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The concept of refractories has evolved over time

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Sumanta Mukhopadhyay, General Manager – Technical, Dalmia Refractories Ltd
Significant energy saving is possible through judicious choice of refractories, with an aim to reduce shell temperature without compromising on lining quality in the critical areas of the kiln, says Sumanta Mukhopadhyay, General Manager – Technical, Dalmia Refractories Ltd.

Being one of India’s oldest and leading refractory companies, can you tell what the latest trends in refractories are for cement?
Two aspects have changed in recent times – first is product/innovation related and second relates to the concept of refractories. In the first case, most cement makers are now moving towards adoption of alternate fuels like pet coke, waste oil, tyre chips, municipal waste, animal meal, paper etc. that allow for suitable and environment friendly waste disposal of highly corrosive material. Usage of these fuels often creates a host of problems such as ring formations, unwanted coatings and degradation of refractories in the pyro-processing system. Refractory makers now have to take into account the usage of these alternate fuels and tailor products accordingly and/or bring in innovations that fight the challenges posed by these fuels.

Second – the concept of refractories has evolved over time. Earlier customers wanted ‘products’- suitable bricks for their kilns and other cement-making equipment. Today, given the pressure on margins and excess capacity, customers are looking for solutions that can reduce their cost of production. Hence, their expectations from refractory experts are optimum solutions that meet their production objectives as well as help in cost savings.

Being market leaders, Dalmia is well-positioned to meet the requirements posed by both these trends. Especially in the second case, Dalmia is one of the few companies that have the knowledgebase and a dedicated technical service team that can evaluate existing usage conditions, recommend solutions and help customers transition to an optimised lining for their kiln.

Why do we need to optimise?
Substantial cost savings is possible through optimisation of refractory lining. In the optimisation process, critical and non-critical areas of the kiln are identified along with an assessment of safety factors, the kiln lining history etc. and an optimised lining recommendation is developed. Our experience and studies have shown that significant reduction in annual refractory cost is possible through careful implementation of the lining optimisation concept. Apart from reduction in refractory cost, optimisation can also help in:

  • Fuel savings by reduction of heat loss
  • Savings in electrical power due to reduction of refractory load

What does the lining optimisation process entail?
Lining optimisation is a 360-degree concept where the first step entails undertaking an assessment of risk factors by studying the customer’s production process and identifying the critical and non-critical areas of kiln. Thereafter, a cost-analysis is done of existing over-engineered refractory products vis-a-vis proposed products, keeping in mind safety factors. Providing products and technical support in installation follows, alongside continuous analysis of refractory performance and evaluation of savings.

What are your latest offerings for the cement industry?
Given the growing usage of alternate fuels, Dalmia is offering a range of specially engineered high alumina bricks that can fight coatings and extend refractory life in coating prone areas. In the absence of superior, locally manufactured coating repellent bricks, customers had been using expensive imported bricks. Dalmia has helped bridge this gap.

There was a similar need in the market given the absence of locally made basic bricks.
Dalmia Refractories, a part of the Dalmia Bharat Group has another refractory leader ‘OCL’ in its stable that has been making basic bricks for steel for over 5 decades now. Drawing from our internal experience and manufacturing capabilities, Dalmia now offers locally manufactured basic bricks for cement industry that are at par with the best in the world in terms of quality, finish and performance.

We are now expanding our castable range and have a dedicated plant at Katni to make a wide variety of products. We have also tied up with Seven Refractories, a boutique European monolithic refractory company to bring advanced products and technologies to Indian cement makers.

With cement makers adopting green production techniques, are you also offering any environment friendly solutions?
We are working in the area of energy efficiency as cement kilns lose substantial energy through radiation from kiln shell. Significant energy saving is possible through judicious choice of refractories, with an aim to reduce shell temperature without compromising on lining quality in the critical areas of the kiln.

Once again optimisation of kiln lining is a way forward because it helps in energy savings by assessing the criticality of usage conditions and recommending appropriate alternatives in place of the highly conductive basic bricks in relatively less critical zones. Dalmia-OCL has a range of special alumina bricks like DALBURN, DALSUPREME which are made with special additives to achieve desired properties and work suitably as replacement for basic bricks. For instance, DALBURN is suitable for burning and upper transition zone of kilns with pet coke firing and DALSUPREME is a good option as replacement for basic bricks for upper transition zones of kilns with higher thermal load.

Apart from this, Dalmia OCL has developed basic bricks with special additives like Zirconia with enhanced thermal properties and reduced thermal conductivity. These bricks are suitable in reducing radiation losses in critical areas like upper and lower transition zones of cement kilns under pet coke and alternative fuel firing. We have also introduced a special energy-saving refractory brick called ‘ALITE’ which has very low thermal conductivity and can be used for inlet and calcining zone of kilns. Apart from low thermal conductivity, ALITE has high resistance to alkali and sulphur attack, good cold crushing strength and low density which helps in reducing total refractory load in the kiln.

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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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