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SNCR and NH3 measurements in the cement industry

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Adage Automation is one of the leaders in the Gas Analytics for Cement Process and is amongst the few manufacturers of kiln inlet systems in the world. ABHIJIT CHATTERJEE speaks about some of these analysers.

Indian cement plants have undergone major changes in the recent past primarily for process improvement and reduction in the emissions. Growth of any nation depends on the success story of certain key industry sectors and cement is one of them.

With installations of gas analyser systems in the cement Industry domain across 40 countries around the world, Adage enjoys a leadership position in the Indian cement Industry in terms of market share and innovation.

Application Task
Today, there are two major types of DeNOx processes known in industry: the Selective Catalytic Reduction (SCR) and the Selective Non-Catalytic Reduction (SNCR). SCR DeNOx installations are common for large scale combustion plants like coal fired power utilities, whereas SNCR technology can often be found in large to mid-size cement plants and incineration plants. LDS 6 insitu Laser Gas analyzers can be used for optimisation of either technology.

The SNCR process
In the SNCR process, usually ammonia (NH3) or urea (CO(NH2)2) is introduced to the flue gases in the hot combustion zone where the reduction of NOx takes place spontaneously. Depending on the type of the reducing agent used, the SNCR process is usually operated in the temperature range of 800 to 950 ?C. At temperatures below the optimum temperature, the reaction rate is too slow, resulting in an inefficient NOx reduction and high ammonia slip. Above the optimum temperature, the oxidation of ammonia to NOx is getting significantly high and the process tends to produce NOx instead of decreasing it.

As combustion processes normally show fast and considerable changes in the temperature distribution and the composition of the flues gas, the efficiency of the SNCR- DeNOx process is strongly dependent on the temperature and NOx distribution in the reaction zone.

At constant NOx level behind the reaction zone, the NH3 slip is a strong indicator of the current reaction conditions.

Ammonium Bisulphate formation

  • Together with acidic flue gas components, the NH3 injected to the flue gas (or formed from an injected ammonia derivative like urea) can lead to salt formation. Mainly ammonium bi-sulphate (ABS) causes difficulties in the process:
  • ABS has a melting point of 147 ?C and will consequently be present as a liquid or solid accumulated on surfaces.
  • It might plug parts of the catalyst, increasing the pressure drop and causing catalyst deactivation. It might also plug the air pleater (AP), decreasing its efficiency.
  • ABS is hygroscopic at lower temperatures and will cause corrosion when absorbing moisture from the gas.
  • ABS formed on ash particles can cause sticky ash on the electrostatic precipitator?s (ESP) hoppers which are problematic to handle.
  • The amount of the NH3 slip determines the total amount of ABS, as the SO3 is usually in excess in the combustion process.

Application solution

  • A single LDS 6 analyser is able to monitor the NH3 slip in up to three measurement points simultaneously.
  • One sensor pair is used to control the ammonia concentration in situ directly after the catalyst or the high temperature reaction zone. see fig. 2.
  • Since LDS 6 delivers NH3 concentration data in real-time, very fast control of the NH3 slip is achieved – runtimes with excess dosage are completely avoided.
  • Another important measuring point is the emission monitoring directly in the stack. Here, the final emission of NH3 and therefore the total nitrous emission is observed. Siemens LDS 6 advantage for DeNOx control :
  • Faster regulation than with other available technologies (e.g., FTIR) and therefore most efficient optimisation. The in situ approach allows representative NH3 measurements without side effects or cross interference. The patented inbuilt calibration cell allows ease of maintenance.

Optimising an SNCR process by controlling the NH3 slip means:

  • To reduce the consumption of ammonia or urea while keeping the legislative threshold values for NOx (and NH3 if required);
  • To stabilise the process and avoid peak emissions
  • To minimise technological drawbacks, increasing DeNOx ef?ciency at reasonable level of NH3 slip
  • To reduce the total nitrogen – NH3 and NOx – emission.
  • An optimised process input is the base of minimized emission.
  • Adage Automation has unique solutions with following advantages to the end user:
  • In-situ technology with fast response time
  • No sampling system
  • Separation of analyser and process environment
  • High resistance to corrosion & measurements are feasible in high dust loads and complex gas mixtures
  • Built-in calibration cell
  • Lifelong calibrated analyzer & zero and span checked 24 timess
  • Multi -points: Up to three measurement locations can be monitored in the same time
  • Laser technology
  • No cross interference

About the author:
Abhijit Chatterjee
, Managing Director, Adage Automation Pvt Limited.

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Process

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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Process

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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Process

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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