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Refractories face the challenge of AFR

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Despite a lot of talk about the usage of alternate fuels and raw materials (AFR) in a cement industry, AFRs are not easy to use as it comes with a set of problems. The cover story discusses these problems in detail.

I n the present day, when energy cost is very high, the cement industry is compelled to use alternate fuels, which are nothing but chemical waste from the industry, RDF (refuse-derived fuel), animal meal, fly ash and many more. The cement industry will go on trying different options.

Initially, the use of these kind of alternate fuels did not pose much of a problem, but once the volatile compounds (chlorine, sulphur and alkali) starts getting accumulated in the system, severe operational problems gets created at a later stage. These compounds form coatings on the kiln lining causing premature wear of refractory lining. One measure taken is to provide a bypass for chlorine.

Some areas that are exposed to chemical attack are cooler bull nose, clinker bed, inlet chamber, riser duct and kiln burner lining. These areas are lined with refractory castables or monoliths. Leading refractory manufacturers are offering a variety of products to suit the requirement. The new development of materials show very good mechanical strength at room temperature, no pre-drying of lining is required, the kiln can be put to use in a very short time.

Application for bullnose
Use of alternate fuels, which are more corrosive than fossil fuels, is one of the cause of failures. The chemical composition of clinker, moduli values of raw meal and volatile alkali salts are affecting the refractory lining. The chemically bonded refractory monoliths with some addition of zirconium oxide and Sic are finding it more user friendly. These are no cement materials with enhanced properties by making use of some chemical additives. Despite higher costs, these materials prove to be better ones in the long run.

Clinker bed
It is another area of application where the life of a refractory can be extended. In this area, the expectation from refractory material is high resistance to high thermal stress and abrasion resistance. The location of application is such that it is difficult to dry and heat. High grade low cement castable still finds its way here. Use of Sic-based castables are becoming popular for these kind of applications.

Rotary kiln burner
The basic requirement here is high strength material and proper pre drying. The lining is exposed to a different kind of wear mechanism, high dust loading, and deposit of alkali salts are more corrosive for castable lining. More and more use of cementless castables are finding its application here.

Inlet chamber-riser duct
This is a typical area where gunning technique is used with low cement or no cement castables. The problems here are increased many fold due to use of alternate fuels. which leads to increase in sulphur and chlorine content. The excessive alkali [if present] will only add to aggravate the chocking. All this has to be taken into account while selecting the refractory. Up to a maximum of 30 per cent of Sic has been proved successful in gunning materials.

Use of alternate fuels is the need of hour, considering both the environment and availability of fossil fuels. Therefore for any kind of problems posed by use of alternate fuels is to be taken a challenge. Any new development in the area of refractories is to be viewed from that perspective. The refractory producers will have to come out with not only cost effective solutions, but which are user and environment friendly, better in terms of life.

RHI AG is an Austria-based leading manufacturer of refractories to the cement industry across the globe. It is a solution provider, not just a product supplier. The products designed by the company are able to offer solutions to the above-mentioned problems. It is interesting to know about the new technologies developed by RHI AG.

SOL Mixes (Castables)
In the case of sol bonded mixes (castables), the binder is delivered separately from the mix. These cannot be called as castables because water is not used for hydration reaction. The liquid binder that is used contains nano particle of silica in an aqueous solution. This binder is added during the mixing procedure instead of water. The mixing procedure is similar to that for cement-bonded castables, except the binder is added instead of water and the mixing time is slightly shorter. The setting mechanism is based on a condensation reaction, during which water is released and Si-O-Si bonds are created. In contrast to the cement bonding, no hydrate phases are formed, which makes the residual water easy to remove. Accordingly no pre-drying or heating up procedure is required, just following the typical 36-hours heating up schedule applied for rotary kiln bricks is sufficient.

Advantages of SOL mixes:

  • No pre-drying requirement.
  • Fast and easy heating-up procedure.
  • Reduced ambient temperature impact on setting properties.
  • Reduced sensitivity to incorrect dosing of the mixing fluid.
  • Easily adjusted to the desired setting time.
  • Higher refractoriness compared to equivalent cement-bonded products.
  • Improved chemical resistance (e.g., alkali as well as sulphur) compared to equivalent cement-bonded products.
  • Longer shelf life than low cement castables (LCC).

The sol-bonding technology is available in a wide range of mixes and even gunning mixes (dry gunning), and recently also a selected range of shotcreting mixes (wet gunning) were also developed. No special equipment is required for either casting or gunning and conventional mixers and gunning machines can be used. The technology has rapidly spread worldwide and the references gained so far are impressive.

SOL castables is a new group of alumina-based no-cement castables, which combine the high performance of no-cement castables, but the application technique is same as that of conventional castables.

Besides the mentioned advantages in physical and chemical properties, we can rely on very good workability under difficult circumstances (e.g. winter repair period). The shelf life of the products is very high, and except for the binder liquid, not sensitive to storage conditions.

