Concrete

Synthetic lubricants have gained popularity in the cement industry

Published

1 year ago

June 12, 2023

admin

Sudhahar P, Executive Director (Lubes), Bharat Petroleum Corporation, speaks about the role of lubricants in maintaining the efficient operation of various machinery and equipment, and the innovations in this segment.

Different lubricants have different specific functions in a cement plan.
Explain this with reference to the lubricants that you manufacture.
Cement manufacturing is an equipment-intensive industry. Lubrication of equipment in the cement industry poses some unique challenges with the kind of environment the machinery operates and the plant location. The integrated cement plants had a complete off-highway fleet to cater their limestone mining operation as well as the heavy-duty plant machinery required for cement manufacturing. The working conditions and the machineries at mining and plant operations are unique and require a very high quality of lubricant to achieve 24×7 operation. MAK lubricants portfolio includes tailor-made lubricants for cement industry such as industrial gear oils, hydraulic oils, compressor oils, engine oils and greases.

What role do lubricants by your organisation play in the functionality of the cement industry?
Lubricants are essential for maintaining efficient operation of various machinery and equipment involved in the cement production process. It plays a crucial role in reducing friction, heat and wear in machinery and equipment, thereby enhancing their efficiency, reliability and lifespan.
By using high-quality MAK Lubricants for the cement industry and implementing proper lubrication practices, cement plants can not only optimise their operational performance but also increase equipment reliability, improve energy efficiency, and reduce total cost of ownership.

How do you ensure high quality of lubricants that are made specifically for the cement sector?
MAK lubricants always strive to ensure the highest quality of lubricants supplied to our customers by investing R&D, implementing quality control measures, and complying with quality management system standards.

R&D: We invest in extensive Research and Development to formulate high quality lubricants specifically designed for the cement industry
after analysing the operating conditions, equipment requirements and challenges faced in cement plants.
Quality control: Rigorous quality control measures are implemented throughout the production process including receipt of raw materials, blending, filling, etc. Quality control process includes using advanced laboratory testing equipment and techniques to analyse the raw materials, monitor the manufacturing process, and verify the finished product quality. We have dedicated quality control teams to ensure adherence to strict quality standards of lubricants.
Compliance with standards: We as a major lubricant manufacturer in the industry, adhere to recognised industry standards and certifications. These standards (ISO 9001/ 14001/45001/50001) ensure that the lubricants meet specific performance criteria and rigorous testing procedures.

Tell us about the key areas where your products can improve the performance and efficiency of cement industry equipment.
Critical equipment like kiln, vertical rolling oil, ball mill, crushers and roller press operate continuously under challenging conditions. Gear boxes in these equipment are subjected to extreme loading conditions and may cause micro pitting, premature wear problems and consumes a lot of energy. MAK Lubricants offer energy-efficient gear oils with anti-micro pitting resistance, reducing energy consumption and extending the equipment life respectively.
Heavy loads, high pressures, and temperatures in the hydraulic system of the grinding mill causes increased stress on hydraulic oil and thereby reduces its service life. Our energy efficient long life hydraulic oil not only has a potential to save energy but also provide longer oil life along with improved reliability of equipment.
In the limestone quarry section, continuous and reliable operation of Heavy Earth Moving Machinery (HEMM) is very much required to meet the demands of the production plant. MAK Lubricants offer total lubrication solutions for these machinery, which includes long life engine oil, energy efficient hydraulic oil, axle and transmission oil with proven field performance credentials.

What environmental factors influence the performance of lubricants? How do you address concerns arising from it?
Mining and mineral processing equipment in the cement industry are often subjected to extreme working conditions. High operating temperatures, extreme heavy/shock loads, continuous operation, cement dust, and seasonal variations in temperatures pose tough operating conditions in cement production.
First of all, seasonal variation (high heat >45oC/ extreme cold <0oC) and high humidity levels primarily affect the lubricant storage stability. Higher operating temperatures increase the rate of oil oxidation, which can lead to deposit formation and faster degradation of oil. Similarly, higher humidity levels cause moisture ingression into the product, accelerating the oxidation process, reducing the anti-wear performance and depleting overall additive performance.
Our MAK Lubricants are formulated using best in class Group II+ base oils produced at LOBS plant, Mumbai Refinery. With higher saturate content and negligible aromatic and sulphur content in our base oils, these provide exceptionally high oxidation and thermal stability. The selected advance additive technology in combination with the Group ll+ base oil ensures that our lubricants provide optimum performance under adverse operating conditions present in cement industry.

