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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