Environment
April price hikes indicative of improved profitability | Analysts
Published
7 years agoon
By
adminAccording to a few analysts and industry watchers, the hikes in the prices of cement by various cement manufacturers are an indication of a possible growth in volumes and probable profitable for cement makers during the current quarter. A recent report released by analyst firm Edelweiss says that cement prices have picked up u on an average – during the month of April.
‘Average all-India prices rose 6.7 per cent month-on-month led by (the) western and southern markets where price jumped in double digits, followed by the eastern market (up 6 per cent month-on-month) and other regions,’ the report said. The report claims that cement off-take was ‘robust’ in the eastern region of India, ‘stable’ in the north and ‘marginally weak’ in Uttar Pradesh.
PhillipCapital India said in a 27th April report that despite assuming flat volume growth for the sector, Q1 earnings are likely to surprise positively, driven by prices hikes. ‘Given a favourable demand scenario, we understand cement prices have been raised across pockets by about 10 per cent and further price hikes of 3-5 per cent cannot be ruled out in May 2017. After the monsoon arrives, cement prices are unlikely to be increased until the end of H1FY18,’ the report said.
Vijayawada builders to import cement to combat cartelisation
Alleging that cement companies were engaging in cartelisation, builders’ associations in Vijayawada have decided to import cement from Sri Lanka, China, Bangladesh, Malaysia and Korea.
According to estimates from these builders, the import of cement from the countries indicated above would reduce the price per bag by around Rs 30, which will eventually benefit consumers as construction prices will come down.
The Vijayawada chapters of the Confederation of Real Estate Developers’ Associations of India (CREDAI), Andhra Pradesh Real Estate Developers Association (APREDA) and Capital Region Builders Association (CRBA) have formed a joint action committee (JAC) to oppose the alleged cement cartel.
Concrete admixtures chemical market may touch $16,324 million
According to a new report published by Allied Market Research, Concrete Admixtures Construction Chemical Market: Global Opportunity Analysis and Industry Forecast, 2015-2023, the global concrete admixtures construction chemical market is projected to reach $16,324 million by 2022. This translates into a CAGR of 5.7 per cent from 2017 to 2023 (the market was valued at $11,027 million in 2016).
Concrete admixtures construction chemical are ingredients other than water, aggregates and cement, which are used to modify the properties such as, heat of hydration, accelerate or retard setting time, workability, water reduction, dispersion and air-entrainment, impermeability, and durability factors. Concrete admixtures are available as mineral and chemical admixtures.
The rapid growth of the construction industry due to change in lifestyle patterns in emerging countries such as China, India, Brazil, Middle East, and Africa, owing to the rapid economic development and increase in disposable income has fueled the growth of concrete admixtures market. Moreover, fast adoption of latest manufacturing standards globally is expected to increase the penetration level of concrete admixtures.
Andhra Pradesh asks cement companies to drop prices
A Group of Ministers (GoM), constituted by the Andhra Pradesh government to look into the issue of rising cement prices has held talks with representatives of various cement companies. The government has directed cement companies to slash prices ‘immediately’, but these firms have said that they would ‘revert on the issue’ in two days.
According to the cement companies, they would face an approximate tax incidence of around Rs 40 per bag after the new Goods and Services Tax (GST) comes into force. But the GoM does not want the cement companies to hike prices before the new tax regime is rolled out.
The Andhra Pradesh government is now arguing that it already gives the state’s cement companies ‘many concessions and benefits’, so the GoM has maintained that the cement firms cannot hike prices unilaterally, placing a burden on the common man.
Orient Cement is member of Cement Sustainability Initiative
Orient Cement Limited will become part of the Cement Sustainability Initiative (CSI), a CEO-led business initiative. The entity operates under the umbrella of the World Business Council for Sustainable Development (WBCSD), an effort by global cement majors towards sustainable development.
Orient Cement expects membership of this initiative to give further impetus to its efforts to create a safe and ecologically favourable environment, and is in line with its vision to be the employer of choice and the neighbour of choice in the geographies where it operates.
After the announcement, Deepak Khetrapal, Managing Director and Chief Executive Officer, Orient Cement said, ‘We are delighted to be a part of the global mission to make our industry shoulder the responsibility for global sustainability. We thank the WBCSD and the CSI for partnering with us in our journey. We expect to contribute to and benefit from our participation in the various working groups of this initiative, and look forward to a very engaging and fulfilling journey ahead. We accept this membership with a deep sense of responsibility and intend to play our role to the utmost extent in this noble mission.’
