Connect with us

Process

Latest developments in FLSmidth Pyro process technology

Published

on

Shares

New pyro process technologies from FLSmidth are helping to maximise productivity and plant operational efficiency for today’s cement producers.

As cement producers are continually looking to improve the plant performance, many are seeing the advantages of making upgrades in the production process. In particular, preheater top stage cyclone, kiln burner, clinker cooler replacements are highly attractive, providing compelling reasons for retrofits and upgrades.

Next-gen Top stage cyclone – CCX
FLSmidth’s new Counter Current Cyclone (CCX) delivers cement plant owners greater opportunities to boost production capabilities and improve their plant operations. CCX is a ground-breaking technology designed to make the preheater process economical and set the standard for today and tomorrow.

Several innovative design features like raw meal feed to top of the cyclone, rotating spreader, combined heat exchange and separation, light weight lining, upward facing central pipe, bottom gas outlet, etc. contribute significantly to its outstanding performance.

These unique design features ultimately lead to a sustainable productivity enhancement in existing as well as new plants.

FLSmidth JETFLEX? burner –
A revolutionary kiln burner

FLSmidth JETFLEX? burner is the development of a new revolutionary burner to satisfy the changes imposed by the market in burner technology and meet diverse needs of cement industry which includes fuel flexibility, superior combustion, outstanding heat and energy efficiency, lower % primary air, NOx emissions, long refractory life, etc.

The innovative design features like Rectangular Jet air nozzles and Swirler, central and common fuel channel, common blower for Axial and Swirl air, replaceable burner tip, lower pressure drop, longer fuel retention time, fuel rich flame core, etc. contribute significantly to an optimum performance.

These unique design features provide efficient fuel combustion, superior flame shaping capabilities and stable flame formation, which ultimately ensures stable burning zone conditions and high clinker quality in existing as well as new plants.

FLSmidth Cross-Bar? Cooler – Setting the latest standard
The FLSmidth Cross-bar? cooler represents the latest evolution in clinker cooling technology. As a result of FLSmidth’s continued R&D efforts as well as on-site experience, a state-of-the art cooler was unleashed representing the highest standard in clinker cooling technology.

The fundamental design features like Air Blast Controlled (ABC) Inlet, self-adjusting mechanical flow regulators, stationary seal grate line, separate clinker conveying and cooling systems, horizontal construction, modular concept play a key role in superior plant performance.

The FLSmidth Cross-Bar? cooler makes use of the company’s advanced clinker cooling technology and has been implemented in cement plants around the world, helping cement producers to eliminate bottlenecks in production and improve the overall efficiency of the pyro processing system.

A Full Flow sheet provider
FLSmidth has successfully delivered solutions to the demands of cement plant owners for productivity enhancement, cost-efficiency and fast payback on their investments. Through the years, different customer focused solutions have been developed depending on the specific needs of the cement industry.

FLSmidth delivers maximum value to cement producers through the practical application of innovative technologies. Applying innovative technologies to achieve energy-efficient pyro processing system is a key enabler to increase production and reduce operating costs.

Making the best even better
FLSmidth Counter Current Cyclone’s (CCX) several design features contribute significantly to achieve an outstanding performance and meet industry requirements like reliability, efficiency (power and heat) and low installation cost.

FLSmidth JETFLEX? Burner’s design features offer reliability, energy efficiency, fuel flexibility and low emissions.

FLSmidth Cross-Bar? cooler’s design features have made it possible to meet customer demands like reduced vent losses, maximised recuperation efficiency, and improved WHRS generation.

Potential UNLEASHED

Author: G Renga Prasad, Product Line Manager-Pyro, FLSmidth.
(Communication by the management of the company)

Continue Reading
Click to comment

Leave a Reply

Your email address will not be published. Required fields are marked *

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.

Published

on

By

Shares

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…

To read the full article Click Here

Continue Reading

Process

Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings

Published

on

By

Shares

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

Continue Reading

Process

Wonder Cement shows journey of cement with new campaign

Published

on

By

Shares

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.

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds