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We are committed to improving the energy efficiency of our products

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Krishnaraj Sreedharan, Head of Customer Service, Flender India, talks about latest innovations and modernisation of their product lines to help improve cement processes.

Tell us about the role of geared drives in cement plant machinery.
The manufacturing of cement involves an elaborate process, starting from the mining of necessary mineral resources to the processing of these minerals to obtain the final products with desired physical and chemical properties. In this process, rotary geared drive systems
play a crucial role in powering heavy-duty critical equipment that operates under harsh conditions and heavy loads. These systems are utilised for various applications such as crushing, grinding, melting, mixing and conveying.

Tell us about the portfolio of drive products that you offer to the cement industry.
Flender provides a wide range of mechanical power transmission products that are extensively used to drive various types of rotary equipment in the cement industry. Our product portfolio is primarily divided into gear units, couplings and drive systems. This comprehensive range includes standard catalog series products, application-specific standardised products and highly engineered products tailored to meet the specific requirements of individual projects.

As machinery in cement plants is advancing with time, how do you accommodate the change in drive components for the betterment of functionality in cement plants?
Over the years, as the cement manufacturing process and equipment have advanced, Flender has continuously invested in innovative product designs and the modernisation of existing product lines. We are committed to improving the energy efficiency and environmental friendliness of our products and manufacturing processes, while adhering to the highest quality standards and global sustainability goals.

How can Flender products and services help cement manufacturers achieve better productivity and energy efficiency?
The outstanding feature of Flender products has always been their high operational reliability, which ensures maximum equipment availability and delivers optimal output. With over a century of experience serving the industry and leveraging our extensive application knowledge pool, we have optimised our drive solutions to minimise transmission losses. Our wide range of products and sizes allows us to closely match the technical requirements of various applications, eliminating the risk of drive underutilisation. Our customer service team excels in providing comprehensive support, including reengineering, multi-brand retrofit, and repair services. We recognise the significance of optimising output and extending the operational life of equipment for our valued customers.

Which machinery of the cement plant is the most challenging and how do you overcome the challenge?
One of the most crucial and demanding drive applications in cement manufacturing is the pre and post clinkerisation grinding process, which involves high energy consumption and heavy impact loads. When it comes to grinding mill applications like Vertical Roller Mills, Tube Mills or High-Pressure Grinding Roll Mills, Flender drive solutions guarantee optimal equipment availability. Our proactive preventive maintenance measures, along with offline and online condition monitoring systems (CMS), effectively prevent unscheduled equipment downtime and facilitate utilisation of residual life of the drive components. These systems also provide plant operators with real-time information about the operational condition of the drive, enabling them to plan maintenance activities well in advance.

How often do you service and audit your installations at the cement plant?
Flender drive solutions for critical applications are equipped with factory-fitted CMS or can be easily adapted to accommodate monitoring equipment available at the installation site. At our Chennai plant location, we have established a remote condition monitoring hub that is connected to a significant number of our mill drive installations. Our dedicated team of experts provides real-time monitoring support, collects and analyses drive condition data and offers valuable insights and consultation to site maintenance teams. By leveraging proactive information, we assist in maximising equipment uptime and utilisation. Through our standard and customised maintenance programmes, we offer our customers a wide range of service solutions tailored to their specific operational needs. This enables us to effectively assist our customers in maintaining the largest global installed base of our products in the cement industry.

Tell us about the upcoming innovations from Flender that would be beneficial for cement plants?
Flender’s latest innovation introduces a product line of standard gear units that showcases a completely new design, surpassing the limitations of conventional gear engineering and manufacturing. This breakthrough is accompanied by a state-of-the-art advanced monitoring system, which is far superior to other solutions currently available in the industry.

Concrete

Lower sales realization impacts margins for cement makers in Q2 FY25

The industry encountered several challenges, including an extended monsoon season.

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Major cement manufacturers reported a decline in margins for the September quarter, primarily due to lower prices, which led to decreased sales realization.

