GROUP MEMBERS

MAWRA TEHREEM ZAIN KHAN

CEMENT INDUSTRY IN PAKISTAN

WHAT IS CEMENT?

• FINE, SOFT POWDER TYPE SUBSTANCE

• MADE FROM MIXTURE OF ELEMENTS LIKE LIMESTONE, CLAY AND SAND

• IT IS USUALLY GREY IN COLOUR,WHITE CAN ALSO BE FOUND, BUT EXPENSIVE.

• CEMENT MIXED WITH WATER, SAND AND GRAVEL FORMS CONCRETE, WHEN MIXED WITH ONLY WATER AND SAND FORMS CEMENT PLASTER

• ONE KILO CEMENT CONTAINS OVER 300 BILLION GRAINS

HISTORY

• CEMENT LIKE PRODUCTS WERE USED IN GREEK AND ROMAN STRUCTURE OVER 2000 YEARS AGO

• 1824 JOSEPH ASPEDIN INVENTED PORTLAND CEMENT. WHICH HAS REMAINED THE DOMINANT CEMENT USE IN CONCRETE PRODUCTION

• PAKISTAN HAD INHERITED 4 CEMENT PLANTS WITH TOTAL CAPACITY OF 0.5MILLION TONS IN 1947.CURRENTLY THERE ARE 29 FIRMS.WITH TOTAL CAPACITY 45 MILLION TONS

TYPES OF CEMENT PRODUCED IN PAKISTAN

1. ORDINARY PORTLAND CEMENT2. PORTLAND BLAST FURNACE SLAG CEMENT3. SULPHATE RESISTING CEMENT4. WHITE CEMENT

• ORDINARY PORTLAND CEMENT:-IS AVAILABLE IN DARKEN SHADE AS WELL IN LIGHTER SHADE, IN BAGS OF DIFFERENT SIZES UNDER DIFFERENT BRAND NAMES, IT IS USED IN ALL GENERAL CONSTRUCTION ESPECIALLY IN MAJOR PROJECTS WHERE CEMENT IS TO MEET STRINGENT QUALITY REQUIREMENTS

• PORTLAND BLAST FURNACE SLAG CEMENT:-ITS BEST QUALITY IS TO PROVIDE LONG LASTING STRENGTH AGAINST SULPHATE ATTACK, AND IS VERY SUITABLE FOR CONSTRUCTION NEAR SEA SHORE AND CANAL LINING.

• SULPHATE RESISTING CEMENT:-INCORPORATED INTO CONCRETE PROJECTS TO IMPROVE DURABILITY AND REDUCE LIFE CYCLE COST.IT HAS HIGH COMPRESSIVE STRENGTH AND IMPROVED RESISTANCE TO AGGRESSIVE CHEMICALS

• WHITE CEMENT:-HAS THE SAME PROPERTIES AS GREY CEMENT EXCEPT THE COLOR

LOCATION OF CEMENT INDUSTRIES

• CLASSIFIED INTO 2 REGIONS1. NORTHERN REGION • 80% SHARE IN TOTAL CEMENT• CAPACITY OF 38 MILLION TONS

2. SOUTHERN REGION• 20% SHARE IN TOTAL PRODUCTION• CAPACITY OF 7 MILLION TONS

MATERIAL USED IN CEMENT MAKING

• THE FOLLOWING RAW MATERIALS ARE REQUIRED, WHICH ARE FREQUENTLY AVAILABLE IN PAKISTAN

1. LIMESTONE (75-80%)2. CLAY (15-20%)3. GYPSUM (5%)4. FURNACE OIL OR COAL

CEMENT PRODUCTION PROCESS

SOURCES OF ENERGY

60-70% IS THE COST OF ENERGY IN PRODUCTION OF CEMENT• COAL • GAS • OIL FURNACE• ELECTRICITY

• MOST OF THE COMPANIES HAVE SWITCHED TO COAL OR GAS 1. FURNACE OIL RS 2083/TON2. COAL RS 868/TON• INITIALLY 90% OF COAL CONSUMPTION IS MET BY IMPORTS IN PAKISTAN, HOWEVER DUE

TO RISE IN PRICES COMPANIES ARE USING LOCAL COAL(DANDOT CEMENT,70% FROM QUETTA)

• LOAD SHEDDING OF GAS IS ANOTHER MAJOR ISSUE,DOMESTIC CONSUMPTION IS HIGH.FOR, ELECTRICITY COMPANIES WERE RELYING ON WAPDA,BUT NOW HAVE INSTALLED ITS OWN GENERATION PLANT

REASONS TO IMPORT COAL

• PRODUCTION OF 1TON OF CEMENT CONSUMES 3400-5000 MJ OF FUEL ENERGY(50% IN CLINKER BURNING.20% IN PREHEATER EXHAUST GAS,14% IN COOLER EXHAUST GAS)

