Cement industry in India play an important role in the economy
Cement industry in India play an important role in the economy, provides employment to around more than a million people. Post deregulation, industry has been able to attract large investments from foreign and Indian investors, and it is the second largest cement industry in the world. Presently the industry is in repealing stage and on its way to achieve global benchmarks in safe productions.
India has enormous amount of potential for infrastructure development. Construction and cement industry are the two expected to be experience benefit from it. Newly form government is very keen to give a boost to infrastructure and the first initiative is a positive not foe the project to build 100 smart cities across the country. Having seen such expectations and favorable government policies, various foreign giant companies have invested in last half a decade. Favorable factor which attracts these investors the most except government policies is, raw material for making cement, which is largely and conveniently available in India.
Cement market is anticipated to grow at CAGR 9 percent in next five years, till 2020. Housing sector has always been the biggest contributor and has contributed 66% last year. The other industries which contributes in consumption of cement are commercial space construction and industrial space construction respectively. To match the upsurge in demand, companies are anticipated to add additional 60 million tons of capacity to produce within next four years. Industry experts are hoping that industry would register a growth of 8% and the total production would increase to 400 million tons. Presently country has recorded 200 kgs of per capita consumption.
Around 190 large scaled cement plants produces 96 percent of total installed machinery in the country, while rest of the plants are accounted for remaining 4 percent. Mostly large plants are located in Rajasthan, Tamilnadu and Andhra Pradesh. As happens in most of the economies, India too is dominated by few large companies, which account for 70 percent of total cement production. Cement demand was curbed down in south India last year, mainly due to having excessive capacity in the region. The production capacity in south is 120 million tons per year, however came as 73 million tons per year, which resulted in cutting the capacity and lowering down losses. Some company started exporting cement to neighboring countries which consequently depressed the domestic market. Though the main reason was getting the losses down as much as possible, but the result was not positive. Some even started closing the plants and starting on project based operation, because the cement companies did not see any practical demand, however the new union budget gave a positive boost to stay positive and see growth in future. New government stepped up investments in housing sector and major contribution came from partition of Andhra Pradesh by having two sets of different government policies.
Blended cement is derived by mixing ordinary Portland cement with minerals and extra fly ash and silica. Blended cement in India is considered better than the traditional ordinary Portland cement. Blended cement is widely used in commercial construction and gives a relatively better strength then ordinary Portland cement. Mostly small scaled cement companies in India do go for blended cement as it is not motivated to use by large construction giants.
India has enormous amount of potential for infrastructure development. Construction and cement industry are the two expected to be experience benefit from it. Newly form government is very keen to give a boost to infrastructure and the first initiative is a positive not foe the project to build 100 smart cities across the country. Having seen such expectations and favorable government policies, various foreign giant companies have invested in last half a decade. Favorable factor which attracts these investors the most except government policies is, raw material for making cement, which is largely and conveniently available in India.
Cement market is anticipated to grow at CAGR 9 percent in next five years, till 2020. Housing sector has always been the biggest contributor and has contributed 66% last year. The other industries which contributes in consumption of cement are commercial space construction and industrial space construction respectively. To match the upsurge in demand, companies are anticipated to add additional 60 million tons of capacity to produce within next four years. Industry experts are hoping that industry would register a growth of 8% and the total production would increase to 400 million tons. Presently country has recorded 200 kgs of per capita consumption.
Around 190 large scaled cement plants produces 96 percent of total installed machinery in the country, while rest of the plants are accounted for remaining 4 percent. Mostly large plants are located in Rajasthan, Tamilnadu and Andhra Pradesh. As happens in most of the economies, India too is dominated by few large companies, which account for 70 percent of total cement production. Cement demand was curbed down in south India last year, mainly due to having excessive capacity in the region. The production capacity in south is 120 million tons per year, however came as 73 million tons per year, which resulted in cutting the capacity and lowering down losses. Some company started exporting cement to neighboring countries which consequently depressed the domestic market. Though the main reason was getting the losses down as much as possible, but the result was not positive. Some even started closing the plants and starting on project based operation, because the cement companies did not see any practical demand, however the new union budget gave a positive boost to stay positive and see growth in future. New government stepped up investments in housing sector and major contribution came from partition of Andhra Pradesh by having two sets of different government policies.