Sanghipuram joins progressive ‘Less Cash’ township league
Taking forward the vision of Prime Minister Narendra Modi, Sanghipuram, home to Sanghi Industries‘ employees and their families based in Kutch, Gujarat, has moved towards a ‘less cash’ township model with almost 90 per cent of monetary transactions being carried out digitally. In order to promote digital payment systems, shops and existing business entities at the town are equipped with Point of Sale (PoS) machines, major online wallet options and interface apps like Unified Payments Interface (UPI) and Bharat Interface for Money (BHIM).
The efforts have clearly made a mark, as Sanghipuram was launched as one of the ‘less-cash’ townships of India by Prime Minister Modi at Nagpur a few days back. With a population of around 2,500 people, Sanghipuram is a self-reliant town with businesses, shops, hospitals, schools and other infrastructure facilities required for an integrated township.
Aditya Sanghi, Director of Sanghi Industries, said, ‘Our company believes in following the best practices initiated by the Government of India. Not only have we implemented this less cash initiative in our township, we have further extended it to our dealer network in Gujarat as well as other states where Sanghi Cement is sold. About 90 per cent of monetary transactions in Sanghipuram have now turned cashless and digital.’ As a result of these efforts, the number of daily cashless transactions has increased to 140 as compared to 75 prior to the start of the cashless transaction campaign.
Sanghi Industries Limited is a major cement player in western India. The company’s 4 million tonnes per annum capacity plant in Abdasa taluka of Kutch in Gujarat is ranked as one of the largest cement plants at a single location in India. It is one of the top three players in Gujarat, and is now extending its presence to Maharashtra and Rajasthan.
CREDAI protests cement price hike, seeks Centre’s intervention
The Confederation of Real Estate Developers’ Association of India (CREDAI) has sought government intervention to check rising cement prices. The entity said that the spike could ‘create unnecessary roadblocks and impediments’ in achieving the goal of ‘Housing for All’ by 2022. Cement prices have witnessed a sudden jump of 20-40 per cent over the past two months across the country, says CREDAI.
‘We are pained by complaints of unjustifiable and collusive jacking up of cement prices by manufacturers across India, which have the potential to create unnecessary roadblocks and impediments in ensuring ?Housing for All’ by 2022, said CREDAI Vice-President Sushil Mohta. He said the Competition Commission of India, on earlier occasions, had pulled up cement manufacturers for ‘collusive pricing’ and had imposed hefty fines on them.
Seaborne cementitious trade increases globally; Asia-Pacific absorbs over 50% of total trade
According to the latest update of the World Cement, Clinker & Slag Sea-Based Trade Report from CW Research, more than 174 million tonnes (MT) of cementitious materials were traded by sea-going vessels in 2016. The trade volumes grew 1.3 per cent compared to the 171.9 MT of cementitious materials traded by sea in 2015.
CW Research’s latest research shows that seaborne cementitious trade has benefited from low shipping rates. Moreover, the increase in imports in some key markets where cement production has leveled out (such as the US), has also motivated higher seaborne cementitious trade volumes in 2016, compared to 2015
Raluca Cercel, CW Research’s Lead Analyst for the report, stresses that, in the seaborne global trade context, ‘About 2 to 3 per cent of total cement consumption is traded internationally, and two-thirds of the total trade is performed by sea-going vessels’.
In the worldwide seaborne cementitious trade, gray cement continues to be the most traded cementitious commodity by sea. In 2016, more than half of the sea-based cementitious trade, comprising gray cement, white cement, slag, clinker, and fly ash, was made up of gray cement. Clinker (including both white and gray) accounted for 33 per cent of total seaborne cementitious trade in 2016, followed by ground blast furnace slag, with a 12 per cent share of the trade.
Far less traded, white cement and fly ash made for 3 per cent and for less than 2 per cent, respectively, of total seaborne trade of cementitious materials.
According to CW Research, on the main trade routes and regions, the Asia Pacific region absorbs 51 per cent of the total seaborne trade of cementitious materials. Due to proximity and pricing considerations, the largest volumes of cementitious materials were traded within this region, with almost 90 MT shipped in 2016.
Global companies LafargeHolcim, HC Trading and Cemex together control about 30 per cent of the cement trading market. The two largest Asian cement traders (Taiheyo and Tong Yang Cement) together control around 10 per cent of the market.
Worldwide, there are more than 900 cement terminals, more than 100 waterside grinding plants (slag and clinker) and almost 140 waterside integrated cement plants. Most of the cement terminals are located in Far East Asia, followed by the Med Basin and the Black Sea. In terms of waterside integrated plants (used as export facilities), the Far East has a total of 51 plants, while 46 integrated waterside plants are located in the Med Basin and Black Sea region.
