Economy & Market

An Eco-Friendly Option

Published

6 years ago

August 31, 2018

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Today’s blended cements have its origin in the old Roman construction. Due to technological advancements [now] the similar cements are available in the new forms.

The Romans started making concrete more than 2,000 years ago, but it wasn’t quite like today’s concrete. They had a different formula, which resulted in a substance that was not as strong as the modern product. ‘Roman concrete is . . . considerably weaker than modern concretes. It’s approximately ten times weaker,’ says Renato Perucchio, a mechanical engineer at the University of Rochester in New York. ‘What this material is assumed to have is phenomenal resistance over time.’ That resistance, or durability against the elements, may be due to one of the concrete’s key ingredients: volcanic ash. Modern concrete is a mix of a lime-based cement, water, sand and so-called aggregates such as fine gravel.

Indian scenario
Surkhi, was the commonest pozzolanic materials used in India resembles volcanic ash. It has been used along with lime in many of our old structures, before modern Portland cement has taken its roots in India. Even after Portland cement made its appearance in the field of construction, Surkhi was used as an admixture to remedy some of the shortcomings of cement concrete. Surkhi was one of the main constituents in waterproofing treatments in conjunction with lime and sometimes even with cement for extending valuable pozzolanic action to make the treatment impervious. Surkhi is an artificial pozzolana made by powdering bricks or burnt clay balls. In some major works, for large scale production of Surkhi, clay balls are specially burnt for this purpose and then powdered. By its nature, it is a very complex material differing widely in its qualities and performances. Bhakra Nangal Dam is a standing ovation to the use of Surkhi in the construction.

Policy hurdles
The Indian cement sector had been under strict government control for almost the whole of the period 1969 to 1982. Government intervention took place both directly and indirectly. Direct intervention happened in the form of government control over production, capacity and distribution of cement, while indirect intervention took the form of price control. During this period, many companies and their plants started off but still growth was not seen at the desired rate. In 1977, higher prices were allowed for cement produced by new plants or major expansions of existing plants. Due to slow development, the uniform price imposed by the government, was substituted by a three-tier price system in 1979. Different prices were assigned to cement produced in low, medium and high cost plants.

Later on during the shortage of cement the producers were allowed to use Surkhi, burnt clay as a pozzolanic material to produce more quantity of cement and then the problem of quality started. Indiscriminate use of any sort of burnt clay material, without ensuring proper quality control norms created many issues with Pozzolana cement and gave it a bad name in late seventies and early eighties. Therefore initially when blended cements were reintroduced based on fly ash as a performance enhancer had to face users resistance. Now the blended cement available based with fly ash as a pozzolana is much different than the Surkhi-based Pozzolana cement.

Present scene
As per the papers published by NCCBM, the production of ordinary Portland Cement in India has currently remained to about 25 per cent and that of Portland Pozzolana cement has steadily increased to about 67 per cent. The production of Portland slag cement is limited to 8 per cent. The production trend of different types of cement such as OPC, PPC, PSC and others in the last decade indicates that the trend is more towards blended cements. This is a favourable change in the product mix of Indian cement industry as PPC and PSC are more specialised types of cement with advantages in terms of better durability characteristics.

Many developed countries started using such blended cements in large quantities in construction of critical structures such as rocket launch pads, sea water jetties, huge dams, etc. Production of blended cements directly increases the plant capacity without any need for creating additional clinker making capacity. In an environment of growing competition, another development has been the introduction of higher grades of cement particularly for OPC. However, realisation is growing fast amongst the consumers at large, that the properties of durability are of greater importance than strength.

Improvement in construction technologies and the need for durable construction in different aggressive environments have enhanced the use of blended cements. Under such prevailing trend the need of stringent control on quality parameters related to raw materials and cement becomes essential. In the present paper, efforts have been made to present quality trends of OPC and PPC as their production is around 92 per cent of total. In order to conserve high grade limestone and fuels, thrust is given for the production of variety of cements using inferior grade and/or alternative raw materials by adopting state-of-art manufacturing technology. To maintain the quality of cements and to promote the use of different types of wastes/by-products or inferior grade raw materials in the cement manufacture, BIS (Bureau of Indian Standards) has incorporated amendments in the standard specifications and also revised some of the specifications. The salient features of the modifications in standards are:

