Professional Documents
Culture Documents
Mineral India Cement 2013
Mineral India Cement 2013
Mineral India Cement 2013
Indian Minerals
Yearbook 2013
(Part- III : Mineral Reviews)
52nd Edition
CEMENT
(ADVANCE RELEASE)
GOVERNMENT OF INDIA
MINISTRY OF MINES
INDIAN BUREAU OF MINES
Indira Bhavan, Civil Lines,
NAGPUR 440 001
PHONE/FAX NO. (0712) 2565471
PBX : (0712 ) 2562649, 2560544, 2560648
E-MAIL : cme@ibm.gov.in
Website: www.ibm.gov.in
January, 2015
22-1
CEMENT
8 Cement
in 2011-12.
Three cement
economic growth.
Table-1.
22-2
CEMENT
Company
Plant
ACC Ltd(e)
CCI Ltd
No.
of
units
Annual
installed
capacity
(million
tonnes)
Production
(million
tonnes)
16
28.80
23.13
9.3
6.44
10
3.85
0.71
Andhra Cements(e)
1.42
J.K. Group
7.47
5.68
5.3
4.21
Century Textiles
7.80
7.65
India Cements
10
15.55
11.08
Alangulam, Ariyalur
0.79
0.59
Madras Cements
12.72
8.47
Mehta Group
2.70
2.59
22
53.90
42.59
Ambuja Cement, Gajambuja Cement, Ambuja CementHimachal Pradesh (2), Ambuja Cement Ropar (G); Ambuja Cement
Rabriyawas, Ambuja Cement-Bhatinda (G), Maratha Cement; Ambuja
Cement Roorkee (G); Ambuja Cement Bhatapara, Ambuja Cement
Sankrail (G); Ambuja Cement Magdella (G); Ambuja Cement
Farakka (G)
13
27.95
22.31
16
32.55
13.52
Kesoram Industries
7.25
5.16
Mangalam Cement
2.00
1.84
(Contd.)
22-3
CEMENT
Table-1 (Concld.)
Company
No.
of
units
Plant
Annual
installed
capacity
(million
Production
(million
tonnes)
tonnes)
Orient Paper Industries
5.00
4.01
Penna Tadipatri I & II, Penna Ganeshpahad, PennaBoyareddypalli Ltd, Penna -Tandur
7.00
3.91
Prism Cement
5.60
4.72
7.75
6.85
Malabar Cements(e)
0.62
0.53
6.25
5.65
Binani Cement
4.00
2.25
KCP Ltd
2.35
1.73
5.35
3.10
Dalmia Cements
11.8
6.1
1.27
1.10
Chettinad Cement
11.00
6.16
3.40
3.65
3.10
2.84
Shree Cement
13.50
12.33
Others *
12
11.64
8.21
178
318.94
2 2 9 . 11
Grand
To t a l
Figures rounded off. Source: Annual Reports 2012-13 and Cement Manufacturers Association, New Delhi.
* In addition, the following plants produced white cement:
(i) Grasim Industries Ltd (White Cement Division), Kharia Khangar, Jodhpur district, Rajasthan (560,000 tpy);
(ii) J.K. White Cement Works, Gotan, Nagaur district, Rajasthan (400,000 tpy); and
(iii) Travancore Cements Ltd (a Kerala Government Undertaking), Nattakom, Kottayam district, Kerala (30,000 tpy).
(G): Grinding Unit.
22-4
CEMENT
Annual capacity
Growth
Production growth
% Growth
Production
Growth
Growth%
2008-09
230.61
21.21
10.13
185.61
13.30
7.72
2009-10
276.77
46.16
20.02
204.95 (e)
19.34
10.42
2010-11
296.48(e)
19.71
7.12
216.28(e)
11.33
5.53
2011-12
306.21
9.73
3.28
230.25
13.97
6.45
2012-13
324.94
18.73
6.11
235.11
4.86
2.11
22-5
Operating Cost
Power, coal and freight constitute about 15-20%
each of the total cement cost while capital cost
(interest and depreciation) forms 20-30 per cent.
Although the industry is largely under private sector,
Government controls more than 40% of the cost.
Power, coal and freight costs are all regulated by
Government bodies, such as, State Electricity Boards,
Coal Monopolies and the Railways.