The presence of these facilities in the Asia Pacific region favors the trade of cementitious materials, therefore explaining the large volumes that were shipped in the area.
Utilisation of cement carriers has currently reached almost 100 per cent u and is a forecasted to grow in the coming years (mostly concentrated in Far East Asia, India, Northern and the Baltic Sea). In terms of the specialised cement carrier market, there are currently more than 300 cement carriers used for seaborne distribution of cementitious materials. An additional 200 cement carriers under the 1,000 dwt allow for environmental friendly, speedy and weather independent cement distribution.
Driven in particular by production shortages and supply chain optimization efforts, CW forecasts that the total traded volume of cementitious materials will exceed 200 MT, increasing at a CAGR of more than 3 per cent between 2016 and 2021.
Cement trading ensures that surplus and shortages of cementitious materials are ironed out across markets. More than that, maintaining utilisation rates weighs heavily in the future of traded cement volumes. These are only two of the factors that balance the scale in favour of increased sea-trade volumes in the next five years.
Hindering factors are potential fuel-related restrictions on the shipping industry, as well as new capacity additions in traditional import markets, will counterbalance positive drivers,: emphasises Raluca Cercel, CW Research’s Lead Analyst for the report. In conclusion, seaborne cementitious trade volumes increased globally between 2015 and 2016. That was largely due to consumption in the Asia Pacific region, which absorbed more than half of the total seaborne trade of cementitious materials. Even though fuel usage regulations in maritime shipping and local autonomy in cement production may condition the promising numbers, the outlook for seaborne cementitious trade volumes remains optimistic.
Cement firm reportedly drills Rs.350-cr hole in IndusInd, Yes Bank profits Exposure to a single cement company has made a Rs 350-crore dent in the net profits of IndusInd Bank and Yes Bank, private lenders otherwise known to have better control on asset quality.
IndusInd Bank and Yes Bank had to make provisions of Rs 122 crore and Rs 227.9 crore, respectively, towards their exposure to this account in compliance with a Reserve Bank notification. Both the banks stressed the reverses are ‘temporary’ in nature, underlining that the cement company in question is all set to be acquired by a better performing city-based company soon and once the deal fructifies, there will be a write back.
Even though the bank managements did not name the company, sources said this relates to the exposure to Jaypee Cements, which is all set to be acquired by UltraTech in a Rs 16,200-crore deal.
To ensure greater transparency and promote better discipline, the RBI has said that it will be flagging divergences in asset recognition to the bank, ask them to make extra provisions or re-classification of the account and instructed lenders to disclose the same in quarterly statements, starting with that for FY2016-17.
Cement demand likely to pick up: Sharekhan
Analyst firm Sharekhan believes that, barring the southern cement players (due to drought-like conditions in key southern states), cement demand is likely to improve on account of diminishing effects of demonetisation and an uptick in government spending on infrastructure development and housing projects. However, the key monitorables going ahead would be the guidance for the upcoming southwest monsoon season (which currently is below normal), and the sustainability of price hikes taken by cement companies during April 2017 (pan-India players have taken Rs 20 per bag month-on-month (m-o-m) hike, while Andhra Pradesh and Telangana cement companies are looking for Rs 50-60 per bag hike (m-o-m).
The firm says that cement stocks have largely factored in better earnings growth for FY2018 due to the impending improvement in the demand outlook and a sustained pricing discipline. However, the drought-like conditions prevailing in south India and a weak southwest monsoon can play spoilsport in FY2018. Consequently, Sharekhan remains selective at present and has a ?Hold’ recommendation on cement stocks under its active coverage.
Bone cement mixer devices’ market to grow during 2017-2021
Technavio market research analysts have forecast that the global bone cement mixer devices market will grow at a CAGR of more than 4 per cent during the forecast period. The market study covers the present scenario and growth prospects of the global bone cement mixer devices market for 2017-2021. The report also lists bench-top bone cement mixer devices, and portable and hand-held bone cement mixer devices, of which the portable and hand-held devices accounted for more than 65 per cent of the market share in 2016.
Technavio healthcare and life sciences analysts highlight the following three market drivers that are contributing to the growth of the bone cement mixer devices:
- Growing prevalence of orthopaedic disorders
- Increased use of bone cement in interventional procedures
- High demand for automated bone cement mixers
- Asia-Pacific to continue driving global cement industry growth
- According to a latest report, the global cement & concrete additive market has seen positive growth over the past few years and as per analysis, the global market will experience a remarkable growth during the forecast period.
