Connect with us

Process

Around 60 per cent of operating costs are determined before the plant is set up and commissioned

Published

on

Shares

Dibyendu De, Director, Reliability Management Consultant

Improving energy efficiency is directly connected to improving the reliability of the plant. Here, reliability means extending the continuous run hours of the plant and its various units by reducing failures to the minimum possible level, which is nearly zero, says Dibyendu De Director, Reliability Management Consultant. Excerpts from the interview.

What are the major challenges in retrofitting / or setting up of new cement plants?

The first major challenge of setting up a new cement plant is to estimate demand as accurately as possible and not to build a cement plant of higher capacity than needed. A higher capacity cement plant operating at a lower capacity simply wastes energy and money.

The second challenge is to conduct a design review before setting up a plant. It consists of three stages, which are review of conceptual design, design review followed by detailed design review. This is important since around 60 per cent of operating costs are determined before the plant is set up and commissioned. Costs and energy efficiency have to be taken into account at this design stage. In such reviews, questions of layout, sizing, selection, reliability, maintenance and maintainability issues of the equipment are to be addressed along with other issues. If not done, higher operating costs would keep reflecting throughout the plant life cycle. And it is really difficult to bring down costs during the operation phase of the plant.

The third challenge is to conduct through pre-commissioning tests of equipment and systems to discover inherent imperfections and faults in the system that would push up costs during operation through breakdowns and inefficient performance.

What is the scope for greenfield projects?

The scope for greenfield projects is huge. With 750 new cities coming up, demand for cement will soar. The demand of cement would further accelerate with growth of other infrastructural facilities that are bound to come in the coming years. However, as of now, the demand is sluggish and is expected to be so for at least the next two years. I don’t think anyone can say how soon the economy will show recovery. In brief, the demand for cement is invariably linked to economic progress and the rise of the middle class.

Which section or processes in a cement industry has the highest scope for improvement in terms of energy efficiency?

In fact, energy savings is connected to preventing waste of energy. And that can happen anywhere in the plant. However, the highest scope lies in the utilities, grinding units and clinker processing.

How much can an existing plant improve its energy efficiency through a repair or retrofit job?

Improving energy efficiency is directly connected to improving the reliability of the plant. Here, reliability means extending the continuous run hours of the plant and its various units by reducing failures to the minimum possible level, which is nearly zero. Such improvement in reliability is connected more to the maintainability of the plant and not directly to maintenance of the plant. Maintainability is the process of improving plant performance on a continuous basis.

What kinds of energy saving measures/technologies do you recommend to your clients?

The normal measures and technologies are now quite well known in industry circles. However, incorporation of all such technologies must be linked to improving maintainability of the plant.

What is your outlook on the PAT scheme introduced by the Bureau of Energy Efficiency?

Many cement plants in India with modern technology have already achieved the minimum possible energy levels compared to the best in the world. So, the scope of gaining from the PAT scheme for these plants is very limited indeed, in my opinion. For other plants which are not as per norms, it is a matter of capital investments, which management might not be willing to undertake, especially during a sluggish economic phase as we are currently experiencing. For such plants, much would depend on marketing and maintenance departments to adhere to the norms of the PAT scheme.

Could you give us with examples where you have helped cement companies reduce energy bills?

For most cement plants where I was involved in improvement of plant reliability and improvement of kiln running hours, the measurable energy reduction was to the tune of 7 per cent to 15 per cent. In some cases, the savings were even higher. The added benefits are that costs go down and productivity goes up. This gives the plant ongoing benefits for years.

The principle is – energy tries to freely flow across systems. However, when impeded or hindered energy goes up and is either wasted or triggers breakdowns. Hence by identifying energy blockages within the system and eliminating such blockages both energy consumption and costs comes down. In addition reliability also goes up.

Following graph illustrates such savings from the real world of cement business. This case was done in one of the largest cement plants in India. Interesting to note that growth of reliability and the lowering of costs are almost mirror images.

How much can a plant expect to save in energy costs by applying IT solutions?

So far, I have not come across any study that links application of IT solutions to energy savings.

Continue Reading
Click to comment

Leave a Reply

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

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

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

on

By

Shares

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.

Continue Reading

Trending News