Blended cement is derived by mixing ordinary Portland cement with minerals and extra fly ash and silica. Blended cement in India is considered better than the traditional ordinary Portland cement. Blended cement is widely used in commercial construction and gives a relatively better strength then ordinary Portland cement. Mostly small scaled cement companies in India do go for blended cement as it is not motivated to use by large construction giants.
Types of cement
Many people often confuse the two terms cement and concrete. Cement is the powder that is used to make concrete. It’s also used in mortar to lay brick and stone masonry. Cement comes from limestone quarries, mixed with different parts clay or shale to achieve different consistencies of concrete. The cement manufacturing process can be fairly involved, with very expensive machinery needed to achieve the best quality. Cement companies in India have perfected the art of cement-making. Let’s take a look.
How Cement is Made Before the cement is made, the limestone is crushed after being delivered from the quarry and the raw mix is delivered to the kiln feed where it is heated at over 1,400 degrees Celsius, where it is turned into “clinker”, a form of the cement process where it is turned into small pebble-sized chunks. Out goes the clinker where it is immediately cooled down. This last stage is the most important as the consistency of the cement degrades very fast at the high temperatures, once the baking process has completed.
After cooling, the clinker may be stored temporarily in a clinker store, or it may pass directly to the cement mill.
The cement mill grinds the clinker to a fine powder. A small amount of gypsum is normally ground up with the clinker. The gypsum controls the setting properties of the cement when water is added. This can allow up to 2 hours of extra time to set the cement before it hardens.
Various types of Cement Depending on the contractor’s needs, cement can vary many different ways:
· Rapid Hardening Cement: this cement type contains a higher limestone content. This gives more strength and durability.
· Quick setting cement: less Gypsum is added to the final grinding processing of the cement, allowing for rapid drying and the ability to lay concrete in running water.
· Low Heat Cement: this cement is used for when a job calls for massive quantities of concrete.
· Sulphates resisting Cement: this is useful for construction like canals, water retention, and siphoning.
· Blast Furnace Slag Cement: this type of cement is very similar to the widely-used Portland cement.
· High Alumina Cement: this is a type of cement that is highly-resistant to extreme temperatures and has a quick hardening time.
· White Cement: this is mainly used for aesthetic purposes, providing a cheap alternative to other stone masonry options.
· Colored cement: various pigments are used to dye standard cement for an alternative to tiling.
· Pozzolanic Cement: Portland cement is added to pozzolanic clinker to create a water-proof concrete with high durability. Often used is large, major structures.
· Air Entraining Cement: various glues and resins are added to clinker in the grinder to improve capabilities in water and frost environments at a lower cost.
· Hydrographic cement: this cement is used to create water-repellent binders and concrete layers. Very easy to work with and high-grade quality.
These are most of the types of cement that are available, with each formula varying in each cement company in India. These exact recipes are often kept secret, as most recipes are.
How Cement is Made Before the cement is made, the limestone is crushed after being delivered from the quarry and the raw mix is delivered to the kiln feed where it is heated at over 1,400 degrees Celsius, where it is turned into “clinker”, a form of the cement process where it is turned into small pebble-sized chunks. Out goes the clinker where it is immediately cooled down. This last stage is the most important as the consistency of the cement degrades very fast at the high temperatures, once the baking process has completed.
After cooling, the clinker may be stored temporarily in a clinker store, or it may pass directly to the cement mill.
The cement mill grinds the clinker to a fine powder. A small amount of gypsum is normally ground up with the clinker. The gypsum controls the setting properties of the cement when water is added. This can allow up to 2 hours of extra time to set the cement before it hardens.
Various types of Cement Depending on the contractor’s needs, cement can vary many different ways:
· Rapid Hardening Cement: this cement type contains a higher limestone content. This gives more strength and durability.
· Quick setting cement: less Gypsum is added to the final grinding processing of the cement, allowing for rapid drying and the ability to lay concrete in running water.
· Low Heat Cement: this cement is used for when a job calls for massive quantities of concrete.
· Sulphates resisting Cement: this is useful for construction like canals, water retention, and siphoning.
· Blast Furnace Slag Cement: this type of cement is very similar to the widely-used Portland cement.
· High Alumina Cement: this is a type of cement that is highly-resistant to extreme temperatures and has a quick hardening time.
· White Cement: this is mainly used for aesthetic purposes, providing a cheap alternative to other stone masonry options.
· Colored cement: various pigments are used to dye standard cement for an alternative to tiling.
· Pozzolanic Cement: Portland cement is added to pozzolanic clinker to create a water-proof concrete with high durability. Often used is large, major structures.