Globally, the cement & concrete additive market has completely driven the rising demand for residential and non-residential properties. As per the data, the construction business is likely to increase in the near future, which in turn will escalate the demand for cement & concrete additives. Geographically, Asia-Pacific is expected to be the largest market owing to the rising construction and infrastructure investments in China, India, Indonesia and other countries as well.
The report, ‘Global Cement & Concrete Additive Market’ comprises extensive primary research along with detailed analysis of qualitative as well as quantitative aspects by various industry experts, and key opinion leaders, to gain deeper insight into the market and industry performance. The report gives a clear picture of the current market scenario which includes historical and projected market size in terms of value and volume, technological advancements, macro-economical and governing factors in the market. The report provides detailed information and strategies of the key players in the industry. The report also gives a broad study of the different market segments and regions.
Note-ban, polls impact cement companies’ Q4 bottom-line, says India Ratings Cement production would have shrunk in the March quarter primarily due to the base effect coupled with the note-ban-induced cash crunch and polls in many states during the period, says a report. ‘The lagged impact of cash crunch and state polls will take a toll on cement production in Q4. Latest data showed cement volumes in February 2017 declined the most in over a decade by 15.8 per cent y-o-y. Volumes also declined by 5 per cent on (a) month-on-month basis,’ says an India Ratings report. The report notes the decline in cement production growth is also on account of a high base last year, as in the March 2016, quarter production grew by 9.2, 13.5 and 11.9 per cent respectively.
On the prices front, the wholesale price index of grey cement and slag cement has shown a softening trend through November 2016-January 2017. Cement players got some respite on the cost front, with pet coke and coal prices showing moderation in January and February 2017, after pet coke prices almost doubled since March 2016, the report said.
Volumes of national players in Q3 contracted by 5 per cent y-o-y; while for central and north-based players fell by 3 per cent and 6 per cent respectively. The southern region, in contrast, showed strong volume growth of 21 per cent. Growth in the southern region is led by an increase in government expenditure in Andhra Pradesh and Telangana.
On the policy front, due to the recent measures announced by the Railways Ministry that require long term agreements/contracts for industries like cement, steel and fertilisers, cement companies may see improvement in demand.
As per the policy, the Ministry will provide a minimum guaranteed volume linked discount, on the basis of incremental growth in gross freight revenue, in return for a commitment to provide a minimum guaranteed quantity of traffic. The discounts will range from 1.5 to 35 per cent, as per the incremental growth in gross freight revenue.
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Concrete
Grinding aids help in reducing the agglomeration of particles
Published
3 weeks agoon
August 23, 2024By
RoshnaLokesh Chandra Lohar, General Manager – Technical and Executive Cell, Wonder Cement, shares insights on overcoming challenges, leveraging innovations and the crucial role of R&D in maintaining high standards in cement production.
Can you provide an overview of the grinding process in your cement manufacturing plant and its significance in the overall production process?
Cement grinding unit is used to grind clinker and gypsum into a fine powder, known as cement. The process of grinding involves grinding of the clinker to a fine powder, which is then mixed with gypsum, fly ash and other additives to produce cement.
At Wonder Cement, our grinding processes are pivotal in ensuring high-quality cement production by utilising state of art technologies ex. Vertical Roller Mill (VRM), roller press with ball mill in combi circuit and finish mode grinding and high-efficiency classifier, have achieved optimal particle size distribution and energy efficiency.
Our commitment to sustainability is evident with usage of energy-efficient equipment, eco-friendly grinding aids and renewable energy sources. Continuous research and development efforts ensure we stay at the forefront of innovations, optimising our grinding operations and minimising impact on the environment.
The main processes involved in a cement grinding unit are:
- Clinker grinding: This is the main process in a cement grinding unit, where the clinker is ground into a fine powder using a ball mill or combi mills (RP+ Ball Mill) or vertical roller mill circuit. The grinding process is controlled to achieve the desired fineness of the cement.
- Gypsum and other additives: Gypsum is added to the clinker during the grinding process to regulate the setting time of the cement. Other additives such as fly ash, BF slag and pozzolana may also be added to improve the performance of the cement.
- Packaging: Once the grinding process is complete, the cement is stored in silos before being packed in bags or loaded into bulk trucks for transportation.
- Quality control: Quality control measures are in place throughout the grinding process to ensure that the final product meets the required specifications, including strength, setting time, and consistency.What are the main challenges you face in the grinding process, and how do you address these challenges to maintain efficiency and product quality?