Power is a major parameter that influences the
operating cost. Grid power purchased from SEBs is
costlier than captive power from coal-based plants by
more than 25-30 per cent. Where conditions are
favourable, setting up captive wind power farms has
become a realistic option for cement plants with
operating cost at ` 0.50 per unit (kWh) power excluding
capital cost, interest and depreciation.
CEMENT
Coal Distribution
Cost Control
Power Availability
The industry's average energy consumption is
estimated to be about 725 kcal/kg clinker thermal energy
and 80 kWh/t cement electrical energy. The best thermal
and electrical energy consumption presently achieved
by the Indian cement industry is about 667 kcal/kg clinker
and 67 kWh/t cement which are comparable to the best
reported figures of 660 kcal/kg clinker and 65 kWh/t
cement in a developed country like Japan. Since the
controls were lifted, aggregate power requirements have
grown rapidly with rising cement capacity without
commensurate growth in power generating capacity in
the country. To offset the power crisis situation, many
cement plants have set up installations for captive
power generation. Further, as part of reform process in
coal sector, the Government has also permitted 100%
FDI in captive coal blocks in cement sector along with
power and steel to facilitate and augment power
availability.
Freight Costs
Logistics in the cement sector affect freight costs
to a large extent. The basic raw materials for
manufacturing cement such as, limestone and coal are
low value high bulk material and, as a result, entail huge
freight cost which form the single largest cost
component, usually accounting for 33% of the variable
costs. During 1990s, the most significant developments
were the emergence of big plants and formations of
clusters of cement plants. These clusters, typically
located far away from the major consumption centres
meant that cement has to be transported over very long
distances. The Indian Railways transported 107.66
million tonnes of cement in 2011-12 as against 99.08
million tonnes of cement in 2010-11 as a part of revenue
earning freight traffic. Alternatively, the cost-conscious
manufacturers have attempted to use sea route for
transportation as sea route is cost-effective and could
benefit coast-based manufacturers.
Environment
Ministry of Environment and Forests has notified
the emission standards for cement plants in 1987, which
was subsequently revised in February, 2006. In India,
the permissible stack dust emissions from various
sources for existing cement plants is 1.50 mg/Nm and
100 mg/Nm for plants located in critically polluted many
areas. However, the limit for new plants in our country
is 50 mg/Nm which is at par with some of the developed
countries. All large plants have provided necessary air
pollution control equipment to control dust emissions.
Thermal power stations use bituminous or subbituminous coal and produce large volumes of fly ash.
Fly ash is a fine powder recovered from gases created
by coal-fired electric power generation. These micron
sized earth elements consist primarily of silica, alumina
and iron. When mixed with lime and water the fly ash
forms a cementitious compound with properties very
similar to portland cement. For producing one tonne of
cement about 0.2 tonnes of fly ash can be used. It not
only reduces the cost of cement using fly ash by 5 to
10% but also saves on transportation & disposal of
materials and 30 to 40% of land required for the power
projects towards ash handling. A 1,000 MW project
requires around 1,000 acres for ash dykes for a 25 year
period for storing of fly ash.
At present, about 95 million tonnes fly ash is being
generated annually. It is estimated that about 32%
utility of fly ash can be made in cement industry.
Promoting use of fly ash would be an environmentfriendly measure without sacrificing the quality of OPC.
22-6
CEMENT
WORLD REVIEW
The cement production in 2012 was estimated at
3,800 million tonnes. China (2,210 million tonnes) was
the largest producer in the world, contributing about
58% to the world output, followed by India (270 million
tonnes), USA (75 million tonnes) and Japan (51 million
tonnes) (Table-3).
POLICY
Foreign Trade Policy (FTP) for 2009-14 was
announced on 27.08.2009 and came into force w.e.f.
27.08.2009. The Export & Import Policy incorporated
in the FTP for cement is free. The import of cement
includes portland cement, white cement, aluminous
cement, slag cement, super sulphate cement and
similar hydraulic cements, whether or not coloured
or in the form of clinkers, under ITC (HS) Code 2523
is free. The export of cement is also free.
