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Industrial Filters and Fabrics back to back success stories.

INDUSTRIAL Filters and Fabrics is a market leader in industrial filtration by catering to everything right from non-woven fabric manufacturing, making of filter bags, cages and accessories. Three decades of versatile experience and technical expertise in the field of industrial air pollution control systems is something that sets apart IFF from other manufacturers. IFF TSS (Technical Support Services) division had many more opportunities to take up challenges of non- performing bag filters and bag houses installations.

Case study 1

Cement Plant-RABH for kiln+raw mill; Cement plant in South India

Problems

The bag house (RABH) was facing problem of continuous stack emission and failing of glass fabric bags in all 14 modules. This bag house was designed and commissioned by reputed OEM But, from beginning visible constant emission and cause of bags` failure couldn’t get identified. The nature failure of bags was at the anti-collapsible rings and most of the bags were found damaged in front of RA duct which opens in the module. Also, uneven distribution of gases in all modules and excessive bags tensioning was found to be an additional reason.

Data
*Design Flow 7,62,120 m3/hr @ 220-240 0C
*Air to Cloth Ratio 0.416
*Inlet Dust Loading 60gm/Nm3
*Baghouse Type: Reverse Air
*Bag Quantity 3192 pcs
*Bag Dimensions 305mm X 10.82 mtr.

Solutions

IFF Technical Support Services (TSS) analyzed the problem of bags` failure and took immediate action. All the modules were checked for damaged bags and replaced with new IFF- make bags. The modules were checked for leakages in tube sheets and thimbles. All the bags were removed and re-oriented and re-fixed with proper tensioning of 34 PSI(Originally-40PSI) and bottom bag clamping was also re-fixed.

IFF supplied 1,200 new bags which were replaced as against imported failed bags. The mechanical modifications at inlet gas distribution screen and RA opening duct in module was main change carried out as per the new design inputs and recommendations given by IFF.

Results

After attending to the above suggested modifications points and under supervision of IFF TSS team, the emission from stack was reduced to practically zero. The DP of the bag house was also under control and in between 130-150 mmwc. After three months of operation, the continuous failure of bags phenomenon stopped and overall performance of bag house was observed / reported to be satisfactory by plant head.

Case study 2
10 TPH boiler-bag filter Site:
A mega steel plant, Western India

Problems

A mega steel plant was facing the problem of performance in the boiler bag filter for the past 5-6 years. The problems were as follows:
1 Boiler in operation frequently exerts backfire.
2 The DP of bag filter always remains high [250 mmwc-300mmwc].
3 The dust from bag filter was not dislodging and was found stuck on bags.
4 In the bag filter, most of the bags near the outlet were failing due to improper gas distribution and at the centre, the bags were getting damaged frequently.
5 The life of fabric bags were a maximum of 6-8 months.

*Design Flow: 27,500 M3/HR.
*Air to Cloth Ratio 1.35
*Inlet Dust Loading 10-20 GMS/NM3
*Baghouse Type: PULSE-JET
*Bag Quantity: GLASS + MEMBRANE
*Bag Dimensions : 149 X 3650 MM

Solutions
IIFF studied the design and actual parameters and conducted internal inspections of the bag filter.

A detail report of internal mechanical modifications was explained to plant operations with supporting drawings. The inlet gas distribution was modified in such a way that gases were equally distributed in entire bag house. IFF- recommended internal mechanical modifications were carried out onsite under supervision of the IFF TSS team. One set of glass+ membrane bags as against bags was supplied and cages were reconditioned.

Results

The bag filter was re-commissioned after a long shutdown of 30 days. The results were recorded as follows:

1 First, boiler sudden backfire was stopped; even boiler was taken on full load.
2 The DP of bag filter was checked during boiler full load and recorded a maximum of 50-55 mmWC as against 200-25 mmWC.
3 Before revamping, no dust was dislodging from bags. But now in a day, 11 tonnes of fly ash was found continuously discharged.
4 The stack emission was checked for boiler in full-load and observed emission of less than 18 mg/nm3.
5 I/D fan power savings by 4.5 KW/Hr & by DP reduction has gained Rs1113/- per day. So, within one year of operation, client could able to recover cost of IFF supplied bags.
6 Also, ambient air quality and environment in the boiler house was found improved drastically.

Case study 3

Cement Plant RABH- for kiln + Raw mill application

Cement plant in South (India)

Problems

The bag house was facing problem of continuous failure of glass fabric bags and constant high emission of 2gms/nm3 from stack. The emission and bag failure problem was detected since this bag house was installed and commissioned. The bags were originally supplied found variations in lengths. Bag- to- bag friction, internal supporting structure fouling with bags, and sagging of bags was noticed.

Data

*Design Flow 9,35,000 m3/hr @ 220-240 0C
*Air to Cloth Ratio 0.44
*Inlet Dust Loading 50 gm/Nm3
*Baghouse Type: ReverseAir
*Bag Quantity 3696 pcs
*Bag Dimensions 292mm X 10.37 mtr.

Solutions

IFF rectified around 3,000 bags of imported make installed bags which were in extra dia and length. IFF Technical Support Service (TSS) visited site, studied and analyzed problem of the bags` failure. All 3996 nos bags were removed and checked modules for mechanical healthiness.

The modules, inlet/outlet ducts, RA ducts and all mechanical abnormal points were attended which were left out during installation. All modules leak test was carried out and proper fixing of bags was done under supervision of IFF TSS. IFF- altered bags were re-installed and proper tensioning was done. The internal bag fouling with thimbles were made blind. IFF TSS conducted technical session of RABH operations in connection with doÆs and donÆts in process, mechanical, instrumentations and control logic to plant operations.

Results

After successful re-installation of bags, a proper pre-coating was done and the bag house was taken on load. Initially stack was puffing but within 24 hrs, stack got clear. The DP of bag house was also observed under control of 130-160 mmwc.

The kiln was taken on a hundred per cent load and found stack is visually clear and DP is always less than 150mmWc. The emission measurements were taken and recorded at <20 mg/nm3.

Industrial Filters & Fabrics offer diagnostic solution for the filter bags, cages and accessories for dust collectors.

S.W.Satpute is with IFF as VP , Technical and field services. Web site: www.iffgroup.com email : iffgroup@iffgroup.com, ssatpute@iffgroup.com

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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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