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Pipe conveyor| An economically convincing alternative

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Cement manufacturing is energy intensive. For an economical and sustainable operation, Aalborg Portland [therefore] relies on alternative fuels and raw materials (AFR) in its Denmark lead plant to ignite the calciner and the main burner.

BEUMER Group supports the manufacturer with its AFR systems and develops individual single-source solutions in order to efficiently convey, store and feed the differently composed materials. The core of these systems is represented by an innovative pipe conveyor. The enclosed conveying systems ensure an environmentally safe, dust-free and low-energy transport of fuels and raw materials.

Aalborg Portland is a subsidiary of the Italian cement group, Cementir S.p.A, which is one of the largest and leading manufacturers and exporters of this material worldwide. In addition to the main plant in Aalborg, Denmark, Cementir S.p.A has further production plants in China, Egypt, Malaysia, Italy, Turkey and the United States, as well as numerous sales offices.

Secondary fuel instead of primary ones
The production of cement has always been one of the most energy-intensive operations. In order to avoid expensive primary fuels such as carbon, gas and oil, and to produce in more economic and sustainable way, Aalborg Portland has relied on alternative fuels for the incineration process in the calciner for several years. ‘In 2014, we decided to optimise and enlarge the existing system’, says Ole Str?m Hansen, Project Manager, Aalborg Portland. Until then the manufacturer transported the fuels to both calciners through long pneumatic conveying lines. However, the producer [initially] did not have a positive experience, as pneumatic conveying lines are extremely maintenance-intensive and also susceptible to breakdown. ‘In addition, we intended to increase the capacity of the existing conveying line to 20 tonne per hour per calcinator’, explained Hansen.

With the new concept, the Residue Derived Fuel (RDF) is transported for the calciner and the Solid Recovered Fuel (SRF) to the main burner. The solution is to transport alternative fuels from the storehouse to the rotary kiln area as well as the gravimetric feed of both the calciner and the main burner.

The decision was made to reduce the length of the pneumatic conveying line and to replace the remaining line by a mechanical transport system, but the manufacturer also wanted to install a completely new conveying line for the main burner feeding with a capacity of up to 10 tonne per hour. ‘We evaluated different variants of mechanical transport systems’, remembers Hansen. Finally, the Danish company opted for a single-source solution of BEUMER Group based on the innovative pipe conveyor technology.

An ideal solution for each case
In order to support producers of cement in AFR field, BEUMER Group has set up a complete business segment dedicated to AFR systems. ‘Our know-how and tailor-made systems permit us to offer an optimum support to our customers’, says Tomas Hrala, Project Manager at BEUMER Group.

The company has many years of experience and has always considered customers’ specifications. With this capability, the system provider is able to supply and install the whole chain from the acceptance and unloading of the delivery vehicle, up to the storing, conveying and feeding process of the solid alternative fuels for the specific user. The customer receives everything from one source, thus having a unique contact.

Pipe conveyor as hub and pivot
‘Due to the different grain sizes and the various compositions of these alternative fuels, it was necessary to develop an individual system solution for each line’, explained Hrala. To enable the transport of the pre-processed fuels from the storehouse to the calciner and to the main burner, BEUMER Group supplied and installed respectively one pipe conveyor as the heart of these systems as well as the accompanying equipment. ‘This conveying technology is not only eco-friendly but also requires low maintenance’, describes Hrala.

Its enclosed type of construction protects the environment safely from material falling down and emissions. Another advantage is the lack of dust development on the running line. Due to its ability to navigate curves, considerably less transfer towers are required compared to other belt conveyors, allowing for a substantial cost savings to the customer. BEUMER Group can customise each system to the individual routing.

Efficient single-source system
The delivery of the oven-ready material is carried out in moving-floor trailers.
The alternative fuels are unloaded and stored at the receiving station. Both lines receive the material/items transported by the moving floors modernised by BEUMER Group from the existing storehouse.

All transport systems supplied and the accompanying equipment are intertwined to ensure steady fuel feeding. The pipe conveyor of the calciner has a diameter of 350 mm (millimetres), a length of 135 m (metre) and can transport up to 50 tonne per hour to an intermediate hopper with a volume of 35 cm3 (cubic metre). This hopper is equipped with an activator and two double discharge screw conveyors, and distributes the material in two feeding and pneumatic conveying lines to both calciners. The two new pneumatic conveying lines to the calciner with rotary vane feeders and blowers were completely dimensioned and supplied by BEUMER Group.

‘However, during the constructive dimensioning of this system, we were faced with a particular challenge’, remembers Hrala.

The buildings in which the calciners are placed include an additional part called penthouse.

It supports, among others, the discharge station of the pipe conveyor, the intermediate hopper with the two double discharge screw conveyors and also both weigh belt feeders with the pneumatic conveying system. ‘From a static viewpoint, the penthouse had to be calculated trying to not exceed the available load application in the existing building’, explains Hrala. ‘At the same time, the subjacent requested throughway for plant vehicles had to be ensured.’

The heart of the line for the main burner is a pipe conveyor with a diameter of 200 mm and a length of 201 m. It achieves a conveying capacity of twelve tons per hour and is equipped with a spillage scraper conveyor for minimising the cleaning, as well as a de-dusting filter. The fuel feed of the moving floor in the storehouse to the pipe conveyor is carried out by a screw conveyor. The feeding system in the main burner building includes an intermediate hopper with a volume of 10 cm3, also with activator and double discharge screw conveyor and a weigh belt feeder. In addition, there is a pneumatic conveying line with blower and rotary vane feeder.

‘We are very pleased with both single-source systems’, Ole Str?m Hansen of Aalborg Portland sums up. ‘The transport systems and the accompanying equipment are intertwined to ensure steady fuel feeding.’ Hrala continues emphasising BEUMER Group’s role: ‘We could again demonstrate that we have substantial competence with regard to the handling of alternative fuels in the cement industry and that we can support our customers efficiently.’

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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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