FOREIGN TRADE
Exports
Export of cement (total) decreased substantially
to 2.8 million tonnes in 2012-13 from 3.4 million tonnes
in 2011-12. In 2012-13, exports of portland grey cement
were 1.78 million tonnes and those of cement clinker
0.78 million tonnes in the total cement exports. Exports
of portland white cement and other cements were
87,801 tonnes and 158,211 tonnes, respectively. Exports
of cement in 2012-13 were mainly to Sri Lanka (61%),
Nepal (26%), and Bhutan (5%) (Tables - 4 to 8).
Imports
Cement imports in 2012-13 increased marginally to
1.18 million tonnes from 1.01 million tonnes in 201112. In 2012-13, imports of grey cement were 4.62 lakh
tonnes, those of cement clinker 5.57 lakh tonnes,
other cements 1.47 lakh tonnes and portland white
cement about 16 thousand tonnes and the main
suppliers in 2012-13 were Pakistan and Vietnam (34%
each), Bangladesh (17%) and China (7%) (Tables - 9
to 13).
22-7
CEMENT
2010
3310000
2011
2012
3600000
Qty
(t)
3800000
Brazil
59100
64100
68800
China
1880000
2100000
2210000
Egypt
48000
44000
46100
Germany
29900
33500
32400
India
180000
240000
270000
Indonesia
22000 (e)
30000
32000
Iran
50000
61000
70000
Italy
36300
33100
33000
Japan
51500
51300
51300
Korea, Rep. of
46000
48300
48000
Mexico
34500
35400
35400
Pakistan
30000
32000
32000
Russia
50400
55600
61500
50000
Saudi Arabia
42300
48400
Spain
23500 (e)
22200
Thailand
36500 (e)
36700
37000
Turkey
62700
63400
63900
USA
67200
68600
74900
Vietnam
50000
59000
60000
510100
473400
523700
All Countries
Sri Lanka
Nepal
Bhutan
Maldives
Madagascar
Comoros
Myanmar
Seychelles
South Africa
Unspecified
Other countries
Qty
(t)
All Countries
South Africa
Nepal
UAE
Thailand
Nigeria
Tanzania
Kenya
Sri Lanka
Saudi Arabia
Bahrain
Other countries
2012-13
Country
Value
(` '000)
Qty
(t)
Value
(` '000)
2808080
9374641
Sri Lanka
2012486
5640835
1719868
5153910
Nepal
890117
2976356
740865
2570524
Bhutan
58838
357149
129531
623152
Maldives
48074
164472
44751
175574
South Africa
81314
285682
25785
165642
Madagascar
61147
138861
33220
101227
Comoros
16792
45937
25541
81996
UAE
14915
73941
11559
73148
Myanmar
Thailand
Other countries
28
169
22466
69899
7434
45475
8205
56920
207401
692338
46289
302649
Value
(` '000)
2011-12
Qty
(t)
Qty
(t)
2012-13
Country
2011-12
Value
(` '000)
Other countries
(rounded)
2012-13
Country
Value
(` '000)
81467
16879
12418
14851
7434
6736
3609
5567
3402
3097
547
6927
476371
91929
90562
73142
45475
42353
20769
32034
20195
15504
2718
41690
Qty
(t)
Value
(` '000)
87801
20560
19232
11340
8204
8430
4521
4133
3812
2826
797
3946
567061
146992
106842
68800
56805
50562
31078
29038
26616
16271
5194
28863
2012-13
Country
Qty
(t)
All Countries 1267166
Nepal
461355
Sri Lanka
687113
Bangladesh
44787
Zambia
Brazil
China
Germany
14
Myanmar
Other countries
73897
22-8
Value
(` '000)
2738494
966680
1489229
118846
25
163714
Qty
(t)
Value
(` '000)
783254 2091095
417776 1168328
364938 920326
516
2306
20
120
1
6
1
4
2
4
++
1
-
CEMENT
2011-12
2012-13
Country
Qty
(t)
Value
(` '000)
Qty
(t)
All Countries
92842
1190224
158211
710334
Nepal
72712
906737
68123
319129
Sri Lanka
5961
19497
74539
259813
Bhutan
5182
167981
7871
34069
Iran
149
3280
308
17910
Belgium
620
9738
720
11483
98
956
1056
11044
Italy
200
3122
776
10838
Maldives
517
2592
1301
6696
79
660
270
5746
660
10412
300
4637
6664
65249
2947
28969
Saudi Arabia
Nigeria
Netherlands
Other countries
Qty
(t)
Value
(` '000)
Qty
(t)
All Countries
746028
2542808
461782
1833280
Pakistan
