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“Commitment of top management critical for boosting AFR use”

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– Milind Murumkar, Advisor AFR, Vicat India

What are the main AFR materials being used by cement plants in India?
The initial trend in cement industries started with utilisation of easy to use alternative fuels (AF) materials like biomass, segregated non-recyclable plastic waste, etc. Presently, we can say that the cement plants in India can co-process different types of waste like industrial wastes (hazardous and non-hazardous), tyre derived waste, plastics-derived waste, derived waste from municipal solid waste (MSW) segregation process, animal waste, waste from windmill sources, etc. Many of the matured cement plants with proper knowledge of this technology also offer cradle to grave solution for different industrial sectors like pharmaceutical, FMCG and tyre, food and beverage, wind mill sectors and municipal corporations for segregated MSW, etc.What are the challenges companies are facing in sourcing AFR materials and what are the strategies they follow?
Cement plant having this high temperature profile system can practically co-process all types of wastes, without having any impact on product quality and environment. Focus and care is needed to be exercised by the cement plants in selection of wastes, selection of equipment and selection and deployment of trained people for co-processing of any type of waste. Unless the cement plant understands its raw material characteristics, the fuel characteristics, the waste characteristics and the knowledge to make a proper recipe, the usage of AFR materials at higher volumes becomes difficult.
The challenges during utilisation of hazardous waste are much more difficult as it is very much necessary to have a proper input from waste generators about the waste characteristics and a proper Material Safety Data Sheet (MSDS) to understand the precautions needed during transportation storage handling and usage of different wastes. Manpower is also required to be properly trained for handling of these wastes in the plant and provided with required personal protection equipment. Proper displays of various hazards need to be displayed in local language at the work site. Once the waste quality and its hazards are known to the operating persons, the safety aspect gets addressed well.
Waste generators need total solution for their different wastes generated and the success in utilisation of different types of waste in cement plant lies in having co-processing ability for providing total solution to the generating industry. Business success depends on having a good win-win model between the cement plant and the waste generating industry.
It is better to have a proper market data mapping and have long term agreements with the waste generators for building trust and confidence in them.To what extent Indian cement companies are exploiting AFR compared to global benchmarks?
As indicated in the CII approach paper, India plans to achieve 25 per cent TSR by 2025. In comparison to global standards we are far behind as in many countries the substitution is in the range of 60-100 per cent. The main differentiator is waste characteristics and the lack of support by the required agencies for generating a good segregated quality waste. This long term plan of achieving 25 per cent substitution rate from the present national level of 4 per cent is as a big challenge.In terms of earnings, how beneficial is this for a cement company?
There is no second opinion on the benefits that accrue to a cement plant when they utilise higher quantities of AFR materials in their cement kilns. The direct benefits are reduction in fuel costs and raw material additive costs. Presently, the Rs/Thermi cost in a cement plant that uses coal/ pet coke is to the tune of around 1.20 to 1.40, where as if proper blended waste is utilised the Rs/Thermi of the quantity that is used as substitute to coal is at around Rs 0.5-0.60/Thermi. In case the cement plant is in a position to give a proper solution to the waste generating industries the waste generator also pays a ‘gate fees’ that adds to the cement plants bottom line.
In addition to these direct cash benefits, indirect benefits like reduction in use of fossil fuels, reduction in mined materials and improved life of mines will also acrue. However, the operating strategy at the plant and the commitment and will of top management to this concept of co-processing is necessary for improved utilisation of these untapped resources.What are the factors one has to look into while selection of AFR materials, including technology?
One should initially understand the cement plants’ infrastructure, plant capacity, process capability, available plant machineries and equipment, storage and blending facilities in the plant, quality check mechanism and facilities, and knowledge of their technical personnel. As regards AF materials it is important to know the feed points in the kiln system, the storage facilities especially for the hazardous materials in the plant with proper leachate collection mechanism, fire protection mechanisms, handling and dosage systems available etc. It is suggested that the existing technical teams visit a matured cement plant having these types of infrastructure to understand the requirements.– BS Srinivasalu Reddy

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Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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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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