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Making Business Case
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7 years agoon
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adminAdoption of alternative fuels as a means of increasing cost competitiveness is gaining ground in India. But the industry has a long way to go before achieving 25% TSR.
There are three different types of competitive advantages that companies can actually tap – cost, product/service differentiation, and niche strategies. While the cost competitive advantage can be highly successfully employed, it has its own challenges. This advantage calls for utilising its skilled workforce, inexpensive raw materials, controlled costs, and efficient operations to create maximum value to consumers.
Though there are many ways through which cost advantage of a cement company could be improved, increasing the use of alternative fuels and raw materials (AFR) is one that is an important means to achieve this goal.
"The concept of co-processing of waste in the cement kilns has been well understood by the cement industries over a period of last 3-4 years and also its impact on their bottom lines," says Milind Murumkar, Advisor AFR, Vicat India.
Since the fuel costs have shown upward trend over last few years, affecting the total manufacturing cost at their plants, the focus on AFR substitution rates has become a buzz word in the cement manufacturing sector.
Waste materials used for ‘co-processing’ are referred to as AFR. AFR can be used alone also as fuel in cement kilns. "A proper understanding of the processes, raw material characteristics and the waste compositions are the key factors that need to be assessed before use of AFR in a particular kiln system," Murumkar adds.Lagging behind
The Thermal Substitution Rate (TSR) in India has shown a very positive trend year on year, though at a very slow pace earlier and started picking up in the last 2 years to a level of around 4 per cent. This recycling of industrial waste is done on a negative cost basis. But plants using agricultural waste have to pay for it. For Refuse Derived Fuel (RDF), the companies are mostly in touch with municipalities.
The basic reason for the slow growth in AFR use can be broadly attributed to lack of knowledge on AFR usage in Indian cement industry in the earlier years, especially on usage of industrial waste, lack of skilled manpower for handling and usage of industrial waste, lack of proper infrastructure for storage and feeding of AFR materials to cement kilns, lack of proper understanding on the permitting process etc, Murumkar says.
Experts are unanimous that Indian cement industry is far behind and need to pull our socks as far as alternate fuels are concerned. 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 itself is a big challenge," explains Murumkar.Benefits
Utilisation of waste material as AFR in Indian cement industry plays significant role in bringing down consumption of fossil fuels at a time when fuel costs are going up, uncertainty over fuel availability and the consciousness over rising CO2 emissions and global warming are on the rise.
AFR use also brings in financial in the form of reduction in operating and capital costs, and non-financial benefits to the companies. The direct benefits are reduction in fuel costs and raw material additive costs. Indirect benefits like reduction in use of fossil fuels, reduction in mined materials and improved life of mines will also accrue when AFR is adopted.
Explaining the financial benefits, Murumkar said, "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 as substitute to coal this figure comes down to around Rs 0.5-0.60/Thermi." In case, the cement plant is able 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. Challenges
The challenges for setting up AFR facilities include selection of right technology in alignment with the existing equipment and infrastructure available at the plant, developing skill sets for monitoring enormous data like Material Safety Data Sheet (MSDS) and taking corrective measures when the need arises, precautions needed during transportation, storage handling and usage of different wastes. Besides, it is better to have a proper market data mapping done for selection of alternative materials and enter into long term agreements with the waste generators for ensuring uninterrupted supply of raw materials.
Used tyres garner the highest average Net Calorific Value of 7,500 kcal/kg, compared to hazardous wastes, including industrial plastic waste at 4,000 kcal/kg, followed by biomass at 3,000 kcal/kg and RDF from municipal solid waste (MSW) at 2,200 kcal/kg. Selection process
One should initially understand the cement plants’ infrastructure, plant capacity, process capability, available plant machinery and equipment, storage and blending facilities in the plant, quality check mechanism and facilities, and knowledge of their technical personnel, while choosing technology, cautions Murumkar. Even for selection of materials it is important to know the feed points in the kiln system, the storage facilities, especially for hazardous materials, in the plant with proper leachate collection mechanism, fire protection mechanisms, handling and dosage systems available etc.
