Concrete

We implement rigorous raw material testing

Published

3 weeks ago

August 23, 2024

Roshna

Manish Samdani, Head – Quality Control, Udaipur Cement Works Limited (UCWL), shares a comprehensive view on optimising cement grinding processes and enhancing plant performance.

Can you provide an overview of the grinding process in your cement manufacturing plant and its significance in the overall production process?
In UCWL, we use the following types of mills for grinding raw materials and cement:

Vertical Roller Mill (VRM): We employ the M/s Loesche (LM 38.4) and Gebr. Pfeiffer (MVR 6000C6) technology for raw material and cement grinding respectively. The VRM is a type of grinding mill that combines crushing, grinding, drying, and classification functions into a single compact unit. It operates by rotating a grinding table, equipped with rollers, while the raw materials are fed into the mill from the top. The rollers exert grinding pressure on the material, resulting in comminution and fine grinding. The ground material is then conveyed upwards and collected in a cyclone separator, while the coarse particles are returned to the grinding table for further grinding. The use of VRM technology allows for efficient grinding and improved energy utilisation. We are operating a mill with lowest power i.e., 12.5 KWh/MT with 10 per cent on 90 micron for raw material grinding.
CPI and LNVT Ball Mill: CPI and LNVT is a renowned manufacturer of grinding equipment for the cement industry. Their ball mills are widely used for grinding cement clinker, gypsum, and other materials into a fine powder. The ball mill operates by rotating a horizontal cylinder, filled with steel balls, which impact and grind the material as it rotates. The ground material is discharged through the adjustable central diaphragm, while the coarse particles are returned for further grinding. CPI optimises material flow and thin linear plate, which increases the overall area of grinding also as a highly efficient dynamic separator with top feeding.
Both the VRM and ball mill technologies provide effective grinding solutions for raw materials and cement production, each with its advantages and specific applications. The choice of the grinding mill depends on various factors such as the type of raw materials, desired fineness, production capacity, and energy efficiency requirements.

What are the main challenges you face in the grinding process, and how do you address these challenges to maintain efficiency and product quality?
At UCWL, the main challenges in the grinding process include high energy consumption, maintaining consistent product fineness, and managing moisture content in raw materials. To address these issues, UCWL uses energy-efficient VRMs, optimising parameters and employing SMARTA control systems to reduce energy usage. Consistency in product fineness is achieved through the use of online and offline PHD analysers and real-time quality control measures. Additionally, proper mixing and covered storage of raw materials help minimise moisture variations, ensuring efficient and high-quality grinding.

Energy consumption: Grinding is an energy-intensive process, and high energy consumption can lead to increased operational costs. UCWL utilises energy-efficient grinding mills like the VRM, which consumes 23-24 kWh/MT for PPC cement compared to higher consumption in ball mills. The optimisation of grinding process parameters and the use of SMARTA advanced control systems help reduce energy usage without compromising product quality.
Consistency in product fineness: Achieving and maintaining consistent product fineness is crucial for the quality of the final cement product. UCWL employs both online and offline PHD analysers for continuous monitoring and control of the grinding process. Advanced instrumentation and automation systems, along with real-time quality control measures, ensure the desired particle size distribution is maintained.
Moisture content in raw materials: High moisture content in raw materials can lead to difficulties in grinding and affect the efficiency of the grinding process and quality. UCWL ensures proper mixing of raw materials and optimal storage conditions by utilising a covered storage yard, minimising variations in moisture content.
Process and quality variability: Variability in raw material properties can lead to fluctuations in the grinding process, affecting product quality and efficiency.

We implement rigorous raw material testing and quality control procedures to ensure consistent feed quality. Real-time data is used to adjust process parameters, compensating for any variations in raw material properties. By addressing these challenges with advanced technologies, continuous monitoring, and strict quality control measures, UCWL maintains high efficiency and superior product quality in its grinding operations.

How do grinding aids contribute to the efficiency of the grinding process in your plant? What types of grinding aids do you use?
Grinding aids are chemical additives used in the cement manufacturing process to improve the efficiency and effectiveness of the grinding process. At UCWL, grinding aids play a crucial role in enhancing the performance of the grinding equipment and ensuring high-quality cement. We are using glycol-based grinding aid, which is reducing the energy required for grinding, improving one day’s strength by 2 to 3 MPa. These chemical additives lead to more efficient use of the grinding equipment, resulting in higher throughput and lower energy consumption. They also improve the flow properties of the ground material, reducing blockages and downtime. By enabling higher mill output and optimising overall mill performance, grinding aids contribute to cost savings, increased productivity, and improve product quality in the cement manufacturing process.

Can you discuss any recent innovations or improvements in grinding technology that have been implemented in your plant?
UCWL has recently implemented several innovations and improvements in grinding technology to enhance efficiency and productivity. Key among these is the integration of SMARTA and RAMCO systems for the automation of grinding systems. The SMARTA system optimises the grinding process parameters through advanced analytics and real-time monitoring, leading to significant energy savings and improved product quality. Meanwhile, the RAMCO system provides comprehensive automation, ensuring consistent control over the grinding operations and reducing the likelihood of human error. These systems enable better predictive maintenance, minimising downtime and extending the lifespan of grinding equipment. By adopting these cutting-edge technologies, UCWL has not only improved operational efficiency but also maintained high standards of product quality, positioning itself at the forefront of the cement manufacturing industry.