How does your organisation work with cement clients to customise lubrication solutions?
MAK Lubricants team carries out lubrication surveys at various cements to understand the specific lubrication requirements of all process equipment, current lubrication practices, condition monitoring, storage handling, etc. Technical team interacts with the user section to understand their challenges / requirements associated with lubricants. Based on the inputs received from the cement plants, our team provides a comprehensive lubrication survey report with right lubricant grade recommendation, grade rationalisation, improve current lubrication practices, identify critical equipment for regular condition monitoring and offer tailor-made lubricants to suit customer requirements and improve reliability.

How do you ensure compliance with environmental regulations?
Environmental compliance encompasses a wide range of regulations, and standards enacted by governments and other regulatory bodies to safeguard the environment even while businesses continue to manufacture and sell products to several markets.
All our MAK Lubricants are produced at our blending plants compliant with ISO 9001 / 14001 / 45001 /50001 standards along with necessary statutory pollution control board requirements.
As we understand, many cement plants today are bound by sustainability targets set by the government. Significant progress has been made in this direction by many cement plants, by implementing usage of our energy efficient lubricants, long life lubricants, environment friendly biodegradable lubricants, etc.

How do you prioritise customer service and support for your cement clients?
We believe that ‘satisfied customers become the best referral sources’. Customer service to us is providing timely, responsive, highest level of technical support to meet the customer expectations. We have a strong network of technical services teams who prioritise prompt response to customer enquiries, concerns and service requests. We provide customised lubrication solutions, trouble shootings, guidance, and recommendations to reduce unscheduled downtime and costly additional maintenance.
We also provide training programmes, workshops, seminars, knowledge sharing sessions to enhance the understanding of the importance of proper lubrication, right lubrication techniques and best usage practices.
With our condition monitoring solutions, we offer detailed analysis reports of in-service oil which not only provides condition of oil but also keeps track of equipment health. It offers early detection of equipment failure and better planning of preventive maintenance.
We offer unique and reliable testing solutions through ‘Mobile Lab,’ first-of-its-kind in the industry with onsite testing of lubricants at customer premises and release of test reports on the same day itself. This initiative is very well received by many customers, as it reduces the overall lubricant sample testing time and enables them to take faster decisions preventing catastrophic equipment failures.

Tell us about any recent developments or innovations in lubricants specifically designed for the cement industry.
We work closely with many cement plants and equipment OEMs to develop innovative specialty lubricants for crushers, ball mills, rotary kilns, vertical mills, and roller presses. These highly application-specific solutions help to effectively protect the equipment components from wear, reduce maintenance cost and prolong equipment life.
MAK Lubricants has developed energy efficient hydraulic oils / industrial gear oils, biodegradable hydraulic oils, long drain engine oils specifically for the cement industry.
Synthetic lubricants have gained popularity in the cement industry due to their ability to withstand extreme operating conditions. We have developed high-performance synthetic gear oils and compressor oils, which offer improved thermal stability, oxidation resistance, and reduced sludge formation. These lubricants can enhance equipment performance, extend oil change intervals and reduce maintenance costs. Improved equipment efficiency, a by-product of energy efficient lubricants, results in increased machine output, lowering operating temperatures and reduced energy usage. Our energy efficient hydraulic oil lubricants reduce the negative impact of energy consumption on the environment, improving the fuel economy, productivity, while at the same time reducing the energy costs thus contributing towards sustainable development.
With growing environmental concerns, there is an increasing focus on environmentally friendly lubricants for the cement industry. We offer lubricants formulated with biodegradable base oils and additives, reducing their impact on the environment in case of accidental leakage or spillage. They comply with environmental regulations while still offering effective lubrication performance.

