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CEMENT INDUSTRY
SOJITRA JIGNESHKOTADIYA VISHALKAKADIYA PINALSHINGALA NAGJICHAVDA MITALAMBALAM SARANYA
AMBUJACEMENT
Cement in India
A Cyclical Business of Supply
Not Demand
Cement Industry - A Paradigm Shift
• No new cement plants in next two years• Demand supply gap likely to be over in
the next couple of months • Consolidation is well on its way to bring
stability in pricing• Future Demand to be much higher on
account of building of Roads, Ports & other infrastructure
• Housing becoming a major activity in the economy
• Due to ……
• Low Interest Rates
• Availability of mortgage finance due to ample liquidity
• Increasing disposable Income
During Calendar year 2011 Cement demand supply will balance – A situation not seen in past several years
GEOLOGY (RAW MATERIALS)
The fundamental chemical compounds to produce cement clinker are: Lime (CaO) Silica (SiO2)Alumina (Al2O3) Iron Oxide (Fe2O3)
Fly ash: by-product of burning finely grounded coal either for industrial application or in the production of electricity
Raw materials used in the production of clinker cement
THE CEMENT MANUFACTURING PROCESS
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
THE CEMENT MANUFACTURING PROCESS
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
THE CEMENT MANUFACTURING PROCESS
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
Our Business Model
• Own Infrastructure -Logistics Management
• Strong brand & efficient distribution
• Presence in prime markets
• Lowest cost cement producer
Own Infrastructure
• 7 Owned Cement Ships for transporting Cement by Sea
• Large port in Gujarat to handle export of Cement ( 2 mn tonnes this year) & Import of Coal / Oil
• 3 Cement receiving terminals • 190 MW of Captive Power Plants at
various Cement Plants to give reliable and cheap power
Strong Brand• India - A bagged market• Individual home builder - key driver of
demand
• Our focus • Best quality cement• Good packaging• Logistic management - strong distribution
network • Customer service
Uses
Main use is in the fabrication of concrete and mortars
Modern uses Building (floors, beams, columns, roofing, piles, bricks,
mortar, panels, plaster)Transport (roads, pathways, crossings, bridges,
viaducts, tunnels, parking, etc.)Water (pipes, drains, canals, dams, tanks, pools, etc.)Civil (piers, docks, retaining walls, silos, warehousing,
poles, pylons, fencing) Agriculture (buildings, processing, housing, irrigation)
USES
Sea terminalsCement factories
HP
Gujarat
Rajasthan
Maharashtra
Punjab
Ambuja Cement
Gujarat 5.0
North India 6.0
Maharashtra 3.0
Total Capacity 14.0
Mn. tonnes
1986 - 0.7 Mn. Tonnes Today - 14 Mn. Tonnes
A growth of 18 times since inception
FACILITY LOCATION
• Availability of transportations facility.
• Availability of market.
• Availability of services
But
Cement Industry
Not without challenges
Challenges
• Cement is energy intensive industry
• Coal, Power & Oil constitute major costs
• Increasing cost of fuel
• Better realisation only in few markets
Growth in Profits for only those
who can meet these Challenges
Our Strategy
• Presence in the growing markets of North & West
• Retail Focus – Premium pricing
• Largest Exporter of cement – 15% of Production
• 35% Cement transport by sea - Cheapest Mode
• And ... Lowest Cost Cement Producer