How do you ensure that your grinding equipment is energy-efficient and environmentally sustainable?
At UCWL, energy efficiency and environmental sustainability are achieved through several strategic measures. The use of energy-efficient equipment, such as Vertical Roller Mills (VRM), reduces energy consumption significantly compared to traditional ball mills. Advanced control systems like SMARTA and RAMCO optimise grinding parameters and provide real-time monitoring to enhance efficiency and product quality. Regular and predictive maintenance schedules ensure that equipment operates at peak performance, minimising downtime and extending lifespan. Additionally, energy management systems, including regular audits and continuous monitoring, help identify and address inefficiencies. UCWL also employs emission control technologies to minimise environmental impact, complying with regulations and promoting sustainable practices such as using alternative fuels, recycling waste products, and reducing the carbon footprint. These comprehensive efforts ensure that UCWL’s grinding operations are both energy-efficient and environmentally sustainable.

What role does R&D play in optimising your grinding processes and the selection of grinding aids?
Research and Development (R&D) at UCWL plays a pivotal role in optimising grinding processes and selecting effective grinding aids. Our R&D team focuses on process optimisation by exploring new methods to improve early strength and reduce energy consumption.
The UCWL team conducted approximately 80 to 90 R&D trials with various grinding aids to identify the most suitable formulations. These extensive trials helped in understanding the impact of different additives on grinding efficiency and product quality. Moreover, UCWL developed an in-house grinding aid, which, after successful plant-scale trials, resulted in a 2 mpa increase in initial strength and a 5 per cent increase in mill output. This in-house solution demonstrates the significant contributions of R&D in enhancing grinding performance, improving product quality, and achieving cost efficiency. Through continuous innovation and rigorous testing, R&D ensures that UCWL remains at the forefront of technological advancements in the cement industry.
Innovative technologies, such as advanced control systems, control charts and real-time monitoring tools, are developed and integrated to ensure consistent quality. Continuous improvement initiatives ensure ongoing optimisation, integrating feedback from production and quality control teams to address emerging challenges. Through these comprehensive efforts, R&D at UCWL ensures efficient, high-quality and sustainable grinding operations.

Can you share any specific examples or case studies where improvements in the grinding process have significantly benefited your plant’s performance?
The implementation of grinding aids at UCWL has led to significant improvements in the consumption of fly ash in Portland Pozzolana cement (PPC)
and a reduction in power consumption over the past four fiscal years. The data below illustrates these improvements:
Fly ash consumption (percentage):

FY 2020-21: 25.9 per cent
FY 2021-22: 27.7 per cent
FY 2022-23: 30.9 per cent
FY 2023-24: 32.5 per cent

Power consumption (kWh/MT):

FY 2020-21: 31.2 kWh/MT
FY 2021-22: 30.6 kWh/MT
FY 2022-23: 28.2 kWh/MT
FY 2023-24: 26.5 kWh/MT

By using grinding aids, UCWL has managed to increase the fly ash content in PPC from 25.9 per cent in FY 2020-21 to 32.5 per cent in FY 2023-24. This increase in fly ash usage not only improves the sustainability of the cement by utilising more industrial by-products but also enhances the overall performance of the cement. Concurrently, power consumption has decreased from 31.2 kWh/MT to 26.5 kWh/MT over the same period, demonstrating the effectiveness of grinding aids in reducing energy requirements and operational costs. These improvements highlight the critical role of grinding aids in optimising the grinding process, contributing to both economic and environmental benefits at UCWL.

What trends or advancements in grinding processes and grinding aids do you foresee impacting the cement manufacturing industry in the near future?
In the near future, the cement manufacturing industry is expected to be significantly impacted by several trends and advancements in grinding processes and grinding aids. Advanced grinding technologies, such as high-efficiency vertical roller mills (VRMs) and high-pressure grinding rolls (HPGRs), are enhancing energy efficiency and grinding performance.
Innovations in grinding aids are focusing on novel chemical additives and sustainable options that reduce energy consumption and environmental impact. Automation and digitalisation are driving improvements through real-time process optimisation and predictive maintenance, leading to better efficiency and reduced downtime.
Additionally, energy efficiency is being addressed through waste heat recovery systems and more energy-efficient equipment. The use of alternative materials and additives, along with a strong emphasis on reducing the carbon footprint, is also shaping the future of cement manufacturing. These advancements collectively aim to improve operational efficiency, lower costs and promote environmental sustainability in the industry.

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Concrete

Indian Cement Industry Sees Further Consolidation

Cement industry to face consolidation soon.

Published

1 day ago

September 13, 2024

admin

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

1 day 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

1 day ago

September 13, 2024

admin

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.