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Bulk handling equipment is one of the most neglected areas by plant designers.

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The Indian industry has grown rapidly in past two decades. The overall production capacity too, has quadrupled in the last 20 years. This rapid growth has posed several challenges to the industry. As production units expand to leverage the economy of scale, demand for bigger and faster bulk material handling equipment too, is growing. Jai Gupta, Chief General Manager, Holtec Consulting, shares his views with ICR about the new technologies evolved to meet this growing demand. Excerpts from the interview.

What are the new challenges in bulk material handling (BMH)?
The conventional, easy to access locations are no more available. New projects are forced to go to far-off places, away from markets, or are being forced to manage in a limited area. Growing demand for fly ash- based PPC production has pushed several industry players to set up grinding units close to thermal plants for fly ash consumption. As these thermal power plants are generally located close to densely populated areas, space is always a constraint and hence they cannot develop good infrastructure for rail/road movement of material. It is crucial to substantially reduce time and space requirement for loading and unloading the railway rakes.

Which new technologies at BMH can be applied in the cement industry?
Keeping in view of conserving scare resources, several new concepts have emerged in material handling. These include in- motion rapid loading of material in railway rakes, movable wagon loader feeding stationary rake, use of bottom discharge wagon for transport and unloading, and the use of wagon shifters to substantially reduce the area required for the installation of a wagon tippler.

What is in rapid loading? How does it work?
Conventionally, loading of material in rakes is either done via overland hoppers constructed on top of the railway tracks or manually through pay loaders. The usual time taken is 3-6 hours depending on the equipment employed. In rapid loading, it takes only about 60 û 80 minutes to load the entire rake, from a single discharge point, and it is done while the rake is in motion.

In rapid loading, a silo with one full rake capacity is constructed over the rail tack. The rail moves below the silo. Below the hopper of the silo, another small hopper with a capacity to hold one wagonload of material is provided. This second hopper is mounted on load cells. The two hoppers are connected through hydraulic gates in such a way that the material gets transferred from main hopper to the weighing hopper within seconds. The silo is filled with material before the train arrives. First, the load cell hopper is filled with material of desired weight. The loading starts as soon as the wagon comes in position below the hopper. The material is transferred in the wagon before it crosses the loading point. The train is in continuous motion rolling at a speed of about 0.6 to 0.7 km / hr. No time is wasted in starting and stopping the train. The hopper gets ready to load the next wagon much before the next wagon arrives at the loading position. A full railway rake of about 650m length is loaded in about one hour. Holtec has designed such a system with some modifications for lignite loading. Assuming average savings of three hours per rake, we may save about 2,000 rake hours for handling about 2 mio tpa capacity. This helps in better utilisation of rakes. The total investment in such systems is much less than conventional systems; it requires a lesser number of operators and is also free of dust nuisance and material wastage. Requirement of civil work is also less.

What are the requirements for building such a loading facility?
For hauling the railway rake at constant speed of 0.6 to 0.7 km/hr, creep drives must be installed on the locomotive. As normal locomotives with Indian Railways do not have it, plants will have to maintain their own locomotive with such drive for haulage of railway rakes.

How can one reduce space required for material loaders?
Some of our clients had space constraints so we have provided them with a moving wagon loader. In this system the wagon / rake is stationary while the loader moves along the rake with consistent speed from one end to the other. The loader loads the material while in motion. The wagon loader is provided with a diversion chute at the outlet, which is designed in such a way that it diverts the flow to next wagon at the junction point. After a certain amount of travel, it returns to the initial discharge point.

The loader is positioned with two tracks on its either side so that it can load more rakes faster. It is fed by a stacking conveyor and has a reversible boom conveyor for feeding the wagons on both the tracks. It has a capacity of loading 1500 û 2000 tph without any difficulty. And if the material is fed gradually, we get a smooth filling of the wagon. The smoother the filling, the less the dust nuisance. The main benefit of this system is that the land requirement is very less. A rapid wagon loader requires a track length capable of accommodating at least two rakes. However, this system works in one rake space. One can line up two rakes side by side and hasten the process further. Besides this, the plant need not have a locomotive engine for hauling the rakes.

Tell us about space saving developments in wagon unloading.
We all know that land for the industry is gradually becoming scarce resource. Unfortunately, wagon tipplers require a considerable size of real estate. In some cases, we have noticed that entire production unit fits in about five hectares of land, whereas rail installation for smooth functioning of the wagon tippler takes-up about 7.5 hectares of land, that too in a typical plot size of 50 m width X 1500 m length. In our recent projects we have faced several problems on this account. To tackle such issues, wagon traversers are being installed in one of Holtec’s projects. The wagon shifter works at the same speed as the wagon tippler and both pieces of equipment works in tandem. In this way, the land requirement is reduced to almost half. Only one parallel track needs to be constructed aside the track for removal of wagons.

Where do we fall short while installing BMH systems?
Bulk handling equipment is one of the most neglected areas of plant design. Most plant engineers focus on the core equipment and processes. Bulk handling is often seen as an accessory function. One should also envisage the possible impact on the system if such a bulk material handling equipment fails; a contingency plan must be in place. Very few realise the amount of mechanical tension the conveyor belt is in. I know a case where the belt snapped and damaged the support framework structure. BMH is a complicated science and expert opinion must be considered at the design and set-up stage.

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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…

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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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