Long term supply contracts are required for justifying the capital investment in AFR handling and feeding equipment. The quality variation in the AFR needs to be absorbed by the plant by careful process planning and optimisation.
Considering the sincere efforts required in organising AFR processes and operations for deriving the maximum benefit, many cement manufacturers have set up dedicated divisions that look around for alternative fuels. They are in regular touch with other industries for rejects with good calorific value. Some manufacturers have even set-up test laboratories to check the utility of such materials.
LafargeHolcim has a global policy on AFR. It has reached out to several industries and municipalities to source such materials, and the company’s Indian subsidiaries ACC and Ambuja also follow the same policy on AFR.
LafargeHolcim’s global waste management business, Geocycle, treated 10 million ton of waste in 2017, an increase of 13% versus 2016. The 10 million ton is almost twice the total yearly household waste generation of Switzerland or the equivalent of two million garbage collection trucks.
In a statement recently, Jan Jenisch, Group Chief Executive Officer of LafargeHolcim, commented, "At LafargeHolcim we offer solutions which facilitate the simultaneous recycling and recovery of waste. We have ambitious plans to continue investing in all parts of the world in order to bring the most advanced technology and solutions to our partners and play a role in solving the global waste problem."
Though the Indian cement industry has achieved excellence in energy efficiency, in AFR usage much remains to be done for achieving the TSR target of 25%. Increased use of alternate fuel in the industry is not only a potential solution towards sustainability, conserving the depleting fossil fuel, but also identified as one of the key levers to reduce carbon footprint.Vicat plants achieve 20% TSR
Vicat in India is a part of the global Vicat group which is more than 160-years old. It operates two plants in India as Kalburgi cement plant and Bharti cement plant, with an annual capacity of around 8 million tons, to produce superior quality cement since 2009. Since inception the focus was on utilisation of AFR material in both the plants and presently we could achieve Thermal Substitution Rate (TSR) of around 18-20% for Vicat in India.
Vicat’s India’s journey started with substitution rate of around 4% in 2012 and in last five years it reached to a level of 20%. The success story of Vicat group is quite enviable compared to our peers. We started using AFR at our Kadapa plant in the year 2011 and there has been fourfold increase in the TSR over the last 4-5 years. Today the substitution rate at our Vicat plants is 20 per cent, huge investments have been made in creating world class infrastructure at our plants for utilising different kinds of wastes which are hazardous and no-hazardous. Proper feeding systems have been provided for feeding the materials as per the material characteristics and their forms like for liquids, semisolids and solids, RDF and plastic wastes etc.
The different kinds of waste we use in the plants are pharmaceutical waste (liquid, semi-solid, solids), food & beverages / FMCG, black carbon and dolachar, firewood/biomass (mango seeds) refused derived fuel from municipal solid waste, used tyres etc.
We have set up well equipped laboratory for Proximate, Ultimate & Heavy Metal analysis of waste. A team of 50 personnel is working for alternate fuels to increase the substitution rate. All our stacks and ambient air quality monitoring stations are well connected with APPCB website and also we have arranged fire-fighting equipment, fire hydrant systems etc. It is our commitment to reach a substitution rate up to 40 per cent by end of 2020.
Main AF materials in use
- Industrial wastes (hazardous and non-hazardous),
- Tyre derived waste
- Plastics-derived waste
- Municipal solid waste (MSW)
- Biomass & animal waste
- Dried Sewage Sludge
- Waste from windmill sources
– BS Srinivasalu Reddy
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Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings
Published
3 years agoon
October 21, 2021By
adminRegion-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
Published
3 years agoon
October 21, 2021By
adminThe 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.
Process
In spite of company’s optimism, demand weakness in cement is seen in the 4% y-o-y drop in sales volume. (Reuters)
Published
3 years agoon
October 21, 2021By
adminCost 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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