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CONTENTS
4 ICR JULY 2013
44 Supplying Africa
DVG Edwin, Dangote's Cement CEO outlines the
company's plans to become a pan-African producer.
46 Indocement: making it big
ICR visits the 11.9Mta Citeureup cement plant, which
operates with nine kiln lines at Bogor, Indonesia.
50 Giant steps for safetyDevnya Cement explains the measures it has taken toimprove health and safety around its facility.
54 Safe alternatives------
David Gossman of GCI reveals the safety lessonsof
dealing with alternative fuels in cement plants.
59 Aiming for ze ro accidentsThe WBCSD's CSI published revised safety guidelines for
its members this last May - its goal is for zero accidents.
61 Building BelgaumDalmia Cement highlights its new 4500tpd Belgaum cementworks in Karnataka, India.
64 India: feeling the heat
by ICR Research
Indian producers have witnessed a difficult period of
late with rising costs and the price-fixing fines. In the
latest figures from Jan-Mar 2013 the industry indicates
subdued cement demand although optimism remains.
68 UltraTech marches onby Ultra Tech, India
ICR hears from India 's largest cement producer and
biggest cement brand , as UltraTech management
review recent investments, company strategy and future
capacity plans.
71 Housing matters
Schaeffler reports on its new FAG SNS plummer housing
for bearings.
73 Cyclic processes
Dr Clark looks at the different gas, dust and compound
cycles at work in modern cement kilns.
75 Using multiple raw materials
Arthur Harrisson investigates the pros and cons of adding
a greater number of materials to the raw mix.
80 FCT Festus
FCT ACTech provide Buzzi Unicem 's Festus cement plant
with a COSMA unit for XRF/XRD analysis.
NEW PLANT PROJECTS
UltraIech marches on...by UltraTech Cement Ltd,India
Despite the recent challenges being faced by the Indian cement industry,
the country's largest producer, Ultra Tech Cement, has continued to press
ahead with its expansion plans given expectations for long-term domestic
demand growth potential. In the last year alone, it has commissioned five
cement projects to help meet the country's infrastructure and housing
requirements with new facilities established closer to consumption hubs.
"With India's enhanced focus on urban and rural
infrastructure, we are optimistic about Ultra Tech
being a propeller of growth for India. Over the
years we have continually invested in the cement
businessand the result of this action and our
commitment to partner India's growth story. is
evident today. Today, we are not only the single
largest cement company in India, but we are also
the largest single brand in the country. tr
OP Puranmalka, director, UltraTech Cement
ver the past year, the Indian
cement industry has witnessed
challenging times with lower
demand growth due to high fiscal deficit,
high inflation and a worsening current
account balance. A slowdown in global
cement demand also aggravated sluggish
consumption in the Indian cement sector
which recorded growth of just 5.6 per cent
in FY13 compared to a seven per cent
advance in FY12.
The industry has also been reeling
under higher raw material prices and
other rising input costs. Rises in domestic
coal prices and the non-availability of
low-cost linkage coal has increased power
and fuel costs for cement manufacturers .
Though imported coal prices have eased,
these have been offset to some extent
by a depreciation of the Indian rupee.
Nevertheless, the government's focus on
68 ICR JULY 2013
infrastructure development, rural housing
requirement and softening interest rates
are likely to bode well for long-term Indian
demand growth potential.
Despite the slowdown in the domestic
cement sector, UltraTech has remained
steadfast in its outlook for Indian demand
potential and has continued to invest
during the downturn. The company's
belief in India's long -term development
potential is evidenced in its recent
expansion drive, which has seen the
following five projects commissioned in
the last year:
3.3Mta clinker plant at Rawan,
Chhattisgarh, east India
1.6Mta grinding unit at Hotgi ,
Maharashtra, west India
increasing grinding capacity at the
Gujarat Cement Works by 6Mta, west
India
Bulk terminal at Cochin , Kerala, South
India
Birla White (UltraTech's white cement
business)wallcare putty plant, Madhya
Pradesh, central India.