The main challenges in the grinding process include high energy consumption, frequent wear and maintenance, variability in clinker properties, environment impact and ensuring consistent product quality. To address these challenges, we have implemented several strategies: - High energy consumption: Clinker grinding is energy-intensive, and high energy costs can significantly impact the overall production costs of cement.
This is one of the primary challenges in the grinding process. - Use of high-efficiency equipment: We have state-of-the-art energy-efficient grinding equipment, such as vertical roller mills (VRM), Combi Circuit (roller press with ball mill), which consume significantly less energy consumption.
- Process optimisation: Real time monitoring and optimisation of the grinding process to minimise energy consumption.
- Frequent wear and maintenance: The grinding equipment, such as mills and crushers, is subjected to wear over time. Frequent maintenance and downtime can affect production efficiency.
- Regular maintenance: Implement a proactive maintenance schedule to address wear and tear promptly, ensuring the equipment remains in optimal condition.
- Proper lubrication: Adequate lubrication of moving parts can extend the lifespan of grinding equipment.
Use of wear-resistant materials for components, which are prone to wear and abrasion. - Variability in clinker properties: Clinker properties can vary from one batch to another, leading to inconsistencies in the grinding process and the quality of the final cement product.
- Clinker sources: At Wonder we have one clinker source, which is our mother plant at Nimbahera, Rajasthan and we distribute clinker to various split GU’s from Nimbahera. This helps us to maintain uniform clinker quality across each location.
- Quality control: Rigorous quality control measures help us identify and address variations in clinker properties. Adjust grinding parameters as needed to compensate for these variations. (ex. use of cross belt analyser and on-line particle size distribution)
- Environmental impact: Energy-intensive grinding processes can have environmental repercussions due to high dust emissions and energy consumption.
Use of high efficiency dust collection and suppression system to keep emissions below statutory norms - Sustainable grinding aids: Consider using eco-friendly grinding aids that enhance grinding efficiency without compromising cement quality and environmental standards.
- Alternative fuels: Use alternative and more sustainable fuels in the cement kiln and hot gas generated to reduce carbon emissions.
- Use of clean energy in logistics:
To reduce carbon emissions, sustainable alternatives are also sought for inland transport. We have involved neutral internal transports (electric powered trucks). - Automation and digitalisation of production:
- Wonder Cement has already initiated the process to implement Smart Cement Industry 4.0.
- With Industry 4.0, the automation and digitalisation of operations, including the use of sensors, remote diagnosis, analysis of big data (including the artificial intelligence analysis of unstructured data such as images and video), equipment, virtual facilities, and intelligent control systems will be done automatically (based first on ‘knowledge capture’ and then on machine learning). For Process optimisation we are using the FLS Process expert system (PXP) system. This allows for system optimisation and increased efficiency gains in production.
How do grinding aids contribute to the efficiency of the grinding process in your plant? What types of grinding aids do you use?
Grinding aids help in reducing the agglomeration of particles, thus improving the overall grinding efficiency and ensuring a smoother and more efficient grinding process without having adverse effect on any of the properties of the resulting cement. In cement manufacturing, various types of grinding aids are used to improve the efficiency of the grinding process. These include:
Glycol-based grinding aids
- Composition: Ethylene glycol and diethylene glycol.
- Usage: Commonly used in to improve the grinding efficiency and reduce energy consumption.
Amine-based grinding aids
- Composition: Triethanolamine (TEA) and Triisopropanolamine (TIPA).
- Usage: Effective in improving the grindability of clinker and other raw materials, enhancing cement strength and performance.
Polyol-based grinding aids
Composition: Polyethylene glycol and other polyol compounds.
Usage: Used to improve the flowability of the material and reduce the tendency of particles
to agglomerate.
Acid-based grinding aids
Composition: Various organic acids.
Usage: Used to modify the surface properties of the particles, improving the grinding efficiency and final product quality.
Specialty grinding aids
- Composition: Proprietary blends of various chemicals tailored for specific materials and grinding conditions.
- Usage: Customised to address challenges in the grinding process, such as the use of alternative raw materials or specific performance requirements.
Can you discuss any recent innovations or improvements in grinding technology that have been implemented in your plant?
Recent innovations and improvements in grinding technology:
- Selection of state-of-the-art vertical roller mills along with high efficiency classifier (VRMs): VRMs are more energy-efficient and have lower power consumption, leading to significant energy savings. They also provide a more consistent product quality and require less maintenance. For raw meal grinding, we have both VRM and roller press.
- Wear-resistant materials and components: Upgrading grinding media, liners and other components with wear-resistant materials. These materials extend the lifespan of the equipment, reduce downtime, and lower maintenance costs. Examples include ceramic liners and high chrome grinding media.
