Concrete

Digitalisation Paves the Way

Published

8 months ago

January 12, 2024

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Dr BN Mohapatra, Advisor and Consultant, UltraTech Cement, lays emphasis on the various aspects of decarbonisation that are helping the Indian cement industry make optimum use of technology.

The Indian cement industry is one of the core industries of the country, which plays a vital role in the growth and economic development, because of its strong linkage to other sectors such as infrastructure, construction, housing, transportation, mining, etc. The current annual installed capacity of the cement industry in India is about 594 million tonnes with cement production of around 361 million tonnes (2021-22).
There are a total 333 cement manufacturing units in India comprising 150 integrated large cement plants, 116 grinding units, 62 mini cement plants and 5 clinkerisation units. Cement consumption in India is around 260 kg per capita against a world average of 540 kg per capita, which shows significant potential for the growth of the industry.
At present, India is seeing demand for large-scale infrastructure development and the housing in the country is also on a rise. As a result of this, it is expected that cement demand will grow by around 6-8 per cent by 2030. A growing housing sector, which typically accounts for 60-65 per cent of India’s cement consumption, will remain a key demand driver. Therefore, the challenge lies in making the cement manufacturing process cleaner and efficient and sustainable with innovation and technology.
Shifting to sustainable cement manufacturing is also the need of the hour as cement production is one of the highest emitting industries, accounting for 7 per cent global CO2 emission. It is one of the most widely consumed products globally owing to its various applications spanning from residential to urban constructions, which are indispensable for progress. It is thus, necessary to swiftly adopt sustainable practices to mitigate environmental impact and support achieving sustainability targets such as becoming net zero by 2070.

Adoption of innovation and technology
The cement manufacturers have to play a dual role supporting India’s economic growth by meeting the cement demand and contributing to the sustainability mission by ensuring that cement has minimum impact on the environment. This can be achieved by innovative ways backed by technology.
The Indian cement industry is progressive and is continuously adapting to the latest technologies to make the cement industry more efficient and greener with less environmental footprint.
They utilised strategies such as integrating waste heat recovery systems to meet the energy demand sustainably by lowering dependence on carbon emitting fuels and achieving energy efficiency. This can result in reduction in electricity.
They invested in high efficiency coolers and preheaters to minimise kiln heat requirements.
Using clean energy from renewable sources like solar or wind energy. They developed on-site renewable power generation capabilities to procure clean energy and dependence on fossil fuels.
Capturing of CO2 emissions and storing them or utilising them to produce chemicals, concrete or plastics can prove to be a great alternative to utilise waste and promote a circular economy.
Cement production process using alternative fuel like hazardous waste, biomass, industrial waste, agriculture waste to save the environment and produce greener energy.

Green energy
The productivity of different energy sources for cement plants can vary depending on various factors such as technology being used, availability, cost, infrastructure and local regulations.
Some examples are as under:
Fossil fuels (coal, oil and natural gas): Traditionally being used as the primary energy source for cement production due to their high energy content. However, they contribute significantly to carbon emissions and are considered non-renewable resources.
Agricultural waste: Biomass, such as agricultural waste or dedicated energy corps can be used as alternative fuel source in cement production. Its productivity can vary depending upon the availability and sustainability of biomass feedstock.
Municipal and industrial waste: Certain waste materials, such as shredded tyres or municipal solid waste, can be used as alternate fuel sources in cement kilns. The productivity of waste materials as an energy source depends on their calorific value, their characteristics, availability and proper waste management practices.
Renewable energy sources: Renewable energy sources like solar, wind or geothermal power can be utilised to generate electricity for cement plants. Their productivity depends on factors such as location, resources availability and their ability to integrate them into the plant’s energy infrastructure.
Cement industry exhausts high amounts of hot gases and are being utilised to produce power by using waste heat recovery technologies.
Greener energy has a positive impact on manufacturing, including commercial and technical aspects. Potential impacts on environment, energy efficient and productivity enhancement with lower cost.