Increase in limit of pozzolana in PPC
Increase in limit of granulated blast furnace slag in PSC
Increase in limit of MgO in PSC
Specifying the upper limit of compressive strength at 672 ? 4 hrs for OPC-33 & 43 grades
Addition of performance improver up to 5 per cent in OPC
Enhancing the limits of insoluble residue
Increasing the limits of SO3 to 3.5 per cent Specifying requirements of cement for pre-cast concrete

Most of the cement plants in India have the state-of-the-art technology and are able to achieve their capacity utilisation as per the market demand. Cement industry is going ahead with a modification and upgradation of technology particularly in energy conservation. Cement industry’s average energy consumption is about 725 kcal/kg clinker thermal energy and 80 kWh/t cement electrical energy.

Efforts are on relating to utilisation of alternate energy sources/fuels either partially or fully substitute coal in cement manufacture in the coming years, namely, pet coke, lignite, natural gas, and biomass wastes including fruit of Jatropha Carcus, Pongamia and Algae. Although the modern cement plants have incorporated the latest technology, yet there is scope for further improvement in the areas of coprocessing of waste derived/hazardous combustible wastes as fuel, cogeneration of power, bulk transport of cement, palletising and shrink wrapping for packing and dispatch.

Future trends
The R&D activities and thrust to reduce CO2 emission associated with properties has resulted a trend towards the increased use of blended cement with the share of blended cements increasing to 75 per cent followed by Ordinary Portland Cement (OPC) (? 25 per cent). Fly ash based Portland Pozzolana Cement (PPC) contributes the major share (67 per cent) of the total production with 8 per cent of Portland Slag Cement (PSC). In addition to conservation of natural resources, fuel and reduction of green house gases, there are other advantages of using blended cements.

The cement industry in India has also shown potential to utilise hazardous waste. The awareness on utilisation of wastes and environmental pollutants in the manufacture of cement have increased many folds in the last decade. The production of PPC and PSC of uniform quality by utilising more proportion of fly ash and/or slag could be possible by their assured consumer acceptance and research activities.

By and large (BIS) Indian specifications have kept pace with the specifications from developed countries and have been quite dynamic with times and technology. The amendments in the specification are expected to come in the shortest possible of times, which is rather difficult for such a large country. Recently BIS has come out with codes for composite cement which allows the use of two different SCMs like fly ash and slag together. It is one step forward. There is a need for standard specifications for composite cements, using variety of wastes and keeping in view the pragmatic approach of utilisation of cement in different types of construction activities has also been realised.

Various wastes like lead-zinc slag, copper slag, steel slag, marble dust, which were not allowed for utilisation earlier, have now been identified as suitable material for the use in cement and other building products. As availability of coal and limestone are limited and soon these will be finished and on the other hand the requirement for cement is ever increasing. Hence adopting modern technologies and alternate materials is very essential for cement industry to meet this gap.

Cenospheres are one of the most desired by products of fly ash. They are small hollow spheres with roughly 10-1,000 ?m in diameter and constitute about 1-2 per cent of the fly ash obtained from the coal combustion processes. Because of their specific properties, namely their low density and high mechanical strength, cenospheres are an important subject of coal fired power plants. Research results indicate that cenospheres from coal combustion are constituted by aluminosilicate glasses with some crystalline phases like quartz, mullite and calcite. The high alumina content – roughly 25-27 wt per cent is responsible for the high mechanical strength, while density of most cenospheres is lower than 1 g/cm3. Regarding the formation process, there are correlations between the amount of cenospheres and the sodium and calcium content, in the different fly ash samples.

The economics of blended cements will largely depend on the landed cost of fly ash or slag. The common belief that it is a waste material and can be given away at throw away price has already vanished. Cement companies are prepared to pay better rates for consistent quality of fly ash.

Reference: Quality Trend In Indian Cements – A Decade Appraisal

AUTHORS: US Sinha, K Bhatnagar, R Gupta and MM Ali of National Council for Cement and Building Materials, India (NCCBM)

Concrete

Lohia Corp Expands Global Footprint With Acquisitionof J.j. Jenkins Inc and Strategic Joint Venture With Omgm

Published

3 weeks ago

October 22, 2024

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Lohia Corp Limited (LCL) is pleased to announce two significant milestones that mark our
expansion in the global market.

