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Transforming Cement Plants

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Plant upgrades are critical for enhancing manufacturing capabilities, reducing cost of production and curbing emissions.

Over the years, the cement industry in India has grown exponentially, and it currently faces challenges like the need to improve energy efficiency, maximise capacity, eliminate bottle?necks, reduce cost of maintenance, switch fuels, and many more.

In the recent past, new greenfield and brownfield plants, with lower levels of specific fuel and power consumption, have set new benchmarks. Again, with fuel and power becoming more expensive, the cement industry is poised for a makeover. Technological advancement and innovative solutions have helped overcome the challenges and optimise resources.

The reasons for plant upgrades and modifications are not generic across the cement industry, and are plant specific. Some of the prominent reasons are:
1.To meet the growing market demand in a region
2.To enhance the production capacity
3.Reduction in cost of production
4.To meet the government regulations on emissions levels
5.Adopt energy efficient technologies.

Challenges in Upgrades
Retain existing setup: Maximise the possibility of utilising existing building and retain the existing equipment.

Limited space availability: Customise new machinery within the available space. Delivery time: Accommodate short deliveries in line with the plant annual shutdown schedule.

Plant engineering: Customised solutions and innovation in fitment of new equipment. Civil design: Unwarranted changes during project execution due to limited information of the existing plant.

Interface: Minimal modifications in the interface areas.

Erection & commissioning: Detailed scheduling of shutdown activities in order to meet stringent timelines for erection and commissioning of the new equipment to minimise the downtime.

Installation: Facilitate any modifications for fitment of new equipment in limited time and access.

Trendsetting ongoing upgrades in the industry by FLSmidth
Project 1 (Refer to Figure 1)

This upgrade project was taken up to increase the production of the pyro-processing system from 4,150 tpd to 5,000 tpd and reduce the fuel consumption by 70 kcal/kg clinker. In the first phase, latest generation high efficiency FLSmidth? Cross-Bar? 14 x 47 cooler was installed. In the second phase, a new six-stage ILC low NOx preheater tower will be installed in front of the existing tower above the kiln. This new preheater string will be rated for 1800 tpd nominal. The existing four-stage Separate Line Calciner (SLC) preheater tower will be de-rated to 3,200 tpd clinker production, so that the heat transfer efficiency becomes better and the pressure drop across the existing tower is maintained at optimal level. Thus both the existing preheater string and the new preheater string are made optimum towards lesser energy consumption (under execution).

Significant benefits expected of this project are:

  • Increased production by 850 tpd (from 4,150 tpd to 5,000 tpd)
  • Specific heat consumption reduction by ~70 kcal/kg cl.

Project 2 (Refer to Figure 2)
The upgrade project?s target is to make the older line on par with the new line in terms of capacity and energy efficiency. Hence to match the new line capacity, an additional tower with the cooler change became inevitable. The new tower had limitations in tower height and hence by proposing a twin-string ILC for the new tower, the height limitation factor was addressed. The old tower will be de-rated to its original capacity of 2,500 tpd and the new tower will be operating at 2,100 tpd to produce 4,600 tpd clinker production in total (under execution). The upgrade includes the installation of latest generation high efficiency FLSmidth? Cross-Bar? 14 x 43 cooler, modification in kiln drive and additional coal dosing system for the new balancing tower.

Significant benefits expected of this project are:

  • Increase in production by 1,350 tpd (3,250 tpd to 4,600 tpd)
  • Specific heat consumption reduction by ~55 kcal/kg cl
  • Specific power consumption reduction by 7.0 kWhr/T cl.

Project 3 (Refer to Figure 3)
There is an existing five-stage single string suspension preheater tower and a new five-stage single string ILC low NOx calciner together for 1,900 tpd clinker production. The equipment also comprises an ATOX???35 mill system for raw material grinding, RTKM separator for existing coal mill and latest generation high efficiency FLSmidth? Cross-Bar? 8 x 36 cooler.

Significant benefits expected of this project are:

  • Increase in production by 780 tpd (1,120 tpd to 1,900 tpd)
  • Specific heat consumption reduction by ~40 kcal/kg cl
  • Specific power consumption reduction by 7.0 kW hr/T cl.

The above upgrades have driven the technological knowledge base to innovate and bridge the gaps with seamless solutions. These are indeed trendsetters in the industry.

Way ahead
Leaving aside the aspect of maximising the capacity and reduction in cost of production, the rapidly shooting climatic changes owing to the greenhouse gases emission is a concern at large for mankind. Carbon dioxide is a main contributor to greenhouse gas which emanates from cement plants.

In a typical 5,000 tpd clinkerisation plant, if there is a potential to save 50 kcal/kg cl fuel savings, we are going to bring down the greenhouse gas emission by ~30,000 tonnes of CO2 per annum. In addition, growing costs of resources are leading to the possibility of modernisation, optimisation, retrofit or upgrade in a plant and there is immense scope at cement plants in India.

While one decides to take a step in this direction, the following aspects can be looked into:

  • One source provider with strong technology backup and vast experience in such upgrades;
  • Latest technology with customised solutions;
  • Total cost of ownership;
  • Right time for an upgrade: As discussed above, though there are many aspects driving an upgrade, the ideal strategy would be to take it up when the demand is less and capacity utilisation is low.

(This article has been authored by Logesh Baskaran, FLSmidth, Senior Manager – Sales, Products & Upgrades).

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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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