Automation and technology
Automation plays a very pivotal role in optimising the use of energy in cement plants. We are using VFD, Smart MCC, Sensors, Integrated Load Management system, Energy Monitoring System and Smart Lighting System for effectively optimising the use of energy. Here are some ways which help in reducing Energy
Energy monitoring and control: Automation systems can continuously monitor energy consumption in various parts of the cement plant such as kilns, mills and crushers. This real time data allows operators to identify pilferage processes or equipment and optimise energy usage.
Process optimisation: Advanced control systems and predictive analytics can optimise the cement manufacturing process to minimise energy consumption. By analysing data from various sensors and instruments, these technologies can identify opportunities for energy savings and automatically adjust parameters to achieve optimal efficiency.
Energy management system: Automation systems can integrate with energy management systems to provide a holistic view of energy usage across the entire plant. This allows operators to track energy performance and accordingly set targets and implement energy savings measures effectively.
Load management: Automation systems can optimise the scheduling and sequencing of equipment to ensure a balanced load distribution, reducing peak demand and improving overall energy efficiency. For example, by co-ordinating the operation of the kilns, mills and other machinery, the system can minimise energy wastage during periods of low demand.
Energy recovery: Automation technology can facilitate the implementation of energy recovery systems in cement plants. For instance, waste heat from kilns can be captured and used to generate electricity or provide heat for other processes, reducing the reliance on external energy sources.
Equipment optimisation: Automation systems can monitor the performances of Individual equipment and identify inefficiencies or malfunctions that may contribute to excessive energy consumption.

Control dust and gas emission
Cement plants have adopted technologies to meet the new emission norms for PM, SO2 and NOX emissions. Plants have installed highly efficient bag filters, ESPs, and hybrid filters to control dust emissions. For NOX reduction, plants have installed secondary control measures like SNCR. All the cement plants have installed a Continuous Emission Monitoring System (CEMS) as per the guidelines of CPCB. In the same spirit cement industry is the first one to adopt filtration technologies like pulse Jet Bag House (PJBH) reverse air bag house and hybrid filters for controlling dust emission from stack. Advent of new fabrics which can withstand higher temperatures and tough working conditions. Controls and advanced electrical systems provided the opportunity to reduce the dust emissions to very low levels. Cement industry embraced these technologies that helped industry today in achieving consistent and lower stack emissions of 30 mg/Nm3.
Cement plants use various types of dust filtration equipment and techniques to control dust emissions and improve air quality. Some of the common methods used include:

Bag filters
Electrostatic precipitators (ESPs)
Cyclones
Wet scrubbers
High Efficiency Particulate Air (HEPA) Filters

Digitalisation
In the current era of digitalisation and technological advancements, the companies must accelerate adoption of technologies such as robotics, artificial intelligence, IoT, data analytics and others to expedite sustainability efforts. This can support optimising processes, achieving higher efficiency, visibility and control on operations to speed up the decarbonisation journey. Digitalisation paves the way for implementing advanced digital solutions that can help maintenance team’s transition from reactive to proactive maintenance strategies
Remote monitoring of plant operation: Day-to-day plant operation can be monitored in real time from a remote location using Interconnectivity of Technologies [enabled by Internet of Things (IoT)]. Early detection of equipment issues enables planned maintenance, reducing costly unplanned downtime and minimising repair expenses. This optimisation of Inventory levels minimises carrying costs and mitigates the risk of overstocking or stock outs. Cement plants take corrective actions to reduce energy wastage and carbon footprint, thereby achieving significant cost reductions over time. Automated AI -based predictive maintenance solutions consist of 6-in-1 the Wireless sensors that measure the 6 most important parameters of Tri Axial Vibration, Acoustics, RPM, Temperature, Humidity and Magnetic flux. These sensors act as the vigilant eyes and ears of the manufacturing plants.
Cement industry 4.0: Industry 4.0 or digital innovations, which involves advanced data analytics, intelligent neural networks and Internet of Things (IoT) offer tremendous opportunity to improve the efficiency of manufacturing processes and ease of logistics. AI, sometimes called machine intelligence, is intelligence demonstrated by machines, unlike the natural intelligence displayed by humans and animals. The field was founded on the assumption that human intelligence can be so precisely described that a machine can be made to simulate it.
Simulation techniques for plant optimisation: Cement manufacturers can utilise Computational Fluid Dynamics (CFD) simulation solutions to capitalise on all opportunities to improve processes, either through an engineering contractor or in-house facility. Potential improvements include, but are not limited to, reduction in energy consumption, reduced wear on equipment and improved material distribution to key equipment.
Robotic laboratory and quality optimisation: Indian cement plant has already installed robotic laboratory for automatic sampling and testing. Installed XRF and XRD for both Bogue and actual phases. XRD has wider application in the cement sector like optimisation of burning and cooling conditions in kilns. Prediction of cement compressive strength of 1-day, 3-day, 7-day and 28-day.

