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SFTMCross-Bar® cooler upgrade

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SFTMCross-Bar? cooler upgrade from FLSmidth is helping cement producers maximise productivity and improve the operational efficiency of their plants.

With more than 20 years operating experience, SFTMCross-Bar? cooler is considered as proven product and has revolutionized the way in which clinker coolers were installed, operated and maintained.

The increasing demand for productivity enhancement and operational excellence during high cooler loading, drive the need for newer concept in cooler technology. FLSmidth’s Cross-Bar? cooler is well-proven in the market to handle a variety of kiln operating conditions, from small clinker production up to the largest plants today in operation.

Why SFTM Cooler upgrade SFTMCross-Bar? cooler upgrades are highly attractive, providing compelling reasons for retrofits and upgrades – proven from a capacity, control and wear stand point. Increased clinker transport capabilities, production boost, better control of the clinker bed even under heavily loaded conditions, reduced power consumption and increased wear parts life are key highlights with this upgrade.

As a result of petcoke and alternative fuel usage, some plants experience reduced stability in the kiln operations and a general consequence is that the clinker out of the kiln becomes dustier and the risk of snowman formations on the fixed inlet increases. To overcome these problems, it requires an effective countermeasure against the snowman and adjustments of the cooler operation. The good news is that with the effectiveness of the ABC Inlet, the flexibility of converting SFTM cooler to the latest Cross-Bar? cooler and replacing the original grate with the New Wave grate design, paves the way to faster payback of investment and achieve life cycle benefits.

An advance in technology
FLSmidth’s approach is to have thorough review of all existing pyro equipment from both mechanical and process perspective before making a recommendation and ensure optimum results.

ABC Inlet
Air Blast Controlled (ABC) Inlet prevents the formation of snowman and gives an optimal start to the cooling process with a more uniform layer. MFR cooling process is supplemented by an air blast release directly to the grates and the clinker bed. It eliminates snowman and prevents dead zones where the traditional blasters can’t reach. It also ensures uniform clinker distribution. ABC inlet can be fitted on to the existing SF Cooler as well as any grate coolers.

SFTM Cross-Bar? cooler upgrade
The upgrade is achieved with most of the parts untouched, essentially only requiring a change in cross bars and hydraulic system.

The key change involves an upgraded transport mechanism. From an existing SF cooler, all the existing cross bars are removed and new cross bar elements that are all movable will be installed. Together with some minor hydraulic system and PLC programming changes, the upgrade is quickly carried out, depending on the cooler size.

Impressive operating results: The SFTM Cross-Bar? cooler upgrade was implemented and working satisfactorily in Vasavadatta Cement Unit 3/4, Gulbarga, Karnataka since year 2013 and some of the results are indicated below:

Diverse customers worldwide having SF cooler have benefited through this upgrade which is easier / faster to implement and provide impressive benefits.

New wave grate
Cement plant operators around the world know the importance of keeping maintenance time and costs to a minimum. For plants with an SF Cross-Bar cooler there is now a new type of grate available for upgrade.

Reduce power consumption: The design of the Wave Grate reduces airflow resistance through the grate, which results in a significant reduction in pressure drop there by reduction in power consumption of cooler fans and efficient cooler operation.

Save maintenance costs and time: The two-piece grate design helps that the upper part of the grate can be removed, making it easy to clean inside the grate if needed.

The upper Wave Grate with wear strips is the only wear part that needs replacement and has increased wear life. To change the upper Wave Grate, access the bolts from above the cooler grate line. This is an advantage compared to the original grate, where access from both the top and bottom of the grate line is needed.

Great can still get better
A surprisingly simple upgrade is done to convert an existing SF cooler to the FLSmidth’s Cross-Bar? cooler. This unique cooler upgrade meets all current challenges and ultimately leads to sustainable productivity enhancement.

Cement producers choose to implement innovative upgrades like adding an ABC Inlet, SF Cooler upgrade, Wave grate so as to maximise plant productivity, increase operational efficiency and lower operational cost which ultimately keeps them productive today and tomorrow.

Key benefits:

  • No snowman
  • Improved heat recuperation
  • Increased availability
  • Better operational control
  • Fast and simple installation

Customer experienced benefits:

  • Reduced Snowman formation
  • Increased transport efficiency
  • Reduced maintenance cost
  • Reduced down time
  • Improved wear life

Key benefits:

  • Reduced power consumption
  • Increased grate wear life
  • Easy to clean and maintain
  • Fast and Simple Installation

Bundled benefits of ABC Inlet +
SF Cooler Upgrade + Wave grate:

  • Greater throughput
  • Increased transport efficiency
  • Fast and simple installation
  • Lower operating cost (Fuel+Power+Maintenance)
  • Faster payback of investment
  • Low total cost of ownership

Author: Ram Kumar Sridharan, Product Line Manager, FLSmidth.

(Communication by the management of the company)

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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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