Up Next

Waste Heat Recovery System is a key area for cement producers

Don't Miss

ACC launches ‘Bagcrete’, a pre-blended concrete solution

Concrete

Indian cement makers to invest $ 14.3 bn

The bulk of this growth will come from the top-three cement producers–Ultratech, Ambuja and Shree Cement

Published

2 days ago

September 6, 2024

admin

Indian cement manufacturers are set to invest approximately USD 14.3 billion over the next four years to increase capacity by 25 %. This move, driven by rising domestic demand, is expected to add an additional 160-170 million tons of cement production annually. The industry’s expansion will be predominantly funded through internal accruals, with minimal reliance on debt. The expansion is spurred by government’s massive infrastructure push, with plans to invest USD 1.7 trillion in infrastructure projects by 2030. According to S&P Global Ratings, the demand for cement in India is projected to grow at a compounded annual growth rate (CAGR) of 7 % over the next four years, aligning with the planned capacity additions.
The bulk of this growth will come from the top-three cement producers–Ultratech, Ambuja and Shree Cement, which will account for over 70 % of the country’s total capacity increase. This expansion equates to an annual capital expenditure of close to Rs 300 billion, which will be more than double the average annual capex of the past decade. The leading cement companies, which produce 70 % of India’s total cement output, are in a strong financial position to support this expansion. Rising cement prices have bolstered their balance sheets, allowing them to reduce debt significantly while maintaining robust cash flows.

Concrete

SEBI Places JSW Cement’s Rs.4,000 Cr IPO on Hold

SEBI halts JSW Cement’s ?4,000 crore IPO.

Published

4 days ago

September 4, 2024

admin

The Securities and Exchange Board of India (SEBI) has placed the proposed ?4,000 crore Initial Public Offering (IPO) of JSW Cement on hold, citing regulatory concerns. This development comes as a significant pause in the cement manufacturer’s plans to raise capital through the public markets, a move that was expected to bolster its expansion and growth strategies in the competitive construction sector.

IPO Overview: JSW Cement, a key player in the Indian cement industry, had announced its intentions to launch a ?4,000 crore IPO. The offering was aimed at raising funds to support the company’s ongoing expansion projects, reduce debt, and improve operational efficiency.

SEBI’s Decision: SEBI, the regulatory body overseeing the capital markets in India, has decided to withhold its approval for the IPO. The decision was made after careful scrutiny of the draft red herring prospectus (DRHP) submitted by JSW Cement. While specific reasons for the hold have not been disclosed, it is understood that SEBI has sought further clarifications on certain aspects of the filing.

Impact on JSW Cement: The postponement of the IPO is likely to impact JSW Cement’s financial planning and expansion initiatives. The company had intended to use the proceeds from the IPO to fund new projects, including the construction of additional cement plants, modernization of existing facilities, and investments in sustainable practices.

Market Reactions: The decision by SEBI has led to a cautious response in the market. Investors and market analysts are closely monitoring the situation, as the delay could affect investor sentiment towards the company and its future fundraising efforts. The construction sector, which heavily relies on capital-intensive projects, may also be impacted by this development.

SEBI’s Concerns: SEBI’s decision to put the IPO on hold highlights the regulatory body’s commitment to ensuring transparency and investor protection in the capital markets. The regulator may be seeking additional information regarding JSW Cement’s financials, corporate governance practices, or other disclosures to ensure that the IPO meets all necessary requirements.

JSW Cement’s Response: JSW Cement is reportedly working closely with SEBI to address the concerns raised and to provide the required clarifications. The company remains optimistic about receiving the necessary approvals in due course and proceeding with the IPO as planned.

Industry Context: The Indian cement industry has seen significant activity in recent years, with companies looking to expand their capacities to meet growing demand. IPOs have become a popular route for raising capital, allowing companies to fund expansion and reduce debt. However, the regulatory environment remains stringent, with SEBI playing a crucial role in maintaining market integrity.

Future Prospects: While the IPO is currently on hold, JSW Cement’s long-term growth prospects remain robust, driven by its strong market position and ongoing investments in capacity expansion. The delay in the IPO may prompt the company to explore alternative fundraising options, such as debt financing or private equity, to meet its immediate capital needs.

Regulatory Environment: SEBI’s decision underscores the importance of regulatory compliance in the IPO process. Companies looking to tap the capital markets must ensure that their disclosures are thorough and transparent, meeting all regulatory standards to gain investor confidence.

Conclusion: The hold placed by SEBI on JSW Cement’s ?4,000 crore IPO is a reminder of the challenges that companies face in navigating the regulatory landscape. While this may delay the company’s fundraising plans, it also provides an opportunity to strengthen its disclosures and align with regulatory expectations, ultimately benefiting both the company and its investors.

JSW Cement now faces the task of addressing SEBI’s concerns to move forward with its IPO, a crucial step in its growth trajectory within the Indian cement industry.

