Concrete

Taking the Technology Highway

Published

2 years ago

April 1, 2022

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Digitisation is no longer an option, it is the need of the hour. More than the fear of losing out to competition, it is factors such as efficiency, returns and sustainability that are fueling IT initiatives in the cement industry. ICR takes a closer look at the IT approach that manufacturers need to take to remain ahead of the curve.

B e it rise in population or increase in development, all roads lead to an unprecedented increase in infrastructure projects worldwide. This has a direct impact on a country’s cement production. While manufacturing is the next most sought-after commodity after water, cement makers are putting in optimum efforts to meet the increasing demand. The cement industry has witnessed numerous changes since the industrial revolution, and the most important one of them – technology – is here to stay. In modern times, with increasing competition, it is imperative for cement manufacturing companies to keep evolving and matching the speed at which the industry and its technology is growing. It is time for cement makers to go digital in their approach.

Digital transformation for cement manufacturers
The process of cement manufacturing startsfrom locating and obtaining its raw materials to making it reach its end consumer. The whole process is labour intensive and can be made more
effective and streamlined by the use of technology. Digitisation has a lot to offer to a cement organisation. Here’s how.

Control over quality and process: What sounds as a simple step by step process of getting raw material, crushing it, processing it and grinding it to form cement involves a lot more detail and parameters to it. It is essential to measure the quality of raw material which is fundamental for a good quality product, monitoring equipment health while chemical processes are on-going and a lot of other factors are involved in the cement making process. With the use of smart systems and technology, operators at each stage can get quick data of the process and make real-time decisions which shall optimise the production and lead to quality results.
Equipment monitoring and health predictions: Any equipment or machinery at a cement plant undergoes wear and tear with large loads of material, continuous running and due to environmental conditions. With systems that can predict the health of these equipment and machinery, monitoring their health and downtime becomes more effective. It also helps avoid any unplanned down-time which results in loss of time and money for the business. It also prevents any accidents with the help of equipment being monitored round the clock.
According to Rizwan Sabjan, Head – Regional Sales Enablement, FLSmidth, “With equipment in continuous use, damage can happen at any time. While visual inspections are important to provide broad, contextualised operational insights, relying only on intermittent site visits puts customers at the risk of missing the early warning signs that could enable them to drastically reduce both downtime and expenses. Online condition monitoring is a continuous service that enables customers to detect potential failures well in advance, giving them plenty of time to take preventative action and avoid actual failure.”
“By contrast, sensors on customer equipment are able to capture data that may be otherwise ‘invisible. Our online condition monitoring services connect this data to the cloud where it is continuously monitored and trended. If something is wrong, an alarm notifies our team of experts who are able to analyse the data remotely and develop a recommended action plan to rectify the fault well ahead of it escalating. It’s a low-stress, low-cost, low-risk approach to maintenance that offers high returns,” he adds.

Automation and IoT: Functioning as the brain and nervous system of the cement plant is automation. From collecting data to automating processes, the sole motive to implement this technology is to achieve effective load management and efficiency in all verticals of the cement manufacturing process. Internet of Things (IoT) is the buzz word in the world of technology and adapting to that has been known to show results for better management and predictive techniques for the business.
Connected logistics: Transportation of material from one floor to another for the next step in the process is a key component of the cement making process. It involves movement of conveyor belts, special carriers and trucks for taking the end product to its distribution sources. These operational activities can be maintained and optimised by using technological solutions that measure the vitals of the vehicles carrying load. There also are multiple software that help plan the movement of the organisation’s fleet. It contributes towards saving time and cost for the business with effective deliveries and on schedule arrivals.
Cyber security: Cement plants are as likely to be hacked or subjected to system viruses. Technology and firewall prevent such incidents from happening.

Embracing digitisation for sustainable future
The way forward for the cement industry is to embrace automation and technology as part of its core for planning combined with goals of achieving sustainability with their efforts. Optimising isn’t just about increasing productivity, it is also about using digital tools and integrating them in cement making processes to be able to make continuous, real-time, automatic adjustments to ensure energy consumption is reduced, giving a more energy efficient operation result.