In particular, the very fast and easy heat-up procedure of sol-bonded castables compared to conventional low cement mixes provides a big advantage for applications where complex heat-ups cannot be maintained (intermediate repairs, high volume installations, fast repairs…) The products are designed for applications where the exposure of refractory material is very high and service conditions are challenging.

Low cement castables with SiC
How it works? At temperatures of 700?C to 800?C and in an oxidising atmosphere, SiC starts being oxidised and converted into a highly viscous silicate glass. This glass coating seals the pores of the refractory material very effectively. SiC is difficult to moisten and closes the pores effectively due to the volume increase during oxidation. This results in an outstanding resistance to alkaline attack. Because of the formation of a protective coating, the alkaline salts can attack only the surface and a penetration of alkalis can be prevented. The formation of a deposit can thus be avoided completely, with the bond to the surface being so weak that these build-ups are pulled off by their own weight or can be removed very easily. Low cement castables with SiC show outstanding resistance to alkaline attack and coating repellent behaviour.

Advantages of SiC

  • Very hard – high abrasion resistance
  • Improves alkali resistance
  • High strength, even at higher temperatures
  • Advantages of LCCs – Low Cement Castables
  • Low cement content, therefore low amount of mixing water
  • Very dense, low porosity
  • Very wear-resistant, high abrasion resistance
  • Higher resistance to infiltrations, e.g. to alkalis

Source: Innovative Refractory Mixes Technology by Uwe Schneider, Solnhfer Portlandzementwerke, Germany and Roland Krischanitz and Peter Fritsch, RHI AG, Austria.

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Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings

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Region-wise,the southern region comprises 35% of the total cement capacity, followed by thenorthern, eastern, western and central region comprising 20%, 18%, 14% and 13%of the capacity, respectively.

The cement industry is expected to post positive margins on decent price hikes over the months, falling raw material prices and marked drop in overall production costs, said an analysis of Care Ratings.

Wholesale and retail prices of cement have increased 11.9% and 12.4%, respectively, in the current financial year. As whole prices have remained elevated in most of the markets in the months of FY20, against the corresponding period of the previous year.

Similarly, electricity and fuel cost have declined 11.9% during 9M FY20 due to drop in crude oil prices. Logistics costs, the biggest cost for cement industry, has also dropped 7.7% (selling and distribution) as the Railways extended the benefit of exemption from busy season surcharge. Moreover, the cost of raw materials, too, declined 5.1% given the price of limestone had fallen 11.3% in the same aforementioned period, the analysis said.

According to Care Ratings, though the overall sales revenue has increased only 1.3%, against 16% growth in the year-ago period, the overall expenditure has declined 3.2% which has benefited the industry largely given the moderation in sales.

Even though FY20 has been subdued in terms of production and demand, the fall in cost of production has still supported the cement industry by clocking in positive margins, the rating agency said.

Cement demand is closely linked to the overall economic growth, particularly the housing and infrastructure sector. The cement sector will be seeing a sharp growth in volumes mainly due to increasing demand from affordable housing and other government infrastructure projects like roads, metros, airports, irrigation.

The government’s newly introduced National Infrastructure Pipeline (NIP), with its target of becoming a $5-trillion economy by 2025, is a detailed road map focused on economic revival through infrastructure development.

The NIP covers a gamut of sectors; rural and urban infrastructure and entails investments of Rs.102 lakh crore to be undertaken by the central government, state governments and the private sector. Of the total projects of the NIP, 42% are under implementation while 19% are under development, 31% are at the conceptual stage and 8% are yet to be classified.

The sectors that will be of focus will be roads, railways, power (renewable and conventional), irrigation and urban infrastructure. These sectors together account for 79% of the proposed investments in six years to 2025. Given the government’s thrust on infrastructure creation, it is likely to benefit the cement industry going forward.

Similarly, the Pradhan Mantri Awaas Yojana, aimed at providing affordable housing, will be a strong driver to lift cement demand. Prices have started correcting Q4 FY20 onwards due to revival in demand of the commodity, the agency said in its analysis.

Industry’s sales revenue has grown at a CAGR of 7.3% during FY15-19 but has grown only 1.3% in the current financial year. Tepid demand throughout the country in the first half of the year has led to the contraction of sales revenue. Fall in the total expenditure of cement firms had aided in improving the operating profit and net profit margins of the industry (OPM was 15.2 during 9M FY19 and NPM was 3.1 during 9M FY19). Interest coverage ratio, too, has improved on an overall basis (ICR was 3.3 during 9M FY19).

According to Cement Manufacturers Association, India accounts for over 8% of the overall global installed capacity. Region-wise, the southern region comprises 35% of the total cement capacity, followed by the northern, eastern, western and central region comprising 20%, 18%, 14% and 13% of the capacity, respectively.

Installed capacity of domestic cement makers has increased at a CAGR of 4.9% during FY16-20. Manufacturers have been able to maintain a capacity utilisation rate above 65% in the past quinquennium. In the current financial year due to the prolonged rains in many parts of the country, the capacity utilisation rate has fallen from 70% during FY19 to 66% currently (YTD).