The multi channel burner is suitable
for alternative fuels with high flame
momentum.
A four-string, six-stage preheater has
been installed with low NO x calciner and
multiple locations fuel injection.
The vertical coal mill is suitable for
petcoke and other high volatile material.
In line with UltraTech's corporate social
responsibility , the company ensures
staff accommodation is well maintained
with healthcare facilities, high hygiene
standards, continuous supply of water,
as well as regular social events such as
sporting activ ities, cultural celebrat ions and
film screenings.
Part of the Rawan clinker plant project
is a 30MW power plant and a 15.3MW
waste heat recovery plant. This will allow
the Rawan facility to be self-sufficient in
terms of power. A railway siding, wagon
tippler and automated clinker loading
system will complete infrastructure at the
site.
UltraTech's business model in terms of
grinding plants and bulk terminals is to be
close to consumption centres. In line with
this strategy, the company commissioned
the 1.6Mta Hotgi grinding plant in
Maharashtra, in addition to the existing
capacity of 1.8Mta. These capacities
combined make Hotgi the largest split
NEW PLANT PROJECTS
ADITYA BIRLA
UltraTech
UltraTech Cement, part of the
Aditya Birla group. has a total of
11 integrated grey cement plants
in India . 11 grinding units. five
bulk term inals and one white
cement plant in India.
The company also has one clinker
plant. four grinding units and a
bulk terminal outside India .
grinding unit in the country and increase
the availability of cement in Maharashtra.
At Hotgi, a clinker silo instead of a
stockpile is used, which ensures a higher
stock levels and minimises dust emission.
A O.5Mta terminal at Cochin Port
in southern India has also been
commissioned, giving UltraTech better and
faster access to the Kerala market.
The new clinker unit at Rawan is a state
of-the-art automated plant equipped with
roller press technology for raw material
grinding.
UltraTech has partnered wi th leading
global and Indian technology providers,
consultants and contractors for the project
including KHD Humboldt Wedag, Gebr
Pfeiffer, Siemens, Holtec, BAPl, HAPBCo
and Petron. The Rawan plant was
completed in a record 22.5 months and
achieved a good safety record. "Safety
is an integral, non-negotiable cog of our
value system. We build safety in our work
environment by balancing policy issuance,
creating awareness, and incentivising and
rewarding safe behaviour. Onl y a safe
today can ensure a sustainable tomo rrow,"
notes Ratan Shah, chief manufacturing
officer, UltraTech Cement.
Plant highlightsThe lj>6m x 88m kiln is the largest in
UltraTech's cement operations.
JULY 2013 CR 69
NEW PLANT PROJECTS
Earlier in the year, the expansion of
Gujarat Cement Works, UltraTech's unit in
west India, was completed and capacity
enhanced to O.6Mta to serve demand
in the south and west markets. Both of
these markets have coastal facilities which
provide strategic advantages in terms of
locat ion. The expansion plan included the
installation of roller press technology in
three cement mills.
The wh ite cement businessof UltraTech
recently inaugurated a new facility
for Birla White wallcare putty (surface
coating to prevent flaking ) in Madhya
Pradesh in central India. The OAMta
state-of -the-art plant is in close
proximity to raw material supplies.
The increased capacity underlines
Birla White 's leadership position in the
wallcare putty market.
The planned capex for the
current financial year is
INR117bn (US$2.07bn).
Commenting on the
company 's future plans,
KC Birla, chief financial
officer of UltraTech
Cement states: "We have
a strong balance sheet
and our leverage posit ion
is comfortable. We have
the ability to particip ate in
UltraTech's capex plans offer a "holistic" approachto growth of the company 's business,states
KC Birla, CFO of UltraTech
capacity expansion projects that require
capital expenditure.
" In addition, capex is on for installat ion
of waste heat recovery systems, thermal
powe r plants, packaging terminals and
ready mix concrete plants, giving a holistic
push to the growth of our business."
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Innovation with Integrity
70 ICR JULY 2013
XRD