Government initiatives
Indian government also takes initiatives through technology for overall economy, development and environment. Here some government initiatives,Decarbonisation of cement industry: Hon’ble Prime Minister of India Shri Narendra Modi has made the pledge to cut the CO2 emissions in the COP 26 summit at Glasgow in November 2021. The new climate action targets ‘Panchamrit’ by India included:
a Net Zero target for India by the year 2070 installing non-fossil fuel electricity capacity of 500 GW by 2030 sourcing 50 per cent of energy requirement from renewable by 2030 reducing 1 billion tonnes of projected emissions from now till 2030 and achieving carbon intensity reduction of 45 per cent over 2005 levels by 2030 PAT scheme and carbon trading: Perform Achieve and Trade (PAT) scheme is a flagship programme of Bureau of Energy Efficiency under the National Mission for Enhanced Energy Efficiency (NMEEE). The PAT Scheme is a regulatory instrument to reduce the specific energy consumption in energy intensive industries.
Science-based targets initiative (SBTi): SBTi drives ambitious climate action in the private sector by enabling companies to set science-based emissions reduction targets. The SBTi defines and promotes best practice in emissions reductions and net-zero targets in line with climate science.
Logistics – PM Gati Shakti: Logistics cost contributes about 30 per cent of the total cost of the cement prices. The Prime Minister launched PM Gati Shakti-National Master Plan for Multi-modal Connectivity, essentially a digital platform to bring 16 Ministries including Railways and Roadways together for integrated planning and coordinated implementation of infrastructure connectivity projects.
Lead IT initiative: For promoting low-carbon transition especially in the hard-to-abate sectors like iron and steel, aluminum, cement and concrete, petrochemicals, fertilisers, bricks, heavy-duty transport, etc. through active participation of private sector companies, Government of Sweden and India launched an initiative ‘Leadership for Industry Transition (Lead IT)’ at the UN Climate Action Summit in New York in 2019. Stockholm Environment Institute hosts the Secretariat of Lead IT. Under
the Lead IT initiative, preparation of the sectoral roadmap for the cement and steel sector in India has been undertaken.
National Hydrogen Mission: The Mission aims to aid the government in meeting its climate targets and making India a green hydrogen hub. This will help in meeting the target of production of 5 million tonnes of green hydrogen by 2030 and the related development of renewable energy capacity.
Circular economy: The Government has been actively formulating policies and promoting projects to drive the country towards a circular economy. It has already notified various rules, such as the plastic waste management rules, e-waste management rules, construction and demolition waste management rules, metals recycling policy, etc.
National Coal Gasification Mission: Coal gasification is considered as a cleaner option compared to burning of coal. Gasification facilitates utilisation of the chemical properties of coal. SynGas produced from Coal gasification can be usable in producing Synthetic Natural Gas (SNG), energy fuel (methanol and ethanol), ammonia for fertilisers and petro-chemicals. These products will help move towards self-sufficiency under Atmanirbhar Bharat Abhiyaan. Ministry of Coal, Government of India has taken initiative for utilising coal through coal gasification to achieve 100 MT coal gasification by year 2030.

Futuristic technologies
The following futuristic technologies are expected to be developed and adopted by the Indian cement industry in the years to come Carbon capture and storage/utilisation Oxy fuel in the carbon capturing Algal growth promotion and use of biofuels

Nanotechnology in cement
Concentrated solar thermal calcination
Aero acoustics grinding
Beta-mill
Futuristic low temperature clinker system

Novel cement system

New cement systems, listed below, using various varieties of waste are being explored extensively in India:

Portland limestone cement
Portland composite cement (fly ash and limestone based)
Geo-polymer cements
Reactive belite and calcium sulphoaluminate-based cements
Calcined clay-based cement
Low lime and low energy cements

ABOUT THE AUTHOR:
Dr BN Mohapatra is presently working as Advisor and Consultant to Ultratech Cement Ltd, Mumbai HO. Prior to this, he was the Director General of NCCBM. He is a PhD in Cement Mineral Chemistry and presently pursuing his Doctorate in Science, with 13 years of research experience and 22 years of industry experience. He has a strong academic relationship with premier research institutes.

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Concrete

Indian Cement Industry Sees Further Consolidation

Cement industry to face consolidation soon.

Published

2 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

2 days ago

September 13, 2024

admin

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

2 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.