- Intelligent monitoring and predictive maintenance: Utilising IoT sensors and predictive analytics to monitor equipment health. Predictive maintenance helps identify potential issues before they lead to equipment failure, reducing unplanned downtime and maintenance costs. It ensures optimal performance and prolongs equipment life.
- Optimisation software and simulation tools: Using simulation software to model and optimise the grinding process. These tools help in understanding the process dynamics, identifying bottlenecks, and testing different scenarios for process improvement. This leads to better process control and efficiency.
How do you ensure that your grinding equipment is energy-efficient and environmentally sustainable?
- Energy-efficient grinding technologies such as VRMs: VRMs are more energy-efficient than traditional ball mills due to their ability to grind materials using less energy.
- Benefits: Up to 30 per cent to 40 per cent reduction in energy consumption.
Use of renewable energy sources (solar power integration): Utilising solar power for grinding operations - Implementation: Signing of long-term open access power purchase agreements (PPA) with renewable energy developers
- Benefits: Reduces reliance on fossil fuels, decreases greenhouse gas emissions.
Environmental sustainability practices
a. Dust collection and emission control
Description: Using bag filters, and covered material handling system
Implementation: Installing and maintaining high-efficiency dust control equipment.
Benefits: Reduces particulate emissions, improves air quality, complies with environmental regulations.
b. Water conservation
Description: Recycle and reuse water in the grinding process.
Implementation: Installing sewage treatment plant (STP)
Benefits: Reduces water consumption, minimises environmental impact.
c. Use of alternative raw materials
Description: Incorporating industrial by-products like fly ash, BF slag and chemical gypsum in the grinding process.
Implementation: Sourcing and blending alternative materials.
Benefits: Reduces the need for natural resources, lowers carbon footprint, enhances sustainability.
By implementing these practices, the plant ensures that its grinding operations are both energy-efficient and environmentally sustainable, aligning with industry best practices and regulatory requirements.
What role does research and development play in optimising your grinding processes and the selection of grinding aids?
Following is the role of research and development in optimising grinding processes and selecting
grinding aids:
- Testing and usage of new low-cost cementitious material: Dedicated R&D teams work on developing and new low-cost cementitious material to reduce clinker factor in cement and
improve efficiency. - Process simulation and modelling: Uses simulation and modelling tools to understand the dynamics of the grinding process and identify areas for improvement.
- Formulation of new grinding aids with reverse engineering: Formulate new grinding aids to enhance the efficiency of the grinding process.
- Testing and evaluation: Conducting laboratory and plant-scale tests to evaluate the effectiveness of different grinding aids.
- Collaboration with industry partners: Collaborating with suppliers, universities and research institutions to stay at the forefront of grinding technology advancements.
Research and development play a crucial role in optimising grinding processes and selecting the appropriate grinding aids. By focusing on innovation, process optimisation, sustainability and continuous improvement, R&D ensures that the plant remains competitive, efficient, and environmentally responsible. This commitment to research and development enables the plant to achieve higher productivity, lower costs and produce superior quality cement.
What trends or advancements in grinding processes and grinding aids do you foresee impacting the cement manufacturing industry in the near future?
The trends and advancements in grinding processes and grinding aids that we see coming up in the near future are:
1. Digitalisation and Industry 4.0
- Advanced process control (APC) and automation
- Internet of things (IoT) and predictive maintenance
- Artificial intelligence (AI) and machine learning (ML)
2. Energy efficiency and sustainability
- Energy-efficient grinding technologies
- Use of renewable energy
3. Innovations in grinding aids
- Eco-friendly grinding aids
- Tailored grinding aids
- Multifunctional grinding aids
4. Advanced materials and components
- Wear-resistant materials for liners
- High-density grinding media
5. Process optimisation and integration
- Holistic process optimisation
6. Sustainability and circular economy
- Circular economy practices
- Carbon capture and utilisation (CCU)
– Kanika Mathur
Jigyasa Kishore, Vice President Enterprise Sales and Solutions, Moglix discusses the critical role of cement capacity expansion in India’s infrastructure development, highlighting the importance of technological advancements, sustainability and strategic investments amid market challenges.
With an installed cement capacity of 600 million tonnes, India is the second-largest cement producer in the world. Cement consumption in India is expected to reach 450.78 million tonnes by the end of FY27, owing to rapid urbanisation and smart city development plans. Infrastructure, typically, receives the most funding from the government which bodes well for the cement industry. At a time when India is urbanising and building infrastructure at breakneck speed, the role of cement capacity expansion is becoming critical. This expansion, today, supports the market demands as well as contribute towards the nation’s economic ambitions.
