Sen a INDIAN ets HA Dee RNA ea Nae a ee Mle ea BRANDS BUILT ON STO Blurring the limits of commoditised selling prey Ce eeu Se ea ee kena Pen mec T PCO ur) Sues . Ultratech Cement Conca lars UCFEATURE - CONTINENTAL BELTS jontinental Belting (CBPL), part of the $20 million, [Continental Belting Group (India). CBPL is the only company in the bulk material handling industry to be nominated for the ET-Now= Leaders of Tomorrow Awards. Rohit Arora, Director (Sales & Marketing), elaborates on some of the winning strategies, How do you ensure low cost per tonne of material moved? To what extent challenging geographies impact the design ofthe systems? The larger the better. With growing capacities the cost of material handled is reducing substantially. so this is the biggest mantra to bring down the cost to increase volumes. ‘The cement industry has shown that no challenge is challenging enough by building a 17km long conveyor from India to Bangladesh, conveying lime stone to a premier cement plant. The conveyor travels through tough terran, including marsh, and yet there is minimal environmental impact. Choice of modern materials, with improve strength and reduce bulkiness, help reduce in-put costs, yet PREBIEB scevr re wow 218 Our new ‘Power Saver’ range of conveyor belts can save energy from 28 to 39 %. Rohit Arora, contributing to energy efficiency. Have you launched any new products/systems lately? ‘We have many fturistic technologies / products in our armameat, some of them, well ahead of their times, which would be Inunched shortly, We have been instrumental in stitnlating the growth of specialist products such as sidewall bls, pipe conveyor belts, seeel cord belts, et Performance is beyond just quality, and power saving has become an important decision making parameter. We have recently launched our “Power Saver range of conveyor belts, Which have low rolling resistance, and excellent rigidity, reducing energy losses. This product has shown promising resus, with power saving ranging from 28 to 39 per cent. This is the need of the hour. Our range of pipe conveyor belts not only helps convey efficiently, but, alko ensure pollation-free conveying, What is the response of the industry to the newer developments you propose? Ieis very encouraging, We have Director (Sales & Marketing), Continental Belting partnered with many cement plants to install our innovative produces with the rider that the enhanced product cost bee paid to us, only afer the promised benefit is derived. In all these instances the companies have harnessed greater benefit than promised, nd thanks to the cement industry grape wine, even ‘more players are now looking forward to collaborate, Is the cement industry under- valuing the role of consultants? Not at all. This industry respects knowledge and the knowledgeable. Consultants have played a very important role in shaping technology in cement plants. Infict, many of the developments done by us are thanks to encouragement received from the ‘cement fraternity. Where do you see the industry headed in future? Every industry has its unique requirements and while dhe trend is cone of having a standard product for all industries, we are working towards tailoring products to the specific industry requirements. This would help derive superior performance, and value engineer.FEATURE Poised for Exponential Growth The local as well as global requirements for bulk material handling solutions are projected to be strong. The Indian bulk material handling industry is well saddled to make the best of this opportunity. INDIAN CEMENT REVIEW tracks the market and technology trends. fhe Indian ccment industry has industry growth, However for the last levels, there is perhaps, more work, shown excellent results, even one year of new government than ever before e global context, initiatives there is optimism across the Says Rohit Arora, Director - industry and y efficient, moderate 10- Sales & Marketing, Continental Belting (CBPL), “Cement 60kwhr/tonne energy consumption in the bulk manufacturing efficiencies depend ¢ Towest in the world and the coming fature greatly on cost effcetive conveying, hest volume production per ‘The bulk material handling mostly by means of conveyor belts, annum, next only to China. Despite __equipmene industry has had its cycles beginning from the transportation of these achievements, the industry is of growth, inline with the fortunes of limestone at the mine to the end of a rough patch, saddled the core sectors, of which the cement the circuit, where the cement bags are with over capacity mainly due to industry has a sizeable contribution. _loaded by telescopic conveyor belts demand slack, prohibitive costs and an At present the capacity expansion is onto trucks. The Indian belting infrastructure policy mismatch minimal, however, there is industry has a fair reliance on cement Delayed project clearances related to substantial emphasis on efficiency, and companies for utilisation of at-least mining, environmental issues put most for bulk material handling companies 12-15 per cent of their produce of the upcoming projects on held; in who can help the cement industry nent is a serious business for us addition tight cash flows in the convey more efficiently (ower cost/ id fom the long term perspective market totally slowed down the tonne), and help reduce pollution ‘our fraternity is bullish on this sector PERS 0 cones neve 1 ane 205FEATURE Accosding to Nishant Jain, best time to put cher innovation to Another major change inthe Head - Business Development, _contunercal application and to deliver cement industry is many Rollwell Group of Companies, value to the cement industry Any manufacturers are setting up grinding the outlook for BMHE is very bullish player who contributes to improve units closer to to thermal power saiven the fact that India is poised to efficiency and effectivenes would be plans. Logistics has played very develop major infastracture in sost sought afer! Crucial ole in defining final cos of construction, roach, ports and power. Says