• PAKISTAN HAS 4TH LARGEST COAL RESERVES BUT IS 2.5 MILLIONS TONS OF COAL PER ANUM FOR CEMNT INDUSTRY

• LOCAL COAL CONTAIN 6% SULPHUR,NOT SUITABLE FOR CEMENT PRODUCTION,WHILE IMPOTED COAL HAS 1% SULPHUR

FUEL ALTERNATIVES

• THE CEMENT MAY UTILIZE USED TIRES TO MEET 40% OF FUEL REQUIREMENT.LUKCY CEMENT AND DG CEMENT, THIS METHOD IS CALLED REFUSED DRIVE FUEL PROJECT

• RECYCLING THE WASTE BY MAKING IT IN A BUNDLE SHAPE, AND THAN THESE BUNDLES WOULD BURN IN THE KILN

• PAKISTAN CAN IMPORT SULPHUR WASHING PLANTS • WASTE HEAT RECOVERY PLANT SET UP BY LUCK AND DG CEMENT, USES

WASTE HEAT TO GENERATE ELECTRICITY

TECHNOLOGY

• UNTIL 1970’ FIRM WERE BASED ON WET PROCESS, IT WAS EXPENSIVE AND REQUIRED GREATER AMOUNT OF ENERGY SOURCE

• AFTER 1980’, 85% INSTALLED CAPACITY IS BASED ON DRY PROCESS • LUCKY CEMENT USES COMPUTERIZE CONTROL SYSTEM ADVANCED STATE OF

ART SOPHISTICATED EQUIPMENT LIKE X-RAY ANALYZER AND PLC’S• MAPPLE LEAF HAS REDUCED THE EMISSION OF NO TO ENVIRONMENT FROM

4.5KG/TON TO 1.5KG/TON,TO REDUCED ENVIRONMENT POLLUTION.

LABOR AND MACHINERY

• MORE THAN 150,000 PEOPLE ARE EMPLOYED DIRECTLY OR INDIRECTLY BY THE INDUSTRY

• CHEAP LABOR COST IS AN ADVANTAGE. FOREIGN EXPERTS ARE CALLED IN TO PROVIDE TRAINING

• MACHINERY IS IMPORTED,R&D WHEN IT COMES TO SETTING A PLANT IS ABSENT, LUCKY CEMENT HAS NO R&D AND CONSIDERS IT TO BE USEFUL ONLY WHEN PRODUCT INNOVATION IS POSSIBLE

EXPORT

PAKISTAN EXPORTS TO FOLLOWING COUNTRIES• AFGHANISTAN• SIRILANKA• AFRICAN COUNTRIES• SAUDIARABIA• IRAN

CEMENT ASSOCIATION(APCMA)

• ALL PAKISTAN CEMENT MANUFACTURING ASSOCIATION1. PROJECTING THE CEMENT INDUSTRY TO GOVERNMENT2. SUPPLIES INFORMATION ABOUT CEMENT INDUSTRY3. INTERACTS FOR INDUSTRY PROBLEMS4. TECHNICAL SUPPORT

RELATED AND SUPPORTED INDUSTRIES

• HOUSING AND COMMERCIAL PLOTTING• GOVERNMENT PROJECTS• SHIPPING INDUSTRY• PACKAGING INDUSTRY• MINING AND QUERRING INDUSTRY• TRANSPORT

• HOUSING AND COMMERCIAL PLOTTING:-40% OF THE CEMENT DEMAND,IT COMPRISES 50% OF THE CONSTRUCTION SECTOR

• GOVERNMENT PROJECTS:-MAINTENANCE AND CONSTRUCTION OF ROADS,DAMS,CANAL,BRIDGES,UNDERPASSES.NATURAL CALAMITES ALSO RAISE THE DEMAND

• SHIPPING INDUSTRY:-HIGH COST IS A BARRIER FOR EXPLOITING FULL POTENTIAL, INDIAN CARGO LOADS UP IN 6 HOURS AND HERE IT TAKES 3 DAYS. OUTREACH IS UP TILL SOUTHAFRICA,RUSSIAN MARKET IS UNREACHABLE

• PACKAGING INDUSTRY: IS DUE IMPORTANCE TO MAINTAIN CEMENT IN GOOD CONDITION,TWO MAIN COMPANIES SUPPLY AND A SHORTAGE OF 12 MILLION BAGS

• MINING AND QUERRING INDUSTRY: IT DIRECTS DEMAND FROM CEMENT SECTOR, RICH SOURCE OF MINERAL AND RAW MATERIAL ARE EXPLORED.IT PROVIDES HIGH EMPLOYMENT

• TRANSPORT: LOCAL TRANSPORTATION PAKISTAN($8/TON) IN INDIA($3/TON).TRUCKING SECTOR DEPENDS A LOT ON CEMENT INDUSTRY.20% OF CEMENT COST GOES UNDER TRANSPORTATION.

IMPROVEMENTS

• IMPORT SULPHUR WASHING PLANT FROM EUOROPE• ENCOURAGE RESEARCH AND DEVELOPMENT• COAL FIRED POWER PLANTS SHOULD BE IMPORTED