Concrete

Smart Building Choices: Enhancing Life with Green Practices

Published

5 days ago

September 3, 2024

admin

As urban areas expand and cities continue to grow, the need for sustainable building practices becomes more pressing than ever. Today, more people recognize the importance of creating urban environments that coexist harmoniously with nature. The question we must ask is: Can we build cities that not only meet our needs but also embrace the natural world?

The Rise of Sustainable Building

The concept of sustainable building is not new, but its importance has dramatically increased in recent years. With over 5.3 billion square feet of green building space in India alone, the shift towards eco-friendly construction is clear. This transition isn’t just a trend—it’s a necessary evolution as we confront the environmental challenges posed by rapid urbanization.

Reducing Our Carbon Footprint

Buildings are significant contributors to carbon emissions, accounting for nearly 40% of global emissions due to construction activities and the use of energy-intensive materials like steel and concrete. In India, the construction sector is responsible for 30% of the nation’s carbon emissions and generates an astounding 530 million tons of waste annually. This waste could fill 200,000 Olympic-sized swimming pools, highlighting the urgent need for more sustainable practices.

However, sustainable building practices are helping to reduce these impacts. For instance, green buildings in India are already reducing energy consumption by up to 40%, with a significant portion of their energy coming from renewable sources. By 2030, these buildings are projected to decrease carbon emissions by 33-35%. This is a testament to the power of sustainable construction methods and the positive impact they can have on our environment.

Building Smarter with Sustainable Materials

The choice of materials plays a crucial role in sustainable construction. Traditional materials like steel and concrete are energy-intensive and have a high environmental impact. For example, producing new steel emits over 2.5 tons of CO2 per ton of steel. However, using recycled steel can reduce these emissions by up to 60%. Similarly, conventional concrete production emits about 1 ton of CO2 for every ton of cement produced. By incorporating eco-friendly alternatives like geopolymer concrete, we can cut down these emissions by up to 35%.

The Power of Local Materials

Another key aspect of sustainable construction is the use of locally sourced materials. Materials like rammed earth not only reduce transportation emissions but also offer excellent thermal insulation, reducing the need for additional heating and cooling. Rammed earth construction can lower embodied energy by up to 30% compared to conventional materials. This practice not only supports local economies but also minimizes the environmental impact of transporting materials over long distances.

Innovative Approaches to Green Building

Around the world, innovative sustainable building projects showcase the potential of eco-friendly construction. In India, several projects have set remarkable benchmarks in sustainability by integrating cutting-edge technologies, adopting eco-friendly practices, and prioritizing environmental conservation.

The construction industry is one of the largest contributors to environmental degradation. Yet, it also holds immense potential to drive positive change. By adopting sustainable building practices, we can reduce the environmental impact of construction and create healthier, more livable urban environments.

Integrating renewable energy sources into building designs is a key component of sustainable construction. Solar panels, wind turbines, and other renewable energy technologies can significantly reduce a building’s reliance on fossil fuels, cutting down on carbon emissions and promoting a more sustainable energy future.

Water Conservation

Water is another critical resource that must be conserved in sustainable building practices. Rainwater harvesting, greywater recycling, and efficient water fixtures can help reduce water consumption and preserve this precious resource. By implementing these practices, buildings can significantly reduce their water footprint and contribute to more sustainable water management.

As the construction industry continues to shape the landscapes of our cities and communities, it must embrace a more sustainable path forward—one that prioritizes the health of our planet and the well-being of future generations. The choices we make today in building materials, design, and construction practices will have lasting impacts on our environment and quality of life.

By choosing sustainable building practices, we are not just constructing buildings but also building a better future. We are creating cities that work with nature, not against it, and ensuring that our urban environments remain healthy and vibrant for generations to come.

Eco-Blueprints: Mastering Sustainable Construction

By integrating sustainable practices into every aspect of construction, we can reduce our environmental footprint, conserve valuable resources, and create healthier, more livable spaces. The future of urban development lies in embracing these eco-blueprints and mastering sustainable construction practices. The time to act is now, and the path forward is clear. Let’s build a future that enhances life with green practices and ensures a sustainable world for all. To dive deeper into how sustainable building practices are shaping our future, don’t miss our latest YouTube video https://www.youtube.com/watch?v=QYmRyVu-cLwF