Jain, "Bigger is always better. production, especially in the cement Jin sayss"Apart from cement, the Larger capacities translate to higher _industryshence most of the grinding power industry i just waiting to get material handling and conveying tits are located close to thermal ino top gear once the coal allocations capacity which means high capacity power plants. Growing demands for get stream lined and some of the land conveyors, high speed conveyors. It __fly ash based PPC production fas Acquistion isues are resolved, Most also mandstes good quality products forced many ofthe industry players to cavironmental related clearances have which are extremely reliable proven setup grinding units elose to thermal been already obtained and thus the and low maintenance in order to power plant for ly ash consumption cement and power industry will truly ensure cht inefficient material However, the vendors seem to have rive the BMHE!” handling does not hamper production geared up forthe challenge. This close targets,At Rollvell Group we had proximity of grinding units to the Market trends anticipated this few year ago and thus power plants brings to the table “Today clinker production unit id specific emphasis on developing numerous advantages. Reddy explains sizes are becoming higher (fiom 2000 new high speed, igh capacity some ofthese benefits: 3000 TPD to 5,000 10,000TPD) conveyors and components” fain adds, - Logistics eost / Opex costs can be to harness economies of sale. This has “Apart from material handling, brought into greater control by hada positive impact on BMH material storage alo becomes designing suitable bulk material solution providers. According to inyportant a8 capacities are scaled up handing equipment like pipe Y Srinivas Reddy, Managing and thus we entered into a joine conveyor, crost country conveyor Director, Bevcon Wayors the bulk venture with CST Industries of USA__or pneumatic conveying systems material handling industry has really co bring’Dome Storage’ solutions t0 by direcly conveying fly ash from geared up to catering high capacity India forthe first ime. These the thermal plane to grinding unit conveying applications beyond certain aluminum domes can store large location limits of production; there isno other quantities of clinker limestone, coal — Environmental norms and option except use of material cc all under a roof, thus protecting protection can be better managed handling equipment to mect the __the environment fom pollution and by use of bulk material handling present production necds,Als lot of the stored produc fom the elements equipment, ly ash being very light technological evaluation has been of the environ taken place in bulk materi in cerms of conveying the ent” ins density handling needs very industry aceril to ACHIEVING ENERGY EFFICIENCY longest distances of nearly 100 km and highest capacities about 20000 ‘Use of energy efficiency drives and components in equipment tonne or more. Hence enhancing the engineering kill capacities will definitely will add Best use of gravitational energy for material flow. value to BMH industry. ‘Use of imported energy efficiency components while engineering According to Rohit this shift stage ifneed be. towards higher production units ‘Adopting proper preventive maintenance practices. imakes things more challenging and Effective utilisation of machine avoiding idle times and un-even ako exciting as it calls for out of the loading and over loading etc. box thinking. For the bulk material Use of right fit electrical connectivity accessories to avoid power handling especially, those who Joss automation of equipment example: when not in use automatic continue to do things, as always it sa switch off rough ride, So I would broadly think Best use of green energy concepts. thae ma Wy of them would be seeking Developing friction free component to minimize energy absorption. in other industries. “+ Development of re-generation conveyors for energy generation etc. However, for the seasoned, itis the ———FEATURE care fall attention which can be controlled when material is handle by mechanised conveying manner only. ~ Effective space utilisation can be done by synchronising grinding rill needs with respect to power plane fly ash generation. ~ Use of bulk material handling for ash conveying will give option of transporting very high capacities can be handled where in conventional road logisties of truck handling has serious limitations, ~ Reddy adds, "Recently we have commissioned a similar application where in 50 eph fly ash thas been conveyed from a power plane by dense phase pneumatic system cement grinding plant located around 600 m away also under commissioning one more plant where in ash has been conveyed from captive thermal plant to cement grinding pint located about 1.2 kan away by dense phase pneumatic plant, Says Robit,"We are where our customers are. There has been a trend for the cement industry to set up PRE) 0 comerer emer 1 sine 2015 (GUS around power plants. Fly ash which once was a big burden to dispose has become a very valuable commodity: We have set-up service cells in the proximity of such plants to be able to provide a rapid response, ‘ensuring minimal down-time, We understand that ii not just che product, and quality, but, che ability to deliver on a call, which is a ve important part of ehe package According to Jain, this isa good development for the BMHE, There is a good potential to transport fly ash through different equipment directly to the grinding units due to the close proximity thereby reducing challenges ‘Energy Saver’ range of conveyor belts developed after extensive research of the viscoelastic characteristics of conveyor belt polymers. faced im fy ash storage, ransportation and disposal Energy & Environment Enemy arcounts for about 38-40 per cent of the production cost of cement, hence, besides conventional fuck such as oil gas, coal, ct, using alternate fines, such as rice hus, shredded tyres, coconut kernel, wood chips, te helps reduce energy costs besides reducing