With the exception of three leading cement producers—UltraTech Cement, Ambuja Cement, and Dalmia Bharat—smaller companies, including Nuvoco Vistas Corp, JK Cement, Birla Corporation, and Heidelberg Cement, experienced a drop in both topline and sales volume during the second quarter of the current fiscal year.

The industry encountered several challenges, including an extended monsoon season, flooding, and a slow recovery in government demand, all contributing to weak overall demand.

Despite these challenges, power, fuel, and other costs largely remained stable across the industry. The all-India average cement price was approximately Rs 348 per 50 kg bag in June 2024, which represented an 11 per cent year-on-year decrease to Rs 330 per bag in September, although it saw a month-on-month increase of 2 per cent.

In the first half of FY25, cement prices declined by 10 per cent year-on-year, settling at Rs 330 per bag. This decline was notable compared to the previous year’s average prices of Rs 365 per bag and Rs 375 per bag in FY23, as reported by Icra.

Leading cement manufacturer UltraTech reported a capacity utilization rate of 68 per cent, with a 3 per cent growth in volume. However, its sales realization for grey cement declined by 8.4 per cent year-on-year and 2.9 per cent quarter-on-quarter during the July-September period.

In response to a query regarding cement prices during the earnings call, UltraTech’s CFO Atul Daga indicated that there had been an improvement in prices from August to September and noted that prices remained steady from September to October. He mentioned that the prices had risen from Rs 347 in August to approximately Rs 354 currently.

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Concrete

Steel companies face Rs 89,000 crore inventory crisis

Steel firms grapple with Rs 89,000 crore stockpile amid import surge.

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Steel companies in India are facing a significant challenge as they contend with an inventory crisis valued at approximately Rs 89,000 crore. This situation has arisen due to a notable increase in steel imports, which has put pressure on domestic producers struggling to maintain sales in a competitive market.

The surge in imports has been fueled by various factors, including fluctuations in global steel prices and increased production capacities in exporting countries. As a result, domestic steel manufacturers have found it difficult to compete, leading to rising stock levels of unsold products. This inventory buildup has forced several companies to reassess their production strategies and pricing models.

The financial impact of this inventory crisis is profound, affecting cash flows and profitability for many steel firms. With domestic demand remaining volatile, the pressure to reduce prices has increased, further complicating the situation for manufacturers who are already grappling with elevated production costs.

Industry experts are urging policymakers to consider measures that can support local steel producers, such as imposing tariffs on imports or enhancing trade regulations. This would help to protect the domestic market and ensure that Indian steel companies can compete more effectively.

As the steel sector navigates these challenges, stakeholders are closely monitoring the situation, hoping for a turnaround that can stabilize the market and restore confidence among investors. The current dynamics emphasize the need for a robust strategy to bolster domestic production and mitigate the risks associated with excessive imports.

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Concrete

JSW and POSCO collaborate for steel plant

JSW Group and POSCO ink MoU for steel project.

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JSW Group has signed a Memorandum of Understanding (MoU) with South Korea’s POSCO Group to develop an integrated steel plant in India. This collaboration aims to enhance India’s steel production capacity and contribute to the country’s growing manufacturing sector.

The agreement was formalized during a recent meeting between executives from both companies, highlighting their commitment to sustainable development and technological innovation in the steel industry. The planned facility will incorporate advanced manufacturing processes and adhere to environmentally friendly practices, aligning with global standards for sustainability.

JSW Group, a leader in the Indian steel industry, has expressed confidence that the joint venture with POSCO will bolster its position in the market and accelerate growth. The project is expected to attract significant investments, generating thousands of jobs in the region and contributing to local economies.

As India aims to boost its steel output to meet domestic demand and support infrastructure projects, this partnership signifies a crucial step toward achieving those goals. Both companies are committed to leveraging their expertise to develop a state-of-the-art facility that will produce high-quality steel products while minimizing environmental impact.

This initiative also reflects the increasing collaboration between Indian and international firms to enhance industrial capabilities and foster economic growth. The MoU sets the stage for a promising future in the Indian steel sector, emphasizing innovation and sustainability as key drivers of success.

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