592257
1944531
387507
1499621
Bangladesh
128294
521315
69677
317071
280
936
1385
5072
Afghanistan
1536
3193
793
2700
China
5892
17828
560
1868
Bhutan
1086
4574
392
1338
Sri Lanka
3724
11663
308
1214
280
1163
Value
(` '000)
UAE
Taiwan
980
3068
280
1106
Korea, Rep. of
527
1363
280
959
11452
34337
320
1168
2012-13
Value
(` '000)
Qty
(t)
Ghana
Country
Qty
(t)
Value
(` '000)
Chinese Taipei/
Other countries
2011-12
2012-13
Country
Value
(` '000)
2011-12
2012-13
Country
Qty
(t)
Value
(` '000)
Qty
(t)
Value
(` '000)
All Countries
9613
65832
15992
116986
Pakistan
3026
17912
9431
64081
UAE
5859
41624
6076
48822
3795838 1181846
4823532
Pakistan
599400
1972247
402984
1579026
Vietnam
90501
233406
396626
1174164
224167
898940
201588
901579
China
57625
385065
79506
521499
UAE
6168
44070
60588
302923
7062
65837
Ivoire
280
2273
6511
31548
8908
48949
South Africa
112
721
Italy
405
333
23876
1255
42370
USA
13
56
392
176
12073
40213
1191
25236
933
39297
24
464
32
292
25166
181274
10323
107675
703
5819
Bangladesh
Egypt
Malaysia
Chinese Taipei/
Taiwan
Indonesia
Netherlands
Other countries
Ivory Coast/Cote-D
Thailand
Other countries
22-9
CEMENT
Qty
(t)
All Countries
Vietnam
2012-13
Value
(` '000)
Qty
(t)
Value
(` '000)
145897
90501
397100
233406
556649
396486
1788489
1173615
43107
120127
51001
69712
237964
192125
Egypt
Malaysia
5460
24711
7062
8866
65837
46670
Indonesia
Pakistan
4117
9805
12000
6046
36416
15324
Venezuela
Thailand
310
1839
3700
516
10200
3477
634
3411
2402
7212
626
3450
UAE
China
Germany
Other countries
2012-13
Country
FUTURE OUTLOOK
The cement industry plays vital role for the
development of infrastructure in all over the world
as no other material is likely to be its substitute in
the near future. Infrastructure and industrial activity,
real estate business and investment in core sectors
mainly drive the demand for cement. Some emerging
markets for cement demand are concrete roads,
concrete canal lining and rural construction
(housing). Over 65% demand for cement arises from
construction sector.
The country is self-sufficient in terms of
cement production. Most of the cement plants in
India have the state-of-the-art technology and
production facilities. The liberalisation policies
for cement industry have helped in achieving
the strong growth of the cement sector. Cement
industry is going ahead with a modification and
upgradation of technology particularly in case of
energy conservation.
The Working Group on Cement Industry
constituted by the Planning Commission for
the 12th Five-Year Plan period has projected a
demand growth at the rate of 10.75% per annum
during the plan period at an expected 9% GDP
growth rate. The Working Group expects that
the additional installed capacity requirement
would be 139.7 million tonnes by 2017 and 1035.3
million tonnes by 2027.
Based on the demand growth projection, the
consumption of cement by the end of the 12 th Five
Year Plan would be between 366.9 million tonnes
and 397.4 million tonnes assuming growth rates
of 9.75% to 10.75% during the Plan period.
Qty
(t)
All Countries 109526
Bangladesh
95873
China
8259
Chinese Taipei/
Taiwan
333
Netherlands
547
France
1363
Germany
1859
Croatia
147
UAE
29
USA
188
Norway
52
Other countries
876
Value
(` '000)
Qty
(t)
Value
(` '000)
790097
377625
243509
147423
131911
9234
1084777
584508
327506
23876
23375
47575
38972
5560
1511
1928
5705
663
793
563
1335
420
2126
126
30
39519
38846
24080
18517
17693
11066
6171
4996
20461
222
11875
22-10