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Waste to wealth: Use of AFR in cement kilns
Published
3 years agoon
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adminThe Shakti Sustainable Energy Foundation has initiated a large-scale co-processing process in the Indian cement industry, with a focus on rough capacity building, advocacy and development of a legal and institutional framework to boost the use of AFR, writes Shashank Jain.
While there is a lot of intense debate going on about the economic growth of India, there is hardly any discussion about the waste resulting from the same economic growth. Rapid urbanisation and industrialisation, increasing household income and changing lifestyles are leading to an increase in the amount of waste generated. As per Central Pollution Control Board (CPCB) data, India generates about 6.2 million tonnes of hazardous wastes annually; with this quantum of hazardous waste generation, local administration, civic bodies and policy makers are seriously concerned, particularly about its effective and safe disposal. Thus, effective waste management is the need of the hour for the country, indeed, imperative for the sustainable growth of the country.
One innovative approach to handle the problem of waste management is the co-processing of waste in cement kilns i.e, use of waste for the partial substitution of fossil fuels in cement kilns. Cement kilns can destroy hazardous wastes in a safe and effective manner beneficial to industries that generate such waste and to a society that wants to dispose of such waste in a safe and environmentally acceptable manner. The high temperature in the kiln and adequate retention time makes the cement kilns most suitable for disposing almost every type of waste. It is a practical and demonstrated solution that reduces greenhouse gas (GHG) emission from cement kilns, with the added bonus of waste management. The use of waste as alternative fuels in the cement kilns has its own benefits in the form of reduced usage of fossil fuels such as coal and the maximisation of recovery of energy from waste. All developed nations globally have utilised cement kilns in their countries as an effective option for industrial, municipal and hazardous waste disposal.
The Indian cement industry is the second largest in the world, with a total installed cement capacity of about 320MTA, and production of 220MTAa according to the Cement Manufacturers’ Association 2011 Annual Report. Over time, it has made significant progress in terms of improvement in energy efficiency and productivity. Still, the use of alternate fuel and raw material (AFR) to replace coal for thermal energy needs, remains an area where the Indian cement industry is yet to catch up with global benchmarks. Though a few cement plants use large quantities and varieties of AFR in their kilns, on an average, co-processing in the Indian cement industry is less than one per cent, compared to European average of 40 per cent.
The cement industry is also a large energy consumer and GHG emitter. Enhanced AFR usage in kilns will help consumers to achieve or even exceed their energy consumption reduction targets under the Perform- Achieve- Trade (PAT) scheme. The other co-benefits include reduced effort towards waste management, reduced landfill areas and methane emission from these sites. It is said that opportunity often comes disguised in the form of misfortune; with reference to alternate fuel and raw material utilisation in the Indian cement industry, it could not have been a better opportunity. Though current AFR usage is significantly low at about 1%, it offers immense potential for improvement. As per a Ministry of Environment & Forest (MoEF) estimate, even ten per cent of thermal substitution through the use of AFR in cement kilns has the potential to reduce the emission by three million tonnes of CO2 per year, which is about 0.2 per cent of emissions from the country in 2007. (Emissions as estimated in Second National Communication from India)
Challenges
As per a white paper submitted by the Shakti Sustainable Energy Foundation to MoEF in 2011, there are number of challenges faced by the Indian cement industry with regard to using waste for co-processing. Challenges become more pronounced in the Indian scenario as the situation is further exacerbated by a knowledge gap, lack of market incentives and the absence of an encouraging regulatory framework in the country. A few such issues are mentioned below-Information on waste availability and waste quality.
Detailed information on district and sector- wise distribution of waste, type of waste generated, etc, is not readily available in the public domain. As the data available on the quantity and quality of waste is minimal or outdated, cement industries have to spend a considerable amount of time and resources in exploring the availability of different types of alternative fuels.
Also, wastes received by cement plants have varying chemical compositions. Co-processing of such heterogeneous wastes poses considerable difficulty as these require pre-processing to generate a uniform quality of AFR. Getting a regular supply of such pre-processed waste of homogenous quality is a big challenge for cement plants at present.
Long permission process
The time period for getting clearances for conducting trial runs and obtaining permission from state pollution control boards thereafter for regular co-processing takes about 8 to 12 months. This is one of the major hurdles in enhancing the AFR usage. Also, the expenses incurred in conducting a trial run are significantly high.
Handling and storage
Handling and storage of hazardous waste is resource-consuming and requires a lot of precautions. Safety and protection gears are essential during for such handling.
Waste transportation
Collection and transportation of hazardous waste is quite expensive because of large distances between waste generators and cement plants. There is also a need to evolve and implement proper guidelines on the safe transportation of hazardous materials; currently, there is a lack of availability of certified transporters who can safely transport the hazardous materials.
Existing regulations don’t encourage transfer of hazardous waste from one state to another for co-processing. Many countries in Europe permit the movement of waste across international boundaries as a energy/heat recovery option, with significant advantages. A similar perception of waste is much needed here in India.
Aiming to tackle various challenges and issues, the Shakti Sustainable Energy Foundation has started an initiative to promote largescale co-processing in the Indian cement industry. The current Phase 2 (2013-14) of this initiative focuses on capacity building, advocacy and development of a legal and institutional framework to boost the use of AFR in kilns. The activities in this phase include the compilation of information on waste generation and utilisation, building capacity of stakeholders and working with relevant government agencies/departments to enable the regulatory processes.
We still have a long way to go. Notwithstanding several policies, regulatory or technological barriers that we face, this is an opportune time for the Indian cement industry to focus all its efforts on increasing co-processing. With such initiatives, not only will the Indian cement industry become more competitive globally but our country can also get rid of mounting waste.
Shakti Sustainable Energy Foundation (SSEF): Shakti Sustainable Energy Foundation (SSEF) works towards securing the future of clean energy in the country by supporting the design and implementation of policies that encourage energy efficiency and usage of renewable energy.
Shashank Jain, Sr. Programme Officer, Energy Efficiency (Industry), Shakti, Sustainable energy foundation Email: shashank@shakifoundation.in
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Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings
Published
3 years agoon
October 21, 2021By
adminRegion-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
Published
3 years agoon
October 21, 2021By
adminThe 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)
Published
3 years agoon
October 21, 2021By
adminCost 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.