pollution. This has its ramification on che BMH. ‘equipment providers, who have developed new conveying and supporting systems. Company such as CBPL has developed specialise sidewall conveying systems tor Feeding alternate fuel, efficiently, which have been constantly upgraded aver time. BPI has aso come out with the Energy Saver’ rat developed afier extensive research of the viscoelastic characteristics of conveyor bele polymers, which © of conveyor belts prevent un-wanted bending of the belt, leading to loss of energy: “The pay-back period of this product is highly favourable,” informs Rohit, Rohit adds,“Pipe conveyor belt, with built-in chevrons, help completely seal the material being conveyed, fiom the atmosphere. These belts can convey even up to distances of Lokm or more, and can easily ‘manage horizontal and vertical curves. Practically zero spillage and pollutions ‘can be asured, once again, pledging ‘our concern for the environment, and also making economic sense.” According to Reddy energy efficiency is one of the critical design and performance parameter in the bulk material handling, To achieve energy efficiency focus starts from better ay outing of the proj and selection of equipment with optimum service factors. He says,“We are in the process of patting up totally automated idler and pulley manufacturing plant with UK technology to produce low resistance + designtal lers which will bring down the overall power consumptions of the conveyors. On average 10-12 per cent enhanced energy efficiency can be hieved. In specific cases it can be to the extent of 30 per cent” Beveon also has conveying system thnology called pipe conveyor" which conveys materials of high capacity for long distance in enclosed fon ‘am (belt rolls into pipe form) ensuring absolute control of material ‘emission to atmosphere and loss of ‘material and spillage in conveying pat tel that way its very ideal ‘hnology for environmental friendly applications. Similarly sandwich nveyor also highly environment friendly equipment where in conveying of material rakes place between two sandiviched belts equ sulting zero spillage of material to nosphere, Hence its very ideal uipment for open pit mining applications where the ore need to be conveyed from the pit of the mine to surface, Says Jain, “We have brought the Dome technology to India for covered storage of bulk material rckpiles like coal, limestone, iron core etc. The particulate pollution from coal and other fine materials has been the reason for many respiratory disorders like tuberculosis ete in India and itis about time that all bulk. sto piles would be tunder cover and not left open. Not only does this help INDUSTRY HIGHLIGHTS BMHE industry to grow 10-15 per cent Use of pipe conveyors on > the rise New technologies for ‘material stockpile Demand for high capacicy conveying system, ‘More focus on energy: efficient systems the environment by reducing air and ‘ground water pollution but also protects the stockpiles from rains, ‘moisture, spontaneous combusting/ wind etc” Challenges For Reddy execution of turnkey projects in India is really a challenging game. An organisation should have abilities to handle business techno, commercially and should be self sufficiene with inffaseructure, human talent and project management ——— A streamlined policy environment and clear road map for the economy is mandatory for the industry to thrive and survive. —— capabilites to make it as successfial as overall timely completion of a project is big task. He adds," Risk assessment is major challenge considering the tight cash flows and time consuming, financial clearances from institutions. Long pending project clearance from the government also putting extraordinary strain on the project developers in turn its impacting ‘overall business of the industry andl economy: Says Mehul Mohanka, Director Global Business, Tega Industries, “Slowdown in economic growth has led to reduction in sales. This has propelled customers to reduce ‘maintenance and operating costs to ‘maintain profitability. Another challenge is that frequently changing raw material characteristics and operating parameters and pressure 0 maintain production levels on plant sianagers is affecting the efficiency of the equipment. BMH Equipment FEATURE manufacturers need to address these challenges.” According to the BMHE as it caters to the core industries itis highly dependent on policy matters and health of the economy at larg. ‘The BMHE industry cannot seale up ‘or down rapidly and at the same time ‘maintain the quality price and service levels which are expected from it. ‘Thus a streamlined policy environment and clear road map for the economy is mandatory for the industry to thrive and survive Moving ahead So how does the fiture Iook like? In spite of currene complex situations prowling Indian bulk material handling has very bright fature as per 12* Plan. Reddy says, "Investments in inffastructure going to be neatly 10 per cent of the GDP and if this planned investment is realised it will propel the Indian economy growth to higher growth trajectory which leads to creating abundant business ‘opportunities more in for bulk ‘material handling sector being key contributor to infrastructure grovth Rohit says, “Chasing efficiency the size of plants in the steel, cement, power and other sectors ae getting langer, and the requirement for conveyor belting is ever increasing. ‘The local as well a global requirements are projected to be scrong. The Indian material handling industry is wel sided to make the best of this opportunity sums i up on a high note. For him there is only one direction, thats up. Jain sa, "The potential for infiastractare development in India is tremendous, we are a power hungry nation and there is no way this evelopment will be stalled, ie will only grovr leaps and bounds and so will the need for BMHE to cater to the same, June 2016 | INDIAN CEMENT REVIEW a: Sung jeuaunuo| ‘(Sunayxe] 29 soyes) Joye ‘erorY YOY . %BE 0) 9g wo Afraua SARS ULI S}[aq 10A3AU0S JO afuel 13AvS 1aMOd, Mau Ing,