We have successfully acquired J.J. Jenkins Inc. a respected name in machine manufacturing for
high-tech industries, through our US subsidiary, Leesona Corp, a 130-year-old pioneer in winding
machines. This acquisition aligns perfectly with our strategic vision to expand our specialty yarns
and tapes portfolio in medical and defence applications.

In addition, we have formed a strategic Joint Venture with Italy’s O.M.G.M. sas, leading to the
creation of OMGM Extrusiontechnik Srl. With LCL holding the majority stake. This JV represents
a significant diversification of our product portfolio, introducing solutions in Extrusion and
Winding systems for a variety of technical applications.

These advancements are not just about growth; they’re about bringing cutting-edge solutions to
our customers and contributing to industries that make a difference. Stay tuned for more updates
as we continue to push the boundaries of technology and engineering excellence.

Mr. R K Lohia, Chairman & Managing Director of Lohia Corp Limited, expressed his enthusiasm
about the new ventures “Both these new partnerships are a pivotal move that will broaden our
product offerings and provide our customers with even more choices and will enhance our
presence in the North America and European market, at the same time strengthen our presence
in all other global markets.”

About Lohia Corp Limited
Lohia Corp Limited (LCL) stands as a testament to the power of innovation and commitment to
excellence. As the flagship company of the Lohia Group, LCL has established itself as a global
leader in providing comprehensive solutions for the raffia industry.

With an impressive installation base of over 2,250 extrusion lines and 95,000 Circular Looms
across more than 100 countries, LCL’s influence in the plastic woven fabric and bag sector is
unparalleled. The company’s dedication to quality and efficiency has resulted in an astounding
plastic processing capacity of 7.7 million metric tons per annum of PP & PE.

LCL’s products, ranging from packaging systems for solid bulk materials to roof underlays and
tarpaulins, are not just industrial applications; they are the building blocks of industries
worldwide.

The company’s commitment to sustainability and innovation is the driving force that makes it the
world’s largest producer of machines for the raffia sector. As we look to the future, LCL’s legacy
of excellence is more than just a benchmark; it is a continuous journey towards pushing the
boundaries of possibility.

About J. J. Jenkins, Inc
J. J. Jenkins Inc. is a very respected name based out of North Carolina, USA. They remain at the
forefront of the synthetic fiber and monofilament industries. Their unwavering commitment to
innovation, quality, and customer satisfaction has not only set industry standards but also
fostered enduring partnerships with Fortune 500 companies including some in the medical and
defence industries.

Their holistic approach, combining state-of-the-art technology with unparalleled after-sales
support, exemplifies their dedication to client success. With a vast inventory ensuring rapid
response times, J. J. Jenkins, Inc. is synonymous with reliability and efficiency.

About OMGM sas
Since 1965, OMGM sas is a distinguished Italian leader and has been at the forefront of the plastic
processing industry, pioneering in Monofilament Extrusion, straps, ropes and various other niche
applications. Their commitment to excellence is evident in their advanced technologies and
versatile extrusion lines, handling a variety of materials for diverse industries.

As we look ahead, it’s clear that OMGM Extrusiontechnik Srl will continue to lead and transform
the industry with their precision, innovation, and bespoke solutions. They are more than a
company; they are a trusted partner in progress.

Concrete

Adani acquires Orient Cement at INR 8,100 crore equity value

Published

3 weeks ago

October 22, 2024

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Acquisition adds 16.6 MTPA capacity (8.5 MTPA operational, 8.1 MTPA Ready to Execute).