Stating their vision for cement organisations in 2030, a report published by McKinsey and Company says, pursuing digitisation and sustainability levers are key to significantly boosting productivity and efficiency of a typical cement plant in the future. The result is a margin gain of $4 to $9 per tonne of cement, which would shift a traditional plant to the top quartile of the cost curve for plants with similar technologies. The report also throws light on the CCUS technology, stating that in terms of scalability, it is the most advanced option. Using this technology, cement players capture emitted CO2 and can either pursue carbon-cured concrete (one of the few already available utilization options that locks in CO2 in the end product) or store carbon in former oil and gas fields.
“Talking about the commitment, by 2030 the cement industry contributes to possibly around 0.3 per cent annually, reducing the carbon emissions. So, process control becomes very critical to set your old machines to be very efficient, also making the plant connected which is a lot of technologies kept connected together because then you pull in individual resources and then get on to them at the corporate or an enterprise level which helps you look at everything like a dashboard or one consolidated level and that helps you to mind data through quality, production, process parameters and allowing operator to understand the energy consumption,” says Arvind Kakru, Director Sales, Rockwell Automation.
Digitisation also helps achieve a data driven approach for the use of alternative sources of raw materials and energy. It helps make the operating personal be proactive in their reaction towards the changing conditions of the kilns that can be monitored with the help of technology.

Paving a path for artificial intelligence
Data is the new gold. However, having data is one thing and analysing it for the betterment of business is another. Data analytics is paving the way for artificial intelligence (AI), a new technology that is finding its way into the cement industry. AI by collecting and archiving data from the present and the past has the capability to come up with patterns, anamolies and solutions that may not have been possible to recognise otherwise. Using artificial intelligence in a cement plant will allow operators to take corrective actions before an actual problem occurs. Based on the first results of this technology, cement producers can define new, improved optimisation strategies and new approaches to maintenance concepts, such as predictive and prescriptive maintenance.
Traditional Advanced Process Control (APC) worked on an approach of taking actual measurements in at defined set points in various defined processed. However, use of AI is changing the approach of APC. In something as dynamic as a kiln, unknown variables like alternative fuel types, make the traditional Model Predictive Controllers (MPC) drift over time. The result is that most of these APC systems are out of service or require intensive fine tuning. This is where AI makes a big difference because it can also consider the history of the variables and recognise patterns in these trends.
The key advantage it brings to the process is that AI modules compare actual trends with the trends of the past in a kiln and predict what will happen in the future. In case of a failure, they issue a warning to the operator fairly in advance to avoid the situation and cause unplanned downtime. It even suggests corrective actions and best practices.
Raj Pradhan, Global Delivery Head – Building and Construction Materials, BirlaSoft says, “Digitisation brings complete near real time visibility of end-to-end processes, which helps taking timely decisions to avoid any down time and allows best possible utilisation of resources.”
“In the current competitive market where increase in price is not helping much, the only option left to improvise the margins is through market share and optimisation of cost which can be achieved through automation,” he adds.
It is the era of Industry 4.0, manufacturers across the globe are adapting to technology, automation and data exchange in manufacturing technologies. The future for cement industry is also digitisation to achieve effective process flow, optimum productivity and energy efficiency along with flawless logistics and distribution systems.

–Kanika Mathur

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Concrete

Indian Cement Industry Sees Further Consolidation

Cement industry to face consolidation soon.

Published

3 days ago

September 13, 2024

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India’s cement sector is set for further consolidation in the near-to-medium term, according to a recent report. With increasing competition, rising input costs, and the need for economies of scale, companies are expected to explore mergers and acquisitions (M&A) to strengthen their market positions. As the industry faces various challenges, including high energy costs and fluctuating demand, consolidation is viewed as a strategic move to drive growth and sustainability.

Key Points:
Market Consolidation: The Indian cement industry has already witnessed significant consolidation over the past few years, with several large firms acquiring smaller players to enhance their market share. The trend is expected to continue, driven by the need to optimize operations, cut costs, and gain better pricing power. Consolidation helps companies to expand their geographic reach and strengthen their portfolios.

