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Plant Upgradation at Barak Valley Cements

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Barak Valley Cements recently did plant upgradation to improve its efficiency. The company did design fabrication and installation of Clinker Cooler and also increased kiln speed. The company was able to boost production by 33 per cent. Here is a case study on the plant upgradation.

Barak Valley Cements, incorporated in the year 1999, is engaged in the business of manufacturing of cement of different grades and is marketing its product under the brand name "Valley Strong Cement". The company started its commercial production in April 2001. Initially the company started its commercial production at the capacity of the plant at 300 TPD , subsequently company undertook various expansion and modernization plans from time to time which increased the installed capacity to 600 TPD of clinker and 750 TPD of cement. The technology that is used in manufacturing our product is Dry Process Rotary Kiln Technology with 4 stage Suspension Pre Heater technology.

The company is located in Assam and all the operations of the company are concentrated in the North Eastern region. The manufacturing unit of the company is at Jhoom Basti, Devendranagar, Badarpurghat, District Karimganj, Assam. The sales are also concentrated in the North Eastern region of India. The product portfolio includes both Ordinary Portland Cement (OPC) and Portland Pozzolana Cement (PPC). Barak Valley Cements is ISO 9001: 2008 certified company and their products confirm to BIS (Bureau of Indian Standards) specifications.

The BVCL plant is the largest cement plant in the State of Assam. Deficit cement market in North East Region (NER) has benefited the company, since cement demand has been growing at a faster pace in NER than rest of the country due to material gap between demand and supply. The plant is close to north-eastern states such as Mizoram, Tripura, and Southern part of Meghalaya, which are company?s target markets. Barak Valley is at the foot land of all the three states and Badarpur Ghat is the junction point. Continuing withs its trend in improving production efficiency the plant was recently upgraded. Here is a snapshot of few developments that took place.

Design Fabrication and Installation of Clinker Cooler Initially due to space constraint a Rotary Cooler was installed at 900 of kiln line at Barak Valley Cement. This cooler was not effecting so far cooling efficiency was concerned. The conventional cooler such as grate cooler, Ikon, Pendulum etc., were not possible. Conventional cooler requires more depth owing to spillage chambers and then conveying of spillage clinker. With the available space, a Cooler has been designed in house, fabricated & erected which is completely hydraulically operated. Each chamber consists of Zet Plates Fixed, over which pushers run to and fro pushing the hot clinker forward. Cold Air Passing through Zet Plate not allowing Spillage of clinker as found in Conventional Cooler due to having perforated plates.

Special feature over Conventional Cooler

  • No Spillage Chamber.
  • No loss in under Grate Pressure, utilizing full quantity of Air.
  • No wear & tear in Zet Plates because it is not under abrasion life 5-6 years.
  • No drop in pressure.
  • Availability of high & consistant Secondary Crusher.
  • Clinker Grindibility increased due to better air quenching.
  • Clinker temperatures at discharge remain to be below 800 C – 900.
  • Clinker is transported through rubber belt conveyor.

Construction in Brief
This cooler is having 4 chambers. A Chamber 2.2 meter wide x 3.5 meter long having nos. of Zet Plates duly fabricated by stainless steel plates as per the enclosed drg. These plates are fixed over the chamber plateform.

A pair of channel is fixed over the Zet Plates and a pair of channel reversed in position moves to and from through a box connected with hydraulic jack one row of fixed pusher and one row of moving pushers are welded. The driving box is connected with a jack which moves to and fro and the stroke of clinker depth is adjusted through P.L.C. When clinker falls from kiln, it is pushed by moving pusher over the fixed triangular pusher so that clinker does not come back. This way clinker gets forwarded motion and falls to next chamber. Finally cooled clinker gets discharged over rubber belt conveyor and then to clinker yard. A drawing is attached for study.

Kiln Twin Drive Problem

  • Speed of Kiln limited to 1100 rpm of motor.
  • Less Production.
  • Run out at Drive causing tripping of VFD due to excessive current hunting. System Modified
  • Second Auxiliary Motor of 110 kw added on other side.
  • Installation 110 kw V.F.D on secondary drive with different ratio of gear box & different kw of main drive.
  • PLC system for synchronization and load sharing with 220 kw/80:1 gear box with 110 kw/66:1 gear box.
  • Previous system had a 220 KW drive motor. At present the modified system is running smoothly with configuration shown in above table.

Achievement
The company was able to increase the kiln speed. As a result the production capacity increased by 33 per cent. The twin drive system also solved the issue of current hunting & tripping. Overall, the modifications helped in smooth kiln operation and and gave stability to current flow due to load sharing.

Main Drive Auxiliary Drive
Motor KW 220 KW 110 KW
Voltage 415 V 415 V
Make Alstom Alstom
Gear Box 80:1 66:1
Type Squirrel cage Induction
Motor
Induction Motor Squirrel
cage

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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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