CEMENT INDUSTRIES

CEMENT INDUSTRIES IN INDIA:

CEMENT INDUSTRIES IN INDIA Made By:- Krishnakant Jalan

INTRODUCTION:

INTRODUCTION Cement industry is one of the main beneficiaries of the infrastructure boom. Has bright future with robust demand and adequate supply. The Indian Cement is the second largest after China with total capacity of 165 million tones . Cement industry is dominated by 20 companies who account for over 70% of the market. Private housing sector is the major consumer of cement (53%) followed by the government infrastructure sector.

CURENT SCENERIO:

CURENT SCENERIO 130 large cement plants 300+ mini cement plants. In Million Tonnes

STRENGHTS:

STRENGHTS Second largest in the world in terms of capacity. Low cost of production.

WEAKNESS:

WEAKNESS Effect of global recession on Real Estate and Infrastructure. Demand-Supply gap, overcapacity Increasing Cost of Production

TOP COMPANIES OF INDIA:

TOP COMPANIES OF INDIA ACC Gujarat Ambuja Ultratech Grasim India Cements JK Group

CONTD.:

CONTD. Jaypee Group Century Madras Cement Birla Corp.

FACTORS FOR GROWTH OF INDUSTRIES:

FACTORS FOR GROWTH OF INDUSTRIES Government Policies Requirements (Demands of people) Housing facilities and road networks Government of India giving boost to various infrastructure projects Export

CEMENT PRODUCTION AND GROWTH:

CEMENT PRODUCTION AND GROWTH In cement consumption, the state of Maharashtra leads the table with 12.18% consumption, followed by Uttar Pradesh. In terms of cement production, Andhra Pradesh leads the list with 14.72% of production, while Rajasthan remains at second position. The production of cement in India grew at a rate of 9.1% during 2006-07 . MONTH 2007-08 2008-09 April- Oct. 95.05 MT 101.04 MT October 11.61 MT 12.37 MT Production

CONTD.:

CONTD. The cement companies have seen a net profit growth rate of 85%. The cement industry in India has contributed almost 8% to India's economic development.

ZONAL CONSUMPTION:

ZONAL CONSUMPTION ZONE YEAR 2006-07 YEAR 2007-08 EAST 17% 17% SOUTH 26% 30% NORTH 21% 20% WEST 20% 18% CENTRAL 17% 16%

DEMAND DRIVERS:

DEMAND DRIVERS

GOVERNMENT POLICIES:

GOVERNMENT POLICIES Government policies have affected the growth of cement plants in India in various stages.

STAGES OF GROWTH OF INDUSTRIES:

STAGES OF GROWTH OF INDUSTRIES Price and Distribution Controls (1940-1981) Partial Decontrol (1982-1988) Total Decontrol (1989)

GOVERNMENT CONTROLS:

GOVERNMENT CONTROLS The prices that primarily control the price of cement are coal, power tariffs, railway, freight, royalty and cress on limestone. Interestingly, all of these prices are controlled by government

REQUIREMENTS:

REQUIREMENTS Coal Electricity Infrastructure Limestone Transportation Infrastructure for Future Incentives in States

TYPES OF CEMENT IN INDIA:

TYPES OF CEMENT IN INDIA Portland Blast Furnace slag cement (PBFSC): It is most useful in massive construction projects, for example - dams. Sulphate Resisting Portland Cement: This cement is beneficial in the areas where concrete has an exposure to seacoast or sea water or soil or ground water. Rapid Hardening Portland Cement: I t possesses immense compressible strength, which makes casting work easy. Ordinary Portland Cement (OPC): Also referred to as grey cement or OPC, it is of much use in ordinary concrete construction.

CONTD.:

CONTD. Portland Pozolona Cement (PPC): As it prevents cracks, it is useful in the casting work of huge volumes of concrete. Oil Well Cement: Made of iron, coke, limestone and iron scrap, Oil Well Cement is used in constructing or fixing oil wells. Clinker Cement: clinker cement is needed in the construction work of complexes, houses and bridges. White cement: It is preferred for tiles and flooring works. This cement costs more than grey cement.

TECHNOLOGY UPGRADATION:

TECHNOLOGY UPGRADATION A lot of up gradation and assimilation is taking place. Currently, almost 93% of the total capacity is based entirely on the modern dry process, which is considered as more environment-friendly. Only 7% uses old wet and semi-dry process technology. There is also a huge scope of waste heat recovery in the cement plants, which lead to reduction in the emission level and hence improves the environment. Up gradation of technology in all sections of the plant like mining, process, equipment and machinery, packaging and transportation.

CONTD.:

CONTD. Adoption of modern techniques like photogrammetry and remote sensing has enabled the industry to discover virgin limestone. Advanced equipment like hydraulic excavators, surface miners, large wheel loaders and mobile crushers have helped the industry in increasing its productivity considerably.

THREATS:

THREATS Imports from Pakistan affecting markets in Northern India. Excess over capacity can hurt margins as well as prices .

CHALLENGES:

CHALLENGES Cement industry currently has one of the highest inventory levels in recent times. Growth rates have slowed. Capacity additions putting pressure on prices. As a result the cement companies are looking for cutting production.

POLLUTION CONTROL:

POLLUTION CONTROL main source of pollution in cement industry is dust emission. Electrostatic Precipitators (ESPs) and bag houses/fabric filters in various sections of cement plants have been installed. The Central Pollution Control Board has fixed standards for particulate emissions from stacks . Some of the State Pollution Control Boards have also prescribed limits for gas emission from kiln stack. Indian cement industry is adopting on-line monitoring by opacity monitors.

Slide 24:

THE CEMENT MANUFACTURING PROCESS

Slide 25:

1. BLASTING : The raw materials that are used to manufacture cement (mainly limestone and clay ) are blasted from the quarry. Quarry face 1. BLASTING 2. TRANSPORT 3. CRUSHING AND TRANSPORTATION : The raw materials, after crushing , are transported to the plant by conveyor. The plant stores the materials before they are homogenized. Quarry 3. CRUSHING & TRANSPORTATION 2. TRANSPORT : The raw materials are loaded into a dumper . crushing conveyor dumper storage at the plant loader

Slide 26:

1. RAW GRINDING : The raw materials are very finely ground in order to produce the raw mix . 1. RAW GRINDING Raw grinding and burning 2. BURNING 2. BURNING : The raw mix is preheated before it goes into the kiln, which is heated by a flame that can be as hot as 2000 °C. The raw mix burns at 1500 °C producing clinker which, when it leaves the kiln, is rapidly cooled with air fans. So, the raw mix is burnt to produce clinker : the basic material needed to make cement. conveyor Raw mix kiln cooling preheating clinker storage at the plant Raw mill

Slide 27:

1.GRINDING : The clinker and the gypsum are very finely ground giving a “pure cement”. Other secondary additives and cementitious materials can also be added to make a blended cement. 1. GRINDING Grinding, storage, packing, dispatch 2. STORAGE, PACKING, DISPATCH 2. STORAGE, PACKING, DISPATCH : The cement is stored in silos before being dispatched either in bulk or in bags to its final destination. clinker storage Gypsum and the secondary additives are added to the clinker . silos dispatch bags Finish grinding

Slide 28:

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