Rising Costs and Challenges: One of the primary drivers of consolidation is the rising cost of inputs, particularly energy and raw materials. With costs of coal and petroleum coke (key energy sources for cement production) soaring, companies are looking for ways to maintain profitability. Smaller and medium-sized players, in particular, find it challenging to cope with these rising costs, making them more likely targets for acquisition by larger companies.

Economies of Scale: Larger cement companies benefit from economies of scale, which help them absorb the impact of rising input costs more effectively. Consolidation allows firms to streamline production processes, reduce operational inefficiencies, and invest in advanced technologies that improve productivity. These efficiencies become critical in maintaining competitiveness in an increasingly challenging environment.

M&A Activity: The report highlights the potential for more mergers and acquisitions in the cement sector, particularly among mid-sized and regional players. The Indian cement market, which is highly fragmented, presents numerous opportunities for larger companies to acquire smaller firms and gain a foothold in new markets. M&A activity is expected to accelerate as firms seek growth through strategic alliances and acquisitions.

Regional Focus: Consolidation efforts are likely to be regionally focused, with companies looking to expand their presence in specific geographic areas where demand for cement is strong. Infrastructure development, government projects, and urbanization are driving demand in various parts of the country, making regional expansions an attractive proposition for firms looking to grow.

Impact on Competition: While consolidation may lead to a more concentrated market, it could also intensify competition among the remaining players. Larger firms with more resources and market reach could dominate pricing strategies and influence market dynamics. Smaller firms may either merge or struggle to compete, leading to a reshaping of the competitive landscape.

Demand Outlook: The near-term outlook for the cement industry remains uncertain, with demand being influenced by factors such as construction activity, infrastructure projects, and government initiatives. The report notes that while urban demand is expected to remain stable, rural demand continues to face challenges due to slow construction activities in those areas. However, the long-term outlook remains positive, driven by ongoing infrastructure developments and real estate projects.

Sustainability Focus: Companies are also focusing on sustainability and environmental concerns. Consolidation can provide larger companies with the resources to invest in green technologies and reduce their carbon footprint. This focus on sustainability is becoming increasingly important, with both government regulations and market preferences shifting toward greener production practices.

Conclusion:
The Indian cement industry is poised for further consolidation in the coming years, driven by rising costs, competitive pressures, and the need for economies of scale. M&A activity is likely to accelerate, with larger firms targeting smaller and regional players to strengthen their market presence. While consolidation offers opportunities for growth and efficiency, it could also reshape the competitive landscape and influence pricing dynamics in the sector.

Concrete

Cement Companies May Roll Back Hike

Cement firms reconsider September price increase.

Published

3 days ago

September 13, 2024

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Cement companies in India might be forced to reverse the price hikes implemented in September due to weakened demand and pressure from competitive market conditions, according to a report by Nuvama Institutional Equities. The recent price increase, which was expected to improve margins, may not hold as demand falls short of expectations.

Key Points:
Price Hike in September: Cement firms across India increased prices in September, aiming to improve their margins amidst rising input costs. This was seen as a strategic move to stabilize earnings as they were grappling with inflationary pressures on raw materials like coal and pet coke.

Weak Demand and Pressure: However, demand has not surged as expected. In some regions, particularly rural areas, construction activity remains low, which has contributed to the tepid demand for cement. The combination of high prices and low demand may make it difficult for companies to maintain the elevated price levels.

Competitive Market Forces: Cement manufacturers are also under pressure from competitors. Smaller players may keep prices lower to attract buyers, forcing larger companies to consider rolling back the September hikes. The competitive dynamics in regions like South India, where smaller firms are prevalent, are likely to impact larger companies’ pricing strategies.

Nuvama Report Insights: Nuvama Institutional Equities has highlighted that the September price hikes may not be sustainable given current market conditions. According to the report, the demand-supply imbalance and weak construction activities across many states could push cement companies to reconsider their pricing strategies.