Accelerates Ambuja’s journey to achieve 100+ MTPA operational capacity in FY 25

Provides 6 MTPA potential additional capacity in North India, leveraging OCL’s high quality limestone reserves in Rajasthan

EDITOR’S SYNOPSIS

Ambuja enters into a binding agreement to acquire 46.8% stake in Orient Cement Ltd (OCL). The acquisition helps to move towards target capacity of 140 MTPA by 2028.
OCL has an existing 5.6 MTPA clinker and 8.5 MTPA cement operational capacity, 95 MW CPP, 10 MW WHRS, 33 MW Renewable Energy spread across the states of Telangana, Karnataka and Maharashtra. It improves Adani Group’s market share pan-India by 2% in the cement industry.
OCL has secured a concession from Madhya Pradesh Power Generating Company Ltd (“MPPGCL”) to set up 2.0 MTPA Cement GU within the premises of Satpura Thermal Power Station in Sarni, MP.
OCL also has a large high quality limestone mining lease in Chittorgarh, Rajasthan, providing the potential to set up additional 6 MTPA capacity in North India.
The acquisition of OCL complements Ambuja’s existing cement footprint, reducing overall lead distances and logistics costs for the cement business and improving market share in our core markets.
Acquisition will be funded through internal accruals, Ambuja remains debt free.

Ahmedabad, 22 October 2024: Ambuja Cements, the cement and building material company of Adani Cement and part of the diversified Adani Group, today announced the signing of a binding agreement for the acquisition of Orient Cement Ltd (OCL) at an equity value of Rs. 8,100 crore. Ambuja will acquire 46.8% shares of OCL from its current promoters and certain public shareholders. The acquisition will be fully funded through internal accruals.

“This timed acquisition marks another significant step forward in Ambuja Cements’ accelerated growth journey, increasing cement capacity by ~30 MTPA within two years of Ambuja’s acquisition,” said Mr Karan Adani, Director of Ambuja Cements. “By acquiring OCL, Ambuja is poised to reach 100 MTPA cement capacity in FY 25. The acquisition will help to expand Adani Cement’s presence in core markets and improve its pan-India market share by 2%. OCL’s assets are highly efficient, equipped with railway sidings and well supported by captive power plants, renewable energy, WHRS and AFR facilities. OCL’s strategic locations, high-quality limestone reserves and requisite statutory approvals present an opportunity to increase cement capacity in the near term to 16.6 MTPA.”

Mr CK Birla, Chairman of Orient Cement and the CK Birla Group, said, “The CK Birla Group is continuously reallocating capital to sharpen its focus on consumer centric, technology driven and service-based businesses. I take pride in Orient Cement’s impressive track record of building premium brands and maintaining a leading market share in the geographies it operates in. We are confident that the Adani Group, with its strong focus on cement and infrastructure, is the ideal new owner to drive continued growth at Orient Cement for our people and stakeholders”.

Ms Amita Birla, Co-Chairman, CK Birla Group, added, “Orient Cement has a strong market presence, with sustainability initiatives, particularly in renewable energy, being a significant part of its DNA. I am convinced that Ambuja Cements is the right home for all our colleagues at Orient Cement, as well as our customers.”

OCL has 5.6 MTPA clinker capacity and 8.5 MTPA cement capacity along with statutory clearance to increase the clinker capacity by another 6.0 MTPA and cement capacity by another 8.1 MTPA. In addition, OCL also has a limestone mining lease in Chittorgarh for setting up an Integrated Unit (IU) with clinker of 4 MTPA and a split Grinding Unit (GU) of 6 MTPA in North India. OCL has also secured a concession from MPPGCL, Madhya Pradesh for setting up a Grinding Unit within the premises of Satpura Thermal Power Plant. Both these complement the Adani Group’s existing cement footprint. (Refer Annexure – 1 for OCL’s location wise cement capacity and other assets and Annexure – 2 for Adani Cement’s footprint post-acquisition of OCL.)

OCL has recently commissioned a WHRS in Chittapur IU and is in the final stage of commissioning 16 MW solar in Chittapur and 3.7 MW solar in Jalgaon. OCL’s efficient plants, highly motivated teams, strong balance sheet and well-distributed dealer network will be excellent additions to the Adani Group’s existing cement business. OCL’s existing dealers will move to Adani Cement’s market network, creating formidable synergies.

Ambuja plans to optimize OCL’s overall capacity utilization to enhance its cost and competitiveness and improve its operating performance while leveraging the synergies inherent in the existing cement business.