Source:moneycontrol.com

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Wonder Cement shows journey of cement with new campaign

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The campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV…

ETBrandEquity

Cement manufacturing company Wonder Cement, has announced the launch of a digital campaign ‘Har Raah Mein Wonder Hai’. The campaign has been designed specifically to run on platforms such as Instagram, Facebook and YouTube.

#HarRaahMeinWonderHai is a one-minute video, designed and conceptualised by its digital media partner Triature Digital Marketing and Technologies Pvt Ltd. The entire journey of the cement brand from leaving the factory, going through various weather conditions and witnessing the beauty of nature and wonders through the way until it reaches the destination i.e., to the consumer is very intriguing and the brand has tried to showcase the same with the film.

Sanjay Joshi, executive director, Wonder Cement, said, "Cement as a product poses a unique marketing challenge. Most consumers will build their homes once and therefore buy cement once in a lifetime. It is critical for a cement company to connect with their consumers emotionally. As a part of our communication strategy, it is our endeavor to reach out to a large audience of this country through digital. Wonder Cement always a pioneer in digital, with the launch of our IGTV campaign #HarRahMeinWonderHai, is the first brand in the cement category to venture into this space. Through this campaign, we have captured the emotional journey of a cement bag through its own perspective and depicted what it takes to lay the foundation of one’s dreams and turn them into reality."

The story begins with a family performing the bhoomi poojan of their new plot. It is the place where they are investing their life-long earnings; and planning to build a dream house for the family and children. The family believes in the tradition of having a ‘perfect shuruaat’ (perfect beginning) for their future dream house. The video later highlights the process of construction and in sequence it is emphasising the value of ‘Perfect Shuruaat’ through the eyes of a cement bag.

Tarun Singh Chauhan, management advisor and brand consultant, Wonder Cement, said, "Our objective with this campaign was to show that the cement produced at the Wonder Cement plant speaks for itself, its quality, trust and most of all perfection. The only way this was possible was to take the perspective of a cement bag and showing its journey of perfection from beginning till the end."

According to the company, the campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV. No other brand in this category has created content specific to the platform.

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In spite of company’s optimism, demand weakness in cement is seen in the 4% y-o-y drop in sales volume. (Reuters)

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Cost cuts and better realizations save? the ?day ?for ?UltraTech Cement, Updated: 27 Jan 2020, Vatsala Kamat from Live Mint

Lower cost of energy and logistics helped Ebitda per tonne rise by about 29% in Q3
Premiumization of acquired brands, synergistic?operations hold promise for future profit growth Topics

UltraTech Cement
India’s largest cement producer UltraTech Cement Ltd turned out a bittersweet show in the December quarter. A sharp drop in fuel costs and higher realizations helped drive profit growth. But the inherent demand weakness was evident in the sales volumes drop during the quarter.

Better realizations during the December quarter, in spite of the 4% year-on-year volume decline, minimized the pain. Net stand-alone revenue fell by 2.6% to ?9,981.8 crore.

But as pointed out earlier, lower costs on most fronts helped profitability. The chart alongside shows the sharp drop in energy costs led by lower petcoke prices, lower fuel consumption and higher use of green power. Logistics costs, too, fell due to lower railway freight charges and synergies from the acquired assets. These savings helped offset the increase in raw material costs.

The upshot: Q3 Ebitda (earnings before interest, tax, depreciation and amortization) of about ?990 per tonne was 29% higher from a year ago. The jump in profit on a per tonne basis was more or less along expected lines, given the increase in realizations. "Besides, the reduction in net debt by about ?2,000 crore is a key positive," said Binod Modi, analyst at Reliance Securities Ltd.

Graphic by Santosh Sharma/Mint
What also impressed analysts is the nimble-footed integration of the recently merged cement assets of Nathdwara and Century, which was a concern on the Street.

Kunal Shah, analyst (institutional equities) at Yes Securities (India) Ltd, said: "The company has proved its ability of asset integration. Century’s cement assets were ramped up to 79% capacity utilization in December, even as they operated Nathdwara generating an Ebitda of ?1,500 per tonne."

Looks like the demand weakness mirrored in weak sales during the quarter was masked by the deft integration and synergies derived from these acquired assets. This drove UltraTech’s stock up by 2.6% to ?4,643 after the Q3 results were declared on Friday.

Brand transition from Century to UltraTech, which is 55% complete, is likely to touch 80% by September 2020. A report by Jefferies India Pvt. Ltd highlights that the Ebitda per tonne for premium brands is about ?5-10 higher per bag than the average (A cement bag weighs 50kg). Of course, with competition increasing in the arena, it remains to be seen how brand premiumization in the cement industry will pan out. UltraTech Cement scores well among peers here.

However, there are road bumps ahead for the cement sector and for UltraTech. Falling gross domestic product growth, fiscal slippages and lower budgetary allocation to infrastructure sector are making industry houses jittery on growth. Although UltraTech’s management is confident that cement demand is looking up, sustainability and pricing power remains a worry for the near term.

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