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Concrete

Sustainability as a Culture

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Tarun Mishra, Co-founder, Covacsis Technologies, explores the role of technology in driving the cement sector towards a sustainable future.

The industrial era of the 20th century had more sustainable business practices than the 21st century. However, the global community has realised the need to bring sustainable practices back into the manufacturing process. Thus, the idea of sustainability as a culture, not just a metric to comply with, has evolved. Right impetus on innovating and developing effective manufacturing technologies coupled with making sustainability a boardroom agenda are important steps.
Making the world sustainable by minimising all kinds of waste produced in manufacturing processes and by minimising consumption of natural resources are essential parts of sustainability.
The core idea of sustainability is to drive towards:

  1. 1. Zero impact on the environment due to operations
  2. 2. Zero impact on the society

  3. Manufacturing industry worldwide ought to play a greater role in this endeavour. Cement industry must rise to take larger responsibility, and become a role model for other industries in developing this culture as part of business practices by employing design thinking and digital interventions.
    Mineral processing and cement production are extremely energy intensive activities. Reaching net zero and decarbonising cement requires lengthy changes throughout the value chain.
    Cement-based materials, such as concrete and mortars, are used in extremely large amounts. Cement plays an important role in terms of economic and social relevance since it is fundamental to build and improve infrastructure. On the other hand, this industry is also a heavy polluter. Cement production releases 5-6 per cent of the entire CO2 generated due to human activities, accounting for about 4 per cent of global warming. It can release huge amounts of persistent organic pollutants, such as dioxins and heavy metals and particles. Energy consumption is also considerable. Cement production uses approximately 0.6 per cent of all energy produced in the US.
    A huge innovation and solution is underway to make cement greener and sustainable, such as the use of alternative materials that can be used to minimise CO2 production and reduce energy consumption, such as calcium sulphoaluminate and ß-Ca2SiO4-rich cements.
    Also sustainability of the cement industry can be significantly improved by using residues from other industrial sectors. Under adequate conditions, waste materials such as tyres, oils, municipal solid waste and solvents can be used as supplementary fuel in cement plants.
    While the role of research and development is necessary to improve cement industry sustainability over a long run, with intelligent systems it is possible to get immediate results by optimising complex cement plant’s energy use while maintaining high equipment availability. All this must start with measuring various sustainability metrics and dimensions within the organisation.

Measurement metrics
An effective measurement requires:

  1. What to measure?
    The sustainability metrics defined across the value chain becomes extremely important in the overall scheme of things. What is not measured never improves, therefore, a thorough study to map every value element and to identify sustainability metrics is imperative.
    For example, cement manufacturers can think ways and means to measure:
    a. Carbon neutrality at every stage such as kiln, cement mills, etc.
    b. Waste produced or treated
    c. Net health hazard in every process and job function
    d. Net safety hazard in the process and job function
  2. How to measure? What method to use for measuring?
    Current manual mode of recording and logging information is limiting, ineffective and non-actionable. Furthermore, the current method is based on sample data collection once a shift or once a day. It does not fulfill beyond meeting compliance needs.
    A new generation method using IIOT will eliminate manual methods and provide comprehensive, error free and valuable data along with the root cause analysis to improve further.
  3. When do they get measured?
    A comprehensive set of metrics getting measured using elaborate and error free methods is great but still not sufficient. Measuring these metrics in real time delivers unthinkable opportunities to the organisation to arrest performance compromises immediately and set things right without losing anything. Intelligent technologies like Covacsis’ Intelligent Plant Framework uses extensive data science to track all sorts of irregularities instantaneously and provides comprehensive root cause analysis with recommendations.
    For example, C3S percentage change in kiln operation may affect the coal consumption per ton of clinker. Real time discovery and understanding of the right relation between C3S and other process parameters will allow the shop floor team to optimise coal costs. Some of these are not part of conventional distributed control systems (DCS), supervisory control and data acquisition (SCADA) and Historians.

An Organisational Practice
Platforms, tools or solutions like Intelligent Plant Framework provide easy, automatic and autonomous real time understanding with complete visibility about every anomaly.
A large part of assistance is provided through autonomous alerts and notifications mechanisms to users outlining those activities which are potentially compromising on sustainability metrics along with a detailed root cause analysis.
Sustainability is a cross functional agenda in every organisation. Production, quality, engineering, planning, utility, cost, human resource and other departments are required to form a cross functional committee to drive the agenda of sustainability.
Every process in the value stream must have a sustainability index. This index is to be computed in real time and published on a live screen and dashboard along with detailed analytics. Likewise, every department must have sustainability rating done automatically and autonomously on a daily basis to enforce the culture of sustainability.
Every individual must have a sustainability score in the organisation as part of their performance. This will help the human resource department in organising the right training for the right people in the organisation. Digital boot camp on sustainability is a great way to make the agenda pervasive across the organisation.

ABOUT THE AUTHOR:


Tarun Mishra, Co-founder, Covacsis,
is a proponent of industrial IOT since 2009. He helps companies built a profitable business by redefining manufacturing operations and its performance.

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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