and residence time of four to five seconds in oxygen rich atmosphere ensures complete destruction of waste and harmful pollutants.
  • Complete scrubbing of exhaust gas due to countercurrent flow of raw material – resulting in trapping of heavy metals, sulphur and other pollutants within clinker.
  • The waste generated does not require subsequent processing. Cement kiln operates under negative pressure or draft, thus preventing the generation of
  • fugitive emission.
  • With the large mass of clinker processed inside the cement kiln, there is a presence of a huge thermal inertia thereby eliminating the possibility of rapid swings in temperature.
  • Inclusion of ashes and residual metals from the wastes within the clinker crystal structure.
  • Kiln lines equipped with ESP/ bag filters- ensures negligible particulate emission.
  • Destruction and removal efficiency of greater than 99.9 per cent..

Co-processing plastic waste

The need for alternate fuel arises due to the paucity of natural resources. This co-incineration of plastic waste in cement kiln helps in recovery of energy and eco-friendly disposal. Vikram Cement Works uses alternative fuel in its cement kiln since 2007 and conducted several trails to find out the impact of gases on environment and product quality. After successful trial runs, VCW started usage of plastic and polythene in the cement kiln from September 2008 under the guidance of M.P. Pollution Control Board and has obtained regular permission for usage of waste polythene bags, pouches, waste polythene and plastic waste as a co-fuel in cement kiln. the waste is collected by the network of the company and is gathered from the cities like Indore, Ujjain, Nagda and Pithampur.

System for shredding of plastic waste

Shredding machines have been installed to reduce the size of of the plastic. The polythene waste is reduced to 20 mm and is fed in the precalciner. In this automated machine the trucks loaded with plastic waste can be directly unloaded in the hoppers. From the hoppers plastic waste is transported through a small covered belt conveyor to the shredder, which shreds the plastic waste into very small pieces. Then, the shredded plastic waste is pneumatically conveyed to closed storage bunkers. From the storage bunkers, the plastic waste is transported through covered conveyor belt of alternate fuel feeding system.

Characteristics of plastic and polythene-Proximate and ultimate analysis of plastic and polythene was done by our laboratory and the results are given in table-1.

Plastic and Polythene consumption – The efforts have been made to maximise the plastic waste disposal in cement kiln. The year wise plastic and polythene consumptions are as follows:

Source emission monitoring during use of plastic and polythene (2011-12)- During FY 2011-12, we have monitored the PM, SO2, NOx and CO in raw mill+ kiln stack during plastic co-incineration and results are given in table-2.

Impact study on clinker quality

A comparative study of clinker quality with and without using plastic and polythene in our cement kiln reveals that there is no negative impact on clinker, quality. Results of the same are given in table-3.

Physical properties of cement

The clinker samples collected before and during co-processing of plastic and polythene were ground in the laboratory ball mill with same amount of gypsum at identical fineness. The complete physical testing was carried out in quality control laboratory and the result reveals that there is no negative impact observed in cement quality. Results are given in table-4.

Conclusion

The co-processing result shows that there is no adverse impact on the environment,clinker and cement properties. Hence co-processing of plastic waste is one of the best alternatives for its disposal, saving of energy resource, in ecological sustainable and environmental friendly manner.

(The paper was presented by R.K. Shrivastava, Madhya Pradesh Pollution Control Board, Dr. B. N. Mohapatra, Dr. Anand Rai, Sunil Kumar Vyas, Chander Shekhar and Vikram Cement Works a unit of UltraTech.)

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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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