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Ensure safe mechanical conveying with FLSmidth In-Plant Belt Conveyors

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FLSmidth In-Plant Belt Conveyor solution is an easy to operate and maintain mechanical conveying system. Designed with safety at top of mind, easily accessible maintenance parts and a dynamic rock box deliver trouble-free mechanical conveying of materials.

Building on the proven design principles of the current belt conveyor, which has successfully served cement markets around the world for many years, the new version offers low cost onsite installation, improved reliability and has been designed to create safer working conditions.

While offering safe mechanical conveying for the cement industry, it is also built to handle sticky and highly-abrasive materials. We provide a solution that minimises blockages and liner wear while extending the life of the belt and other major components.

Main advantages of FLSmidth new belt conveyor Improved safety: All parts associated with maintenance work required while the mechanical conveying belt remains in operation have been moved outside the lightweight safety guards, including lubrication points. Operation can be observed without opening the In-Plant Belt Conveyor’s cover while adjustments to ensure bulk material lands in the centre of the belt can be made outside the safety guard.

Low cost: A simplified design for troublefree mounting facilitates rapid transport to site and easy onsite installation, lowering cost.

Easy maintenance: All parts requiring maintenance, including lubrication points are located outside of the safety guard surrounding the mechanical conveying belt. This ensures the parts are easily accessible for maintenance while the belt is still in motion.

Reliable: We have years of experience designing and working with operators of In-Plant Belt Conveyors, serving both the cement and mining industries. This has resulted in the development of a reliable mechanical conveying solution.

Handles sticky and abrasive materials: Wear plates in the inlet box are fixed with a simple system and can easily be replaced to handle abrasive and sticky bulk material. For abrasive materials, wear parts can be durable wear-resistant plate and for sticky materials, low friction liners are used to prevent material build up.

Designed for easy mounting: It is quick to assemble onsite, mainly because it contains fewer parts – up to 70 percent fewer than the existing design and it is preassembled in the workshop. Smaller components are welded to the construction in advance,enabling ease in logistics, installation and maintenance.

Another example of simplification is that the number of different bolt sizes have been reduced, which helps reduce installation time significantly.

Main features of FLSmidth new belt conveyor
Light yet strong coverage for easier handling:
A unique feature of the In-Plant Belt Conveyor is the cover. Considerable effort is put into creating an equally strong, more flexible and lighter cover to replace the corrugated iron design. The new cover is easier to open and handle, as the individual covers do not overlap ? it slides open like a breadbox. The lightweight safety guards were introduced in response to a challenge often seen with belt conveyors. Big and heavy safety guards end up being removed and leaned up against the walkway rails as they are too heavy to be placed back by just one person. By having lightweight safety guards, this dangerous practice is avoided.

Adjustable rock box optimises operation: The dynamic rock box is standard in all inlets handling free flowing materials. Situated outside the safety guard for straightforward access, this cutting-edge dynamic rock box ensures a dust-free and centered load to the consecutive conveyor. It also reduces wear from abrasive materials in the inlet box and can be adjusted from outside the safety guard.

Well-designed discharge section to impress: The discharge casing has hollow shaft gears, which hang on the pulley shaft and is supported directly by the main frame. This means it does not need civil construction and offers better access around the discharge. At the same time, it provides full access for the primary and secondary scrapers.Large double working doors and inspection windows means operators can safely gain an overview of the In-Plant Belt Conveyor’s status during operation and have full access for maintenance when stopped. Other special features of the discharge section include space for a spillage conveyor and a specially designed baffle plate.

Safety comes first
A key objective when designing the In-Plant Belt Conveyor was avoiding accidents. This means that all parts involved in the maintenance work – while the belt is still in motion – have been moved outside the safety guards. This includes an innovative patented system for idler frames, which allows operators to adjust idler frames for belt tracking from outside the cover with just a wrench and hammer.

The cover also contains three small holes that allow the operator to see inside the cover without opening it to see if the belt is tracking correctly.

Employing modelling technology for innovation
In earlier models of our In-Plant Belt Conveyor, a mathematical formula was used for material trajectory which wasn’t as accurate as we would like. To cater to "real-life" cement plant mechanical conveying as much as possible, we set about conducting some practical experiments at our Denmark-based research facility, testing sample materials with differing properties at different speeds.

Discrete Element Modelling (DEM) technique was used to predict how solid particles move and interact in space. Mathematical equations considered the shape, position, cohesiveness, velocity and force of each particle and calculated how they flowed as they passed through a predefined space, such as chute work.

The formula for material trajectory was then updated to incorporate results from the practical experiments and from the DEM. This update helped minimise common mechanical conveying challenges such as blockages caused by sticky material, excessive dust, and liner and belt wear.

ABOUT THE AUTHOR: J Raghuraman, Product Line Manager – Material Handling, 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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