Impact on Margins: If companies are compelled to roll back the price hikes, it could hurt their profit margins in the near term. Cement firms had hoped to recover some of their input costs through the price increases, but the competitive landscape and slow demand recovery could negate these gains.

Regional Variations: Price rollback might not be uniform across the country. In regions where infrastructure development is picking up pace, cement prices may hold. Urban areas with ongoing real estate projects and government infrastructure initiatives could see a sustained demand, making price hikes more viable.

Future Outlook: The outlook for the cement sector will largely depend on the pace of recovery in construction activity, particularly in the housing and infrastructure sectors. Any significant recovery in rural demand, which is currently subdued, could also influence whether the price hikes will remain or be rolled back.

Strategic Adjustments: Cement firms may need to adopt a cautious approach in the near term, balancing between maintaining market share and protecting margins. Price adjustments in response to market conditions could become more frequent as companies try to adapt to the fluctuating demand.

Conclusion:
The September price hikes by cement companies may face reversal due to weak demand, competitive pressures, and market dynamics. Nuvama’s report signals that while the increase was aimed at margin recovery, it may not be sustainable, particularly in regions with low demand. The future of cement pricing will depend on construction sector recovery and regional market conditions.

Concrete

Bridge Collapse Spurs Focus on Stainless Steel

Climate change prompts stainless steel push.

Published

3 days ago

September 13, 2024

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The Ministry of Road Transport and Highways (MoRTH) is turning its attention to the use of stainless steel in bridge construction to counteract corrosion, an increasing issue linked to climate change. With recent bridge collapses highlighting the vulnerability of existing infrastructure to corrosion and extreme weather events, the ministry is promoting the adoption of durable materials like stainless steel to ensure the longevity and safety of India’s critical transport infrastructure.

Key Points:

Bridge Collapse and Climate Change: Recent incidents of bridge collapses across the country have raised alarm over the durability of current construction materials, with corrosion cited as a leading cause. Climate change, leading to harsher weather patterns and increased moisture levels, has accelerated the deterioration of key infrastructure. This has prompted MoRTH to consider long-term solutions to combat these challenges.

Corrosion: A Growing Concern: Corrosion of structural materials has become a serious issue, particularly in coastal and high-moisture regions. The Ministry has identified the need for a more resilient approach, emphasizing the use of stainless steel, known for its resistance to corrosion. This shift is seen as crucial in ensuring the longevity of India’s bridges and reducing maintenance costs over time.

Stainless Steel for Bridge Construction: Stainless steel, while more expensive initially, offers long-term savings due to its durability and resistance to environmental factors like moisture and salt. The Ministry is advocating for the material’s use in future bridge projects, particularly in areas prone to corrosion. Stainless steel is seen as a solution that can withstand the pressures of both natural elements and increasing traffic loads.

Government’s Proactive Steps: The government, through MoRTH, has started consulting with experts in the field of metallurgy and civil engineering to explore the expanded use of stainless steel. They are considering updates to construction standards and specifications to incorporate this material in new and rehabilitated infrastructure projects.

Economic Considerations: Although the initial investment in stainless steel may be higher than conventional materials, the reduced need for repairs and replacements makes it a cost-effective option in the long run. This approach also aligns with the government’s push for sustainable infrastructure that can withstand the test of time and climate change effects.

Future of Indian Infrastructure: With the push for stronger, more durable infrastructure, the Ministry’s move to adopt stainless steel for bridge construction marks a shift towards building climate-resilient structures. The use of this material is expected to not only enhance the safety and longevity of bridges but also reduce the financial burden on the government for constant repairs.

Industry Perspective: The stainless steel industry sees this shift as an opportunity to expand its market, particularly in the infrastructure sector. Stakeholders are engaging with the government to demonstrate the benefits of stainless steel, advocating for its increased use not just in bridges but across various infrastructure projects.

Conclusion: In response to the growing threat of climate change and its impact on infrastructure, the Ministry of Road Transport and Highways is prioritizing the use of stainless steel in bridge construction to combat corrosion and ensure the long-term durability of critical transport structures.