Setting a firm foundation
Cement is an essential component in the construction of any nation. Roads and bridges, airports and public buildings all indicate cement’s critical importance in infrastructure development. Urbanisation is fuelled by it through the creation of housing projects aimed at achieving economic growth and development. Here’s why capacity expansion of cement production is critical:
Urbanisation: The demand for cement increases as urbanisation intensifies. This is further evidenced by the budget estimate for the Pradhan Mantri Awas Yojana for affordable housing, which has been pegged at US$ 9.63 billion (Rs.79,590 crore) for the first time, registering an increase of 66 per cent over the previous year’s budget.
Major infrastructure projects: Large infrastructure projects like highways, bridges, and city-development require considerable quantities of cement. Capacity expansion can ensure steady supplies of good-quality cement to these large-scale projects and see their timely and expeditious completion. The National Infrastructure Pipeline (NIP) has been widened to 9,735 projects worth $1,828.48 billion. Many of the upcoming projects will be heavily dependent on the cement industry. In addition, the PM Gati Shakti National Master Plan for infrastructure is further driving up the
cement demand.
Employment Generation: Increased production capacity directly results in job creation in the cement industry. Additionally, a corresponding demand for further employment in complementary sectors such as construction, logistics, and retail is also generated. This bolsters holistic economic development and prosperity.
Regional Economic Growth: New cement plants are often set up in regions with abundant raw materials but stunted industrial development. By setting up new plants in these regions, local resources can be leveraged and the overall growth story of the region can be improved. For instance, Dalmia Bharat recently announced a $10.9 million investment for further expansion of its already existing cement plant in the small town of Banjari in Bihar. The increasing presence of small and mid-size cement players across various regions helps dilute market concentration of industry leaders, leading to a more competitive and diverse market landscape.
Reinforcing the Structure
India’s cement industry is currently experiencing a tough fiscal year and there has been a downturn in pricing. Moderate demand is expected for H1FY25. Temporary setbacks such as labour shortage and heavy monsoons have also caused the demand for cement to take a dip in the past couple of months.
Needless to say, expanding capacity during periods of subdued demand involves risk. Cost implications of such investments can be significant. And firms could fail to recoup their investments if market conditions don’t improve as planned. Over-expansion could also result in an oversupplied market and further impact the prices as well as profit margins. Cement producers are currently under pressure due to reduced prices and slow demand. While this price dip might adversely affect profits in the short term, it could be seen as market adjustment ahead of a surge in anticipated demand during the second half of the fiscal year
Periods of uncertainty can be looked at as opportunities for companies to diversify risks and invest in innovation. Developing and launching new cement products for specific use-cases would contribute to the top line. Targeting export markets for better demand can also ensure the optimal use of additional capacities. At the same time, focusing on operational efficiencies would help the companies keep the cost of production in check.
New investments made in cement production facilities automatically come with the latest technological advancements that can enhance efficiency, minimise environmental impacts, and improve the quality of cement. This leads to construction practices that are more durable and sustainable. JSW, for instance, has initiated research on the integration of supplementary cementitious materials (SCMs) like fly ash, slag, calcined clay, and more. These materials not only improve the durability and strength of cement but also contribute towards reduction of carbon footprint of the cement industry. In order to meet energy demands sustainably, we must look at better industry practices such as usage of waste heat recovery systems, high-efficiency coolers and preheaters, and transition towards clean energy sources like solar or wind power.
There is also a growing need for cement companies to become environmentally conscious. Modern cement plants are increasingly adopting greener technologies owing to the decarbonisation pressure. Capacity expansion while keeping sustainability at its core will help check environmental impact of cement production while also aligning with the challenging global environment-conservation goals. Recently, UltraTech announced that it had received Environmental Product Declaration (EPD) certificates for four of its cement products. Similarly, Dalmia Bharat (Cement) has announced plans to produce 100 per cent low-carbon cement by 2031 and has a US$ 405 million carbon capture and utilisation (CCU) investment plan to achieve this goal. Such efforts are laudable and set a fine example for all industry players.
Shaping a Stronger Nation
Cement capacity expansion is a strategic move for the Indian cement industry. While short-term market fluctuations present challenges, continued investment in capacity expansion reflects a long-term vision for shaping India’s future infrastructure landscape. The current economic climate demands agility and innovation from Indian cement players. The leaders need to lead by example. By adopting industry best-practices, aiming for sustainable development, and working towards continuous growth and advancement, the cement industry is sure to rise like a phoenix from the ashes.
