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We introduce new products to combat stringent air pollution norms

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Anilkumar Mukundan, Head Sales – Cement Product Units, Sub Continental India, FLSmidth, discusses the various products/filters suited for the cement process.

In India, regulatory requirements with respect to environment, particularly air pollution, are changing. How are these changes affecting your business?
The air pollution control norms in India have become very stringent and are in par with some of the emission control norms of the developed countries. With the advancement in technology on Multi-Pollution control, the need to control particulate matter (PM10 and PM2.5), acidic gasses (SOx, HCl, HF ), heavy metal (Mercury-Hg, Arsenic -As, Cadmium -Cd, Chromium-Cr, Lead-Pb, Antimony-Sb, Cobalt-Co, Zinc-Zn, Copper-Cu, Manganese-Mn, Nickel-Ni and Vanadium-V) and persistent organic pollutants-PCDD (Dioxin), PCDF(Furan) and PCB have risen.

The above pollutants are primarily generated from the burning of municipal waste, hazardous waste as well as the waste from cement plants.

FLSmidth has already developed proven technologies and solutions to counter this challenge and some of these solutions are already in operation in various countries complying to low emission. The advent of stringent norms would give FLSmidth an opportunity to introduce these technologies in India. Therefore, we expect to see a boom in this market segment.

How are these changes inducing you to bring in new technologies and helping you to increase the size of the market?
Paired with the pressing need to control emissions across industries globally and FLSmidth’s continuous research on air pollution control, led to the development of newer technologies like GSA? (Gas Suspension Absorbers), CataflexTM, CatamaxTM for multi pollution control and Coromax? MK-IV for handling resistive as well fine dust (PM2.5).

With these technologies, FLSmidth has the unique advantage of offering pollution control solution virtually for industrial application. This will definitely improve our market share.

Cement process is all about high temperatures and air pollution at elevated temperatures is a challenge. How are your products/ filters suited for these challenges, and have you any new offerings in high temperature filtration?
Cement manufacturing is a high temperature process and excess heat is often used for the drying of raw materials. Fabric filter is a preferred technology to meet extremely low emissions and it also handles the future need for multi-pollution control solutions including Respiratory Suspended Particulate matter (RSPM)-PM2.5.

Conventional fabric filter handles flue gas temperature up to 200 Degree Celsius. When temperature exceeds 200 Degree Celsius, we offer glass bags with e-PTFE membrane, which can handle up to 260 Degree Celsius.

When the temperature exceeds 260 Degree Celsius and beyond, the ambient dilution air is added using FAD (Fresh Air Damper). This however, demands designing Bag filters with higher gas volume. FLSmidth has developed high efficiency Heat Exchanger using compact design to control temperature from 500 Degree Celsius to 120 Degree Celsius. Hence a conventional polyester fabric filter could be used. The latest technology to handle high temperature flue gas as well Multi Pollution Control is the use of ceramic candle filter-CataMaxTM designed to operate at a temperature of up to 400 Degree Celsius.

FLSmidth now offers fabric filter technology for complete cement manufacturing process.

Both ESPs and bag filters find applicability in cement plants. Which of these is your strong point and why? Which of these has higher future potential in the cement industry?
Electrostatic precipitator’s (ESP) were widely used earlier in controlling pollution from cement plants because of its advantages like reliability against variance in temperature, lower pressure drop as well low maintenance cost, while meeting an emission guarantee of 50 mg/Nm3, but the vagaries in process condition also results in compromise on emission values, due to change in dust resistivity.

The emergence of fabric technology was to handle wide range of flue gas & dust properties as well the need to handle Multi Pollution Control Particulate matters(PM) as well Respiratory Suspended Particulate Matter (RSPM)-PM10 & PM2.5 , Gaseous pollutants viz., Acidic gases (SOx, HCl, HF as well NOx) , Heavy Metal (Mercury-Hg, Arsenic -As, Cadmium -Cd, Chromium-Cr, Lead-Pb, Antimony-Sb, Cobalt-Co, Zinc-Zn, Copper-Cu, Manganese-Mn, Nickel-Ni and Vanadium-V) and Persistent Organic Pollutants-PCDD (Dioxin), PCDF (Furan) and PCB are some for which fabric filter would always remain as the technology of the future.

FLSmidth has a proprietary Gas Suspension Absorber-GSA? to remove acidic constituent from flue gasses. In addition, an integrated bag filter would remove heavy metals as well persistent organic carcinogenic compounds.

FLSmidth’s latest CataflexTM technology for Multi-Pollution Control was developed jointly with the world renowned Danish catalyst surface technologist, Haldor Tops?e. The proprietary blend of catalyst embedded on glass fabric coated with e-PTFE, ensures conversion of all gaseous pollutants to harmless compounds like oxygen, nitrogen and water. Therefore, fabric filtration technology would remain the technology of future.

In your APC business, do you focus on turnkey solutions or standalone equipment suppliers? Which of these has higher consumer preference these days?
As a technology leader, FLSmidth has experience and expertise of over eight decades in designing, engineering, manufacturing, execution and commissioning of complete ‘flow sheet’ of solutions for cement and mining plants. FLSmidth has provided air pollution control solutions to many projects on a turnkey basis.

It is observed that for greenfield projects, client preference is for technology and often expects the bidder to execute the project on EP basis. For brownfield projects, client often prefers a turn-key solution, since some engineering for BOP (Balance- of- Plant) as well as system design may be required. Many customers now a days consider this as a good option as it ensures accountability and overall project ownership.

Do you have any special products for controlling and reducing ambient air pollution in cement plants and what kind of guarantees they are backed by?
Cement Industries generate a lot of pollutant and dust particles contributing to the ambient air pollution. Various technologies are available to abate ambient air dust viz., water fogging as well chemical fogging at mine mouth as well on road. FLSmidth offers solution that covers dust generation points by shrouding all conveying system and provides suction hood with skirting at dust transfer point, thus meeting stack emission only.

Between new projects and retrofitting, which is looking more positive today?
India has an installed cement manufacturing capacity of nearly 455 million tonnes (MT) and is the second largest cement producer in the world. India has over 210 large cement plants and majority of them are aging plants that have already drawn out major plan for expansion.

With the emergence of stringent emission, the existing units need to be upgraded and FLSmidth has already started offering solution for some of the plants.

As newer projects take longer time to get approvals and considering the difficulties in acquiring land, etc., upgradation is becoming the primary focus for future.

Considering these facts FLSmidth is coming up with various new technologies to remove acidic constituents as well heavy metals from flue gas stream.

What is your view on the cement industry growth prospects over 2-3 years? What component of your APC business caters to cement industry?
The Government of India is strongly focused on infrastructure development to boost economic growth and is aiming for over 100 smart cities thus cement production capacity is estimated to touch 550 MT by 2020.

FLSmidth offers complete flow sheet of technologies on Air Pollution control and have future-ready Multi-Pollution control technologies to address the need.

FLSmidth has over 60 per cent of APC business catering to cement industries and balance spread over power, metallurgical, carbon black, petrochemical and chemical industries.

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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…

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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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