· Air Entraining Cement: various glues and resins are added to clinker in the grinder to improve capabilities in water and frost environments at a lower cost.
· Hydrographic cement: this cement is used to create water-repellent binders and concrete layers. Very easy to work with and high-grade quality.
These are most of the types of cement that are available, with each formula varying in each cement company in India. These exact recipes are often kept secret, as most recipes are.
Ordinary Portland Cement. Quite ordinary? On the contrary
OPC, conveyed overwhelmingly by crushing clinker and gypsum, is created in two collections at Penna Cement plants. Can be described as the holding material having tying & paste properties which makes it fit to unite the unique advancement materials and structure the compacted assembling. Regular/Normal Portland Cement is a champion amongst the most by and large used kind of Portland Cement.
The name Portland bond was given by Joseph Aspdin in 1824 on account of its likeness in shading and its quality when it sets like Portland stone. Portland stone is white grey limestone in island of Portland, Dorset.
The supervisor substance fragments of routine Portland solid are:
1. Calcium
2. Silica
3. Alumina
4. Iron
Calcium is ordinarily gotten from limestone, marl or chalk while silica, alumina and iron start from the sands, soils & iron minerals. Other rough materials may fuse shale, shells and mechanical symptoms.
Why Ordinary Portland Cement?
OPC 53 Grade
This is an Ordinary Portland Cement which has slightest 28 days nature of 530 Kg/CM2 (53 MPa) and is expected to meet all the particulars indicated in BIS IS: 12269 (1987). Produced using predominant quality clinker & gypsum, Penna OPC 53 Grade gives great support to structures; a consequence of its optimal particle size transport, transcendent hardened structure and balanced stage association.
OPC 43 Grade
This is an Ordinary Portland Cement which has minimum 28 days nature of 430 Kg/CM2 (43 MPa) and meets all the particulars determined in BIS IS: 8112 (1989). Unless an endeavor obliges fantastic bond, the usage of 43 Grade OPC is generally recommended all things considered basic improvement work. It is in like manner broadly used as a piece of the generation of precast things, for instance, pieces, pipes and tiles.
Right when typical Portland bond is mixed with water its substance compound constituents encounter a movement of manufactured reactions that cause it to set. These substance reactions all incorporate the development of water to the fundamental compound blends. This compound reaction with water is called "hydration". Each one of these reactions happens at a substitute time and with differing rates. Development of all these reactions gives the data about how Ordinary Portland cement hardens and builds quality. Those blends and their part in setting of solid are as under:
1. Tricalcium silicate (C3S): Hydrates and sets rapidly and is for the most part responsible for starting set and early quality. Typical Portland securities with higher rates of C3S will show higher early quality.
2. Dicalcium silicate (C2S): Hydrates and sets slowly and is for the most part responsible for quality additions recent week.
3. Tricalcium aluminate (C3A): Hydrates and sets the speediest. It liberates a ton of warmth rapidly and adds to some degree to right on time quality. Gypsum is added to Ordinary Portland concrete to retard C3A hydration. Without gypsum, C3A hydration would bring about typical Portland concrete to set rapidly in the wake of including water.
4. Tetracalcium aluminoferrite (C4AF): Hydrates rapidly however contributes alongside no to quality. Most normal Portland bond shading effects are a direct result of C4AF.
High caliber of bond makes it suitable for:
There are loads of biological impacts of Cement on our inclination. One of the noteworthy issues is spread of CO2 from the Cement business. It is watched that world yearly 1.6 billion tons era of bond covers 7% of carbon dioxide's yearly creation. It may cause various respiratory issues like asthma, bronchitis, and nasal sicknesses.
The solid collecting industry is work focused and uses far reaching scale and possibly dangerous gathering systems. The business experiences mishap rates th1+
at are high differentiated and some other collecting business undertakings. There are different dangers inalienable to the bond creation process. It is commitment of the assembly to complete the laws as delineated in EPA (Environmental Protection Agency) principle to guarantee the environment.
The name Portland bond was given by Joseph Aspdin in 1824 on account of its likeness in shading and its quality when it sets like Portland stone. Portland stone is white grey limestone in island of Portland, Dorset.
The supervisor substance fragments of routine Portland solid are:
1. Calcium
2. Silica
3. Alumina
4. Iron
Calcium is ordinarily gotten from limestone, marl or chalk while silica, alumina and iron start from the sands, soils & iron minerals. Other rough materials may fuse shale, shells and