About Ambuja Cements Ltd (ACL)

Ambuja Cements Ltd is one of India’s leading cement companies and a member of the diversified Adani Group – the largest and fastest growing portfolio of diversified sustainable businesses. Ambuja, with its subsidiaries ACC Ltd, Penna Cement Industries Ltd and Sanghi Industries Ltd, has taken the Adani Group’s cement capacity to 88.9 MTPA, with 20 integrated cement manufacturing plants, 20 cement grinding units and 12 bulk terminals across the country. Ambuja has been recognized among ‘India’s Most Trusted Cement Brand’ by TRA Research in its Brand Trust Report, 2024 and among ‘Iconic Brands of India’ by The Economic Times. Ambuja has provided hassle-free, home-building solutions with its unique sustainable development projects and environment-friendly practices since it started operations. The company has many firsts to its credit – a captive port with six terminals that facilitates timely, cost-effective and cleaner shipments of bulk cement to its customers. Its innovative products like Ambuja Cement, Ambuja Plus, Ambuja Compocem and Ambuja Kawach are now listed in the GRIHA product catalogue. These products not only fulfil important customer needs but also help in significantly reducing their carbon footprints. Being a frontrunner in sustainable business practices, Ambuja Cements ranks among ‘India’s Top 50 companies contributing to inclusive growth’ by SKOCH and ‘India’s Top 50 Most Sustainable Companies’ Cross-Industry by BW Businessworld.

For further information on this release, please contact: roy.paul@adani.com

Annexure -1 | Existing Cement Assets of Orient Cement Limited

Plant	Clinker (MTPA)	Cement (MTPA)	CPP/WHRS/Solar	Railway Siding
Devapur IU, Telangana	3.5	3.5	CPP – 50 MW	Yes
Chittapur IU, Karnataka	2.1	3.0	CPP – 45 MW WHRS – 10 MW Solar – 16 MW*	Yes
Jalgaon GU, Maharashtra	–	2.0	Solar – 13.5 MW+ 3.7 MW*	Yes
Operational Capacity	5.6	8.5

* capacity is in commissioning stage

Annexure – 2 | Footprint of Adani Group – Cement business post OCL Acquisition

Economy & Market

Fornnax Announces a Major Launch With Sr Max Series: Sr-max2500 Primary Shredder a Revolutionary and Game-changer

Published

4 weeks ago

October 18, 2024

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Fornnax, a renowned shredding and recycling equipment provider with years of experience in designing and developing SR-Series dual shaft shredders, has unveiled its advanced level SR-MAX2500 shredder specially designed for the Municipal Solid Waste category.

The launch was held IFAT India 2024, a most prestigious event in the waste management industry, on October 16th, 2024, at the Bombay Exhibition Centre in Mumbai.

Fornnax’s successful track record of developing many proven machines for different types of tires, ferrous and non-ferrous metals, which are the most difficult applications has made them a pioneer in the shredding and recycling equipment manufacturing global market over the decade now. The design of the SR-Series machine, a legacy that has prevailed for over a decade, continues to be used in the design of SR-MAX series machines. The advanced SR-MAX2500 shredder features high capacity, modern engineering, and innovative technology.

The remarkable event was inaugurated by Mr Ulhas Parlikar, Ex-Director of Geocycle India; Mr Sanjay Shripatrao Katkar IAS (Municipal Commissioner and Administrator) MBMC; Mr Sharad Nanegaonkar Executive Engineer (Water Supply and Sewerage Department) MBMC; Mr Deepak Khambit (City Engineer) MBMC; Mr Jignesh Kundaria CEO & Director of Fornnax Technology Pvt. Ltd.;

Mr Manoj Kumar Sure, JK Cement Head AFR; Mr Manoj Kumar Modha, Director of Millennium Multi Trade Pvt. Ltd.

Jignesh Kundaria, CEO and Director of Fornnax, shared insights into their newly launched innovation, “With the SR-MAX2500, we’re poised to transform the waste management landscape in India and beyond. Our goal is to line up municipal waste recycling industries with a robust, efficient, and sustainable solution. Our commitment to sustainability and enhancing recycling process is a step forward towards achieving PM’s vision of a Net Zero emissions future by 2050.”

Revolutionizing Waste Reduction: The SR-MAX2500 Advantage We’re excited to introduce the Fornnax SR-MAX2500, a revolutionary primary shredder designed for efficient volume reduction of diverse materials. This high-capacity machine boasts advanced modern engineering and technology, featuring hydraulic motors driving each shaft for optimal power and torque. Its unique cutter design, replaceable cutting table, and shaft design make it an ideal solution for various applications.