About the author
Jigyasa Kishore comes with 15+ years of experience at building brands, enabling enterprise growth, and transforming organisational performance with a technology-first approach. At Moglix, she leads brand growth as a digital supply chain solutions architect for large manufacturing enterprises.
She is an alumnus of the Indian
School of Business, Hyderabad, and Bangalore University.
Concrete
Filtration can help to control climate change
Published
5 months agoon
April 16, 2024By
adminNiranjan Kirloskar, Managing Director, Fleetguard Filters, elaborates on the importance of filtration and its profound impact on efficiency, longevity and environmental sustainability.
Tell us about the core principle of filtration.
Filtration is segregation/separation of matter by density, colour, particle size, material property etc. Filtration is of four basic types:
- Separation of solids from gas
- Separation of solids from liquids
- Separation of liquids from liquids
- Separation of Solids from solids.
As applied to engines/equipment, the main objective of filtration is to purify the impurities and provide the desired fluid or air for enhanced engine/equipment performance in turn optimising their performance and life.
Can better filtration bring productivity to the work process? How?
Better filtration can improve the quality of application performance in multiple ways. Filtration improves engine performance as it filters and prevents dirt, dust, and debris from entering into the engine. This ensures that the quality of air or fluid that reaches the combustion chamber is as per the specific requirements of optimal performance of the engine. It also extends engine life by filtering out contaminants. Efficient filtration ensures optimal performance of the engine/equipment over its entire operating life. Filtration also improves fuel efficiency as a clean filter allows for a better air-fuel mixture in the engine, thus improving combustion efficiency, which in turn results in better fuel economy. It keeps emissions under control as fuels burn more efficiently leading to lesser harmful residue in the environment. Thus, to sum up, an optimal filtration solution ensures better performance, prolonged engine life and less hazardous waste in the environment.
What is the role of technology in the process of filtration?
Innovation, research and development as well as technology play a pivotal role in catering to the ever-evolving environmental norms and growing market demands. At FFPL we have NABL Accredited labs for testing, we have ALD Labs for design, and a team of R&D experts constantly working on providing advanced solutions to cater to the evolving market needs. We have robust systems and advanced technologies that make high-quality, high-precision products. Our state-of-the-art manufacturing facilities use advanced technologies, automation, robotics and also Industry 4.0 as applicable to provide the best products to our customers. To ensure each product delivered to market is of utmost precision, advanced quality equipment such as CMM, scanning systems and automated inspection technologies for real-time monitoring and quality control during the manufacturing of filtration systems and to comply with standard quality requirements are used.
Tell us about the impact of good filtration on health and the environment.
Good filtration of equipment is to the environment what a good respiratory system is to the body. There are various benefits of an efficient air filtration system as it improves the air quality by ensuring optimum combustion of fuel thereby reducing/controlling emissions to the environment. Efficient lube filtration ensures low wear and tear of the engine thereby extending life of the engines and maintaining optimal performance over the entire operating life of the engine. Efficient fuel filtration ensures low wear and tear of expensive and sensitive fuel injection thereby ensuring perfect fuel metering resulting in best fuel efficiency and saving of precious natural resources. This efficient filtration can help to control climate change as it reduces the carbon footprint due to combustion in the environment.
Can your products be customised and integrated with other machinery?
Fleetguard Filters have been known as a leading solutions provider for decades. With relevant experience and close customer relations, we understand the market/applications requirements and develop solutions to address the pressing technical challenges our customers face concerning filtration solutions. Filters can be customised in terms of size, shape and configuration to fit specific requirements. Customised filters can be designed to meet critical performance requirements. Filtration systems can be designed to integrate seamlessly with any auto and non-auto application requirements.
What are the major challenges in filtration solutions?
Major challenges faced in filtration solutions are:
- With every emission regulation change, filtration requirements also keep changing.
- Engines are being upgraded for higher power ratings.
- Space for mounting filtration solutions on vehicles/equipment is shrinking.
- For fuel injection systems, the water separation efficiencies are becoming more and more stringent, so are particle separation efficiencies.
- Due to next level filtration technologies,filtration systems and filter elements are becoming expensive, thereby increasing TCO for customers.
- Customers prefer higher uptimes and longer service intervals to ensure lower maintenance and operating costs.
We, at Fleetguard, strive continuously to ensure that all the pains experienced by our customers are addressed with the fit to market solutions. Balancing the cost of filtration solutions with their performance and durability can be challenging, especially where the requirements of high filtration standards are required. Also, wrong disposal methods for used filters can have environmental impact.
- –Kanika Mathur