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A successful journey of CB Cooler showcasing Commendable Results

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Over the years from Planetary coolers till date, FLSmidth, the pioneers in inventing new technologies for enhancing the energy efficiency of cement plant operations, came out with SF coolers in the year 1997. The SF cooler was launched aiming at the necessity of having consistency in fuel consumption having separate conveying and cooling mechanisms. Installations close to 250 in numbers in a span of 14 years ranging from 540 tpd to 13,000 tpd clinker production speaks for itself about the success.

In the arena of changes, we come across raw material change, fuel change, market demands for different quality clinkers, alternate fuel usage, etc. In all such conditions, the cooler being the final architect giving shape to the quality clinker, should be capable enough to address and take care of our day-to-day material and operational changes.

In the year 2011, FLSmidth launched FLSmidth? Cross-Bar? Cooler to take care of the day-to-day changes with the inbuilt idea of overcoming all our day-to-day operational problems of snow man, red river, in consistent clinker PSD and much more. In a shot span of less than 5 years, more than 70 installations ranging from 1,100 tpd to 12,500 tpd clinker production is yet another benchmark for its success. Consistency in Specific Fuel Consumption for clinker production in the complete pyro system is more inevitable. By having the separate conveying and cooling mechanism with MFRs, FLSmidth? Cross-Bar? Coolers were showcasing the consistency in fuel consumption for more than 18 years and on. A 1% loss in cooler efficiency will impact 5 kcal/kg clinker in terms of fuel consumption. This in turn has the direct impact on the pre-heater fan power consumption, coal mill run hours and coal handling & conveying system. Savings from the constantly higher recuperation from the cross-bar coolers outweigh the marginal savings in specific power consumption of the older generation beam technology coolers.

UltraTech Cement Limited, Awarpur Cement Works is one of the oldest plants of Indian cement industry located in Maharashtra. It has two lines in operation with a combined operating capacity of 3.3 MTPA of clinker production. Line 1 Pyro system was operating with 4 stage SLC tower and CFG grate cooler operating at 4,000 tpd clinker production.

UltraTech went in for FLSmidth as a one source partner to upgrade its Line 1 Pyro system in two phases. FLSmidth as a one source partner is responsible for the complete civil engineering, mechanical engineering, E&I engineering and the hooking up of newly installed equipment with the existing PLC for the complete upgrade project.

In the first phase the existing grate cooler was replaced with the new CB cooler. FLSmidth as a One Source Partner to UltraTech in this upgrade completed the cooler replacement with UltraTech Support and lighted up the plant on 3rd November, 2014. The performance guarantee for the cooler replacement was carried out on 17 October 2015. Sufficient time was given to demonstrate the consistency in cooler performance and cooler losses and the PG trial was taken almost after a year.

Table 1 portrays the values recorded during base line test and during the performance guarantee trial.

Cooler Losses at 1.15 kg/kg clinker recuperation air and 36?C Ambient. Refer Table 2 UltraTech Cement had the WHR system incorporated in the cooler and in the preheater system. The Table 3 portrays the before and after conditions of the hot air taken for power generation in the prevailing WHR system.

In CB coolers, the quality of heat is maintained in such a way that the recuperation and the WHR system get the maximum heat available from the red hot clinker. The reason being in case of CB cooler we pump less quantity of air when compared to the older generation beam technology coolers from underneath the compartment efficiently by means of MFRs. This in turn maintains the air flow as per requirement to the upper clinker bed and ensures uniform cooling and better heat removal from the hot clinker. As we do not dilute the heat available in the hot clinker by pumping more air, the above parameters are achieved without recirculation of hot air from cooler vent and thereby we need not compromise on the clinker temperature as well.

By Logesh Baskaran, Senior Manager – Products and Upgrades Sales, Cement Project Division.

Table 1: CB Cooler Performance Before and After Modification

Parameters

Before Cooler
Replacement-Base line
Guarantee After Cooler
Replacement
Clinker Capacity (TPD) 3,933 Same as Baseline 4,073
Cooler Loss (kcal/kg Clinker) – Cooler Vent & Clinker losses 151 99.5 90.5
Cooler Specific POwer Consumption (kWh/t) – Equipment Include
Cooler Drives, Cooler Compartment Fans (w/o Silencer) & HRB
5.7 5.1 4.9
Clinker Temperature (?C) 115 65 + ambient 48 + ambient

Table 2: Cooler Balance Before & After CB Cooler

Parameter

Before Modification- Base line Measurement Data After CB Cooler Installation
INPUT kg air/kg Clinker

Temp (? C)

kcal/kg clinker kg air/kg Clinker Temp (?C)

Kcal/kg clinker

Clinker 1.0 1450 383 1.0 1450 383
Clinker Dust 0.05 1450 19.2 0.05 1450 19.2
Cooling Air Input 2.6 30 18.8 2.27 36 19.7
Cooler Fan Power 4.7 4.0 4.1 36 3.5
TOTAL INPUT 425 425
OUTPUT kg air/kg Clinker Temp (? C) kcal/kg clinker kg air/kg Clinker Temp (? C) kcal/kg clinker
Tertiary Air 0.78 811 165.1 0.72 938 178.9
Tertiary Air Dust 0.03 811 6.2 0.03 938 5.5
Secondary Air 0.42 840 92.4 0.43 1179 136.9
Secondary Dust 0.02 840 3.5 0.03 1179 7.2
Vent Air 1.42 292 105.6 1.12 270 75.0
Clinker 1.0 115 21.7 1.0 84 15.5
Lat. heat of
evaporation of water
23.5 0
Radiation 8 6
TOTAL OUTPUT 425 425

Table 3: Mid Air to WHR Before & After CB Cooler.

Parameters

Before CB Cooler After CB Cooler
Mid Air Temperature (?C) 375 (Avg) 400 (Avg)
Steam Generation (TPH) 5.3 5.8

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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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