Waste Management Reimagined! SR-MAX2500 Primary Applications Our primary focus for the SR-MAX2500 is serving large-scale municipal waste recyclers, cement plants, waste-to-energy plants, mechanical biological treatment facilities, materials recovery centres, construction and demolition recyclers, aluminium recyclers, and other applications requiring highcapacity machines and robust technology.

The SR-MAX2500’s Impressive ROI Streak The SR-MAX2500 offers several commercial benefits, including increased efficiency, reduced operational costs, and enhanced productivity as it is specially designed for the Indian market. Its robust design and advanced technology ensure minimal downtime, maximizing profitability for our customers. Additionally, our commitment to quality and reliability helps build long-term relationships with clients, fostering loyalty and repeat business.

Innovation Meets Efficiency: Why Choose the SR-MAX2500? Fornnax has carved out a distinctive niche in the highly competitive market and its relevance stems from a unique, tailored approach that addresses specific needs. Thus, the SR-MAX2500 shredder differentiates itself through its versatility, catering to a diverse array of waste management and user needs, specifically designed for Indian waste, which is highly contaminated compared to global waste. Additionally, our unwavering focus on innovation, quality, and customer-centricity sets us apart from competitors and establishes our position in the market.

Turning Trash into Treasure with MSW Waste As you see due to the rapid urbanization and over population, India is among the world’s top 10 countries generating municipal solid waste (MSW) and generates around 62 million tons of waste in a year. Therefore, it is extremely critical to prioritize recycling and conversion of MSW into RDF fuel. Cement industry, which uses a significant amount of coal. Cement industries substituting coal with RDF or alternate fuel to reduce the greenhouse gas emissions, conserve natural resources like coal and more and ultimately minimise the waste disposal issues.

Fornnax’s Exceptional Contribution to India’s Sustainability Goals India has made significant strides in waste management and recycling, and with continued investment, innovation, and policy support, there’s no doubt it can achieve its goals. Fornnax is committed to contributing to India’s sustainability and waste management journey through their advanced recycling solutions, supporting the country’s transition to a more circular and environmentally conscious economy.

Fornnax’s Unwavering Commitment to R&D and Innovative Solutions Fornnax stays updated with global advancements in recycling technology and sustainability practices through several key strategies, such as we invest heavily in research and development to ensure our equipment are at the forefront of technological innovation. Our team closely monitors industry trends, emerging technologies, and regulatory changes to identify potential opportunities for improvement. We also actively seek feedbacks from our valued clients to understand their evolving needs and challenges. This input helps us identify areas where we can boost our meet market demands.

Expanding Horizons: Fornnax’s Growth Plans for the Year Ahead The SR-MAX2500 launch is a strategic step towards expanding our market presence and strengthening our position as a leading shredder manufacturer around the globe.

Also, we are optimistic about the coming year, driven by the growing demand for sustainable waste management solutions and the increasing awareness of environmental issues. We are actively investing in equipment enhancement, engineering, and strengthening our partnerships to meet the evolving needs of our customers. Fornnax’s focus areas for the next year include expanding the manufacturing capacity to meet the rising demand and we already started working on it by acquiring 23-acre land parcel in Ahmedabad, Gujarat. The new site is expected to become operational by March 2025. Its focus will be on producing high-capacity machinery applicable in tyre, cable recycling, ewaste, metal processing and more.

About Fornnax FORNNAX is one of the world’s leading shredding and recycling equipment manufacturers, offering Primary shredders, Secondary shredders and Granulators for tyres, municipal solid waste, cables, e-waste, aluminium and many other industrial applications. Quick after-sales services that increase our customer’s uptime and productivity.

We are committed to shaping the landscape for sustainable recycling solutions in the future. Because we’re not just selling equipment, we’re building business. That’s what we believe. That’s who we are. Fornnax Equipment is built with the idea that the simple, most significant and heaviest is better. Our equipment is an evolution of advanced products designed for the challenges of the recycling world.

The global sales partner network makes us successful worldwide. Our corporate culture is based on our history of providing value to our customers’ success worldwide. This motivates our employees to work together, develop innovative products, and produce high-quality equipment.