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Shailesh Kumar, Manager (Engineering), Allan Smith Engineering

Alignment or optimisation of forces is important, otherwise the unbalanced forces on the kiln will result in the damage of some components / loss of production / expensive replacement / repairs, all of this reducing the kiln reliability, says Shailesh Kumar, Manager (Engineering) Allan Smith Engineering. Excerpts from the interview.

How important is kiln alignment?

A kiln is a huge machine weighing several hundred tonnes rotating on support rollers located between two to eight stations, with a length ranging from 40 to 160 m and inclination of 2-4 per cent. The kiln is used as calciner / roaster with inside temperatures at several hundred degrees Celsius. Due to the operating conditions mentioned above, complex forces generate / act on the kiln system. Optimising / balancing of the complex forces on the kiln support rollers / bearing’s, called alignment, is vital.

Alignment or optimisation of forces is important, otherwise the unbalanced forces on the kiln will result in the damage of some components / loss of production / expensive replacement / repairs, all of this reducing the kiln reliability.

How does kiln alignment impact energy efficiency?

The energy required in a machine is to overcome resistance / friction sliding / rolling. The higher the friction at support roller / journal-bearing / thrust roller / tyre chairpads – stopper blocks, the higher the energy consumed. Higher resistance is concomitant with higher misalignment and reduced efficiency.

Kiln alignment is often seen as additional expenditure by plant engineers. What is your take on this?

Usually it is observed that a reduction in the power required to turn the machine is up to 40 per cent after HKA. The reduction is dependent upon misalignment; the higher the misalignment, the higher the reduction.

The payback period is a couple of months. In addition to this saving, better alignment results in the increased life of mechanical components with reduced wear and tear on journal bearings / rollers, tyres, etc. A higher and more consistent production is added advantage.

What are the diagnostic symptoms that serve as an indicator of kiln misalignment?

Hot kiln alignment is a preventive maintenance tool and we suggest carrying out checks at regular interval to ensure a trouble- free and optimised kiln operation.

Generally, symptoms are erratic with increased journal bearing / thrust collar temperature, kiln operating at a position for longer duration, excessive wear on tyre / roller rolling surface, side-stopper blocks, chairpad surface, gear teeth, premature crack in kiln shell / support roller / tyre, etc.

What are the common causes of kiln misalignment?

A kiln is designed to operate for 24 hours with higher shell temperature. The temperature at some time increases in excess of 4000 Celsius. Excessive temperature and variation results in deviation of the kiln alignment axis. Also, process disturbance causes big boulders to form inside the kiln.

Furthermore, misalignment is a complex issue, when we consider three different axes, the kiln shell, support system and rotation axis. We also consider three different possibilities of misalignment for which we can list main causes:

a. Support system: wear of sliding bearing, sinking of foundation, clearances in the system.

b. Shell: mainly thermal factors, build-ups, loose lining.

c. Rotation axis: mainly determined by support system axis, position of gear rim axis, local slope of support rollers, reaction on the piers, etc.

How detrimental are the different types of wear to the equipment?

Abrasive wear is predominant wear in kiln mechanical elements and occurs between rolling elements / sliding surfaces. The surface is:

a. Rolling surfaces: tyre / roller rolling raceways, thrust rollers.

b. Sliding surfaces: chair pad, under tire surface, tyre retainers, journal – bearings gear / pinion, etc.

Both the above both type of wear contributes toward kiln misalignment and initiates problems in the kiln.

What are the different methods of aligning a kiln?

It is difficult to explain all the methods as each company will say their method is the best. So we think it would be better evaluated by independent representatives.

The majority of alignment correction carried out by us has recorded a maximum of 40 per cent amperage reduction in the main motor compared to data recorded prior to the alignment. In addition, we also observed the kiln float on its own, a reduction in bearing temperatures and pier vibration. Kiln operation was smooth with a higher rpm.

Please elaborate on some basic kiln maintenance procedures.

Regular and meticulous inspection of the kiln and components help to notice if any changes occur after the earlier inspection. The changes can then be recorded and analysed to take appropriate action. Further, in-depth inspection / analysis can be requested from an external professional agency. What is the best time to do kiln alignment and what is your recommended schedule? Our suggestion for the alignment schedule is with reference to kiln rpm / repairs carried out / typical problems observed during operation, etc. Our statistically based experience is as follows:

a. Standard kiln: minimum once per year.

b. Slow rpm Kiln: once in two years.

c. High rpm kiln: every six months.

We recommend carrying out kiln alignment when the kiln is under normal production with more or less normal kiln shells temperatures.

What are the services you provide?

We commenced operations in 2007 with the aim of providing a global standard of service at a local price. We work systematically and take the help of specialised equipment to locate root causes of observed recurring problems. Once the reason is established, it is relatively easier to eliminate the problem permanently.

We work meticulously and our engineers have both specialised experience in world class organisations and global exposure.

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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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