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Production efficiency comes from low shutdowns

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Vivek Singh, Sales Director – Thermal & Exports, South West Asia, Calderys India Refractories Limited, talks about innovations that help to create tailor-made solutions and improve lifespan of refractories.

Tell us about the composition and build of the refractories evolving over the years.
The composition of our refractories is an IP property of the organisation. Let us discuss the focus of our company in terms of making sure the refractories adapt to the operating conditions. Operating conditions in cement plants are changing drastically. The demand of cement is growing by 8 to 9 per cent annually, which means that along with new capacities, utilisation rate of the cement plants has to increase as well. This could be achieved through reducing shutdown days as well as number of shutdowns. Hence Our focus is to provide solutions, which help our customers to achieve both of these objectives.
There are two kinds of application areas. One is non-critical or low critical, where the performance of refractories is one-two years. In these cases, performance is not a challenge. However, in the critical application areas, the life of refractories used to be 4 to 6 months earlier. This led to shutdowns every 4 to 6 months. Our consistent focus has been to increase the lifespan of these critical areas.
To support this, we have launched different variants based on operating conditions.
Supramon Brand: Nano-bonded castables have an average lifespan of more than 9 months
Calde RDS: Ready shaped solution refractions are based on the application area and have a life of 1-2 years.
Calderys Shotcrete and gunning solutions: Mechanised Installation techniques to reduce shutdown time and improve casting performance and safety at site
These refractory variants help cement manufacturers avoid mid-term shutdowns and reduce shutdown duration. A lot of research and development goes into achieving these performance enhancements.

What is the best kind of refractory a cement plant can use for maximum output?
For critical areas, ready-shaped solutions are the best. Depending on the application areas it gives 1-2 years of lifespan. The burner pipe and bull nose refractory lasts for 18 months to 2 years, and tips casting lasts for 1 to 2 years depending on the
fuels, raw materials and operating conditions at cement plant.
If cement manufacturers are using a lot of alternative fuels like various types of wastes, then chemical attacks on the refractories are more and the lifespan may decrease to one year. However, where the operating conditions are more consistent, fossil fuel is used in larger percentages, that is when the refractory lasts for a longer lifespan of up to
2 years.
Primary difference between performance of Ready-Shape Refractory and Nano-Bonded Refractory is casting at site Vs Calderys plant and amount of Alternate Fuel used at Cement plant. In ready shapes large part of installation and dryout happens in factory conditions, this process is much more controlled, hence the lifespan is longer.

Tell us about the impact of your refractory solutions on the production and cost efficiency of cement plants.
Production efficiency comes from low shutdowns. If the cement plants have to take a shutdown for 15-20 days every 5 to 6 months versus taking only one shutdown, the number of days of operations increases by approx 20 days. This means they gain additional production and this is how our refractories help them achieve higher production, higher profits and achieve efficient outputs.
Our focus is to help cement plants increase their outputs with the available infrastructure by reducing the need for shutdowns and possibilities of stopping production.

What is the role of automation and technology in building your solutions?
Our plants are mostly automated. This is primarily because our formulations are very critical and require precision. A deviation of more than one per cent or any RM can lead to rejection. Our plants are therefore largely automated for blending and castable expertise.
Packaging and other functions are a mix of automation and manual processes in our plants. Amongst the five plants, three of our plants are fully automated, from raw material to packaging. The other plants are relatively less automated and have some manual processes for non-critical activities.
However, we do believe, the more automation we have, the better our product will be and this would improve our safety performance as well.

Tell us about the audits, maintenance and services provided by your organisation for refractories installed.
We have a separate arm in the organisation for the maintenance and audits of refractories. This arm is called Project Application and Services. This department provides project management, design & installation services.
It specialises in predictive maintenance with the use of some hi-tech equipment which are used for understanding the life of refractories under the operating conditions. Without shutting down the plants it indicates the need of maintenance or not. We also have highly efficient mechanised installation – gunning and shotcreting are the two automated installation services that we provide. Among these shotcreting is the superior process, but an expensive one, because of higher fixed costs.
Between gunning, shotcreting and manual casting, in a day shotcreting can do around 60-80 tonnes of installations, gunning would achieve approx 20 tonnes and manually would be cheaper, but much less. As the aim is to reduce the shutdown days, reducing the installation time is important. Using these installation techniques will help speed up the installation and bring back the cement plant
operations sooner.

What are the major challenges your organisation faces with respect to cement plant refractories?
In terms of making, our primary raw materials are minerals. Virgin mineral availability is depleting across the geography globally. Mining is getting restrictive with governments capping the mining capacities. Hence, raw materials are becoming costlier and will continue to be so over the years. For example superior quality Indian bauxite is becoming difficult to procure and we have to depend on imports. This is leading to cost escalations. Our recipe is our USP and we do not want to compromise on the quality of the raw materials, to ensure superior performance.
Operating conditions at the customer’s end can also be challenging. If we have to do regular or frequent shutdowns and light ups, then thermal shocks take place, which abuse the refractories, hampering its quality. If the operating conditions are consistent, then the lifespan of the refractories would be much better.
Thirdly, most cement plants these days use alternative fuels, which leads to a lot of chemical interaction with the refractories. These could be alkaline, chlorine or any different chemical. If we do not know which alternative fuel is used and we have provided a refractory solution, then the refractory life is impacted. That is why we generally propose to our customers – cement manufacturers – to inform us about the composition of the fuel, so that we design or tailor-make the refractory accordingly. Otherwise, the life of the refractory will be challenging.

Are refractories for every customer and cement plant customised as per their requirement or do you have a standardised offering?
It is a mix of both. In some cases, specific refractories are designed for specific plants, which is unique for the plant. When we know the fuels used are regular or generic, that is when we provide our standard makes. Even for the same customer for different plants we provide different solutions based on operating conditions.

Tell us about some innovations in your organisation that the cement industry can look forward to.
We are constantly working on following innovation themes:
Fuel cost saving: Energy is one of the major costs for cement players, hence reducing the energy cost is what we are working on. Our product, Hysil Calcium Silicate Insulation, is the flag bearer in this pursuit.
Ready-shaped solution for higher life: It is fairly new in the country. Caledrys brought this technology to India and started providing the same in the country, through local production.
Speed of installation and safety: We are working on this to make sure that installation speed is faster and and safe. Safety is our first priority.
These are the three things we are working on in terms of innovation and we wish to continuously improve our solution offerings.

Kanika Mathur

Concrete

Indian Cement Industry Sees Further Consolidation

Cement industry to face consolidation soon.

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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.

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Concrete

Cement Companies May Roll Back Hike

Cement firms reconsider September price increase.

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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.

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Concrete

Bridge Collapse Spurs Focus on Stainless Steel

Climate change prompts stainless steel push.

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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.

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