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Humboldt Wedag India has been at the forefront of technological developments taking place in the cement industry of Indian subcontinent. ASHOK DEMBLA and BALESH SINGH open up a window for us on various aspects of developments.

The Indian cement industry continues to be second largest producer of this commodity in the world. This sector is expected to continue its fast-paced growth and attain installed capacity of 850 million tonnes (MT) per annum by 2030 and 1,350 MT by 2050. The industry has made tremendous strides in technology assimilation and upgradation.

Single production lines of over 12,000 TPD (tonnes per day) with multi-stream pre-heaters and calciner, thermal energy consumption of 685 Kcal/Kg clinker, or electrical energy consumption of 70 kWh/ton of cement were unimaginable two decades ago when these figures hovered at around 850 Kcal/Kg clinker and 110 KwH ton of Cement respectively.

Some of the important plants supplied by Humboldt Wedag India which are achieving results comparable to best figures in the Industry and sometimes best in the Industry are;

  • Rajashree Cement (UTCL) – All four kiln lines, including raw material and cement grinding. The line no 4 is at present operating at 12,000 tpd.
  • UTCL Raipur – Kiln No II – Presently operating at 12000 tpd
  • UTCL Tadpatri, Kotputli and Aditya Cement (Line II) – Identical Kiln lines, each operating at an average output of 9500-9600 tpd.
  • Shree Cement – All kiln lines at Ras, Raipur and one kiln line at Beawar and cement grinding units at Beawar Ras, Khushkhera and Bihar.
  • JSW Cement -All cement and Slag Grinding Units at Vijaynagar Nandyal and kiln line at Nandyal.
  • KCP Cement – Achieving Electrical Energy Consumption of 45 kWh/t up to Clinkerization and Thermal Energy Consumption of 685 Kcal/Kg Clinker.

Dalmia Cement, Belgaum – Achieving Electrical Energy Consumption of Less than 10 kWh/t for Raw Material Grinding in Roller Press finish grinding KHD has been pioneer in many technologies, to name a few;
I) First 4-stage Preheater Technology – The first plants with 300 tpd capacity and 600 tpd capacity, came in from Humboldt in Andhra Pradesh at the end of the 1960?s.
II)Roller Press Technology – First plants again came from Humboldt in Diamond Cement, Rajashree Cement and Vikram Cement, in the year 1986-87 which have now been upgraded.
III) V Separator Technology – This technology came as a boon for energy-savings and reliability for semi-finish grinding technology in the year 1995.
IV) Alternative Fuels – Extended PYROCLON? and KHD?s Combustion Chamber came as excellent technology to use pet coke, city waste and other waste derived fuels.
V) 5 & 6 Stage Preheater Technology – The first of these type of plants came on line in India e.g. Diamond Cement, Vikram Cement and Rajashree Cement in order to reduce thermal energy consumption.
VI) Latest Generation Grate Coolers – The KHD Grate Cooler got its start at Vikram Cement. Later came the PYROSTEP? Cooler and now PYROFLOOR? cooler. In addition there has been many innovations in Burner Technology, where the original KHD design has become the world standard.
Ref. Pic-2

Energy, Efficiency and Environment
KHD-Humboldt Wedag buzz word for Technology is Energy, Efficiency and Environment.
Energy: The COMFLEX? grinding system consumes less energy compared to other process circuits.. More and more customers began to use this roller press-based system in the finish-grinding mode for Slag, Limestone, and clinker.

Potential in saving with selection of KHD Roller Press circuit than the VRMs:

  • 2-3 Kwh/T in Raw Grinding Application as the total department power ranges between 10-12 Kwh/t according to Material hardness.
  • 2.0-3.0 Kwh/T in Clinker Grinding.
  • 4.0- 5.0 Kwh/T in Slag Grinding in finish mode.

Potential in saving with Selection of KHD Pyro process Technology.

  • Lower Specific Heat consumption due to highest collection efficiency of top cyclones, Lower string temperatures due to efficient calciner which contributes about 5-10 Kcal / kgcl savings.
  • Majority of KHD Pyro-process circuits are operating in range of 685-695 Kcal/kgcl.
  • Specific Power consumption from Mines Crusher to Clinker Silo Feed ranges 48-50 Kwh/t.
  • Efficiency:

  • It is proven that KHD COMFLEX? circuits consist of Roller Press gives more efficiency than other Grinding Systems. Under normal operation conditions our STUDDED roller surfaces are maintenance free for more than years Ref.Pic-1,4
  • KHD Pre-heaters are proven as efficient pre-heater towards reaction time for de-carbonization and sufficient time for combustion of harder to burn materials like AFR and pet-coke as fuel.
  • KHD- Low NOx calciner are known to get more reduction of NOx due to kiln exit gases?s longer retention time in reduction zone.Environment:
  • COMFLEX? grinding plants offer a dust-free circuit with no belt conveyers and a very effective de-dusting concept.
  • KHD offers the new concept of PYROREDOX? NOx reactor which works under reducing and higher reactivity of NOx reduction in a Loop before entering to calciner which can reduce the NOx below 600 mg/NM3 Ref. Table-1
  • Hence no requirement of SNCR or SCR for NOx reduction. Ref. Pic-3
  • KHD Pyro jet Burner emerged as most efficient Burner to control Thermal NOx across the Kiln. 200-400 mg/NM3 Ref. Pic-2

Status of Emissions and CEMS – present Status and Challenges
Emissions are released from cement kilns, coming from the physical and chemical reactions of the raw materials and from the combustion of fuels. At present norms exist for dust, TOC, HCl, HF, SOx, NOx Hg, Heavy Metals and Dioxin in India, which are comparable or better as compared to China, Indonesia and Philippines. Ref. Table-2, shows the comparison; Emission Standards at different countries. In India the CEMS system started approximately 5-7 years ago for monitoring particulate emissions and subsequently NOx. Policy guidelines were also formulated and released on 10th May 2016 for emission control by the Ministry of Environment. A brief status as compared to China, Indonesia and Philippines is given in table in next page; As mentioned above the Indian Government (Ministry of environment, forest and climate change) released a new notification on 10th May 2016 for control of emissions released from cement industry.
The Ministry of Environment addressed Emission Limits for old plants as mentioned in table above. Ref. Table1,3Status of Alternate Fuels and Thermal Substitution Rate
KHD Humboldt Wedag has expertise in using alternative fuels either in the calciner or in the kiln. KHD supply award wining Combustion chamber for dry municipal waste and other difficult fuels In fact Humboldt Wedag India supplied Vikram Cement a handling and firing system in order to use of Jaipur City Waste. We also delivered a similar system to Jaypee Cement to use Chandigarh City Waste.Way Forward
With the unlimited growth potential in India, Technological innovations leading to low thermal and electrical energy consumption become the center point of focus. In parallel there is need of environmental friendly technologies for sustainability. Of course everything comes with a price but advancement and success lies in the technological innovations which are effective and cost competitive also. Continual development based on the need from the industry are the foray in which we as cement technology suppliers have to think ahead.
Table-1:
Table-2:
Table-3:

About the authors:
Ashok Dembla, Managing Director, Humboldt Wedag India.
Balesh Singh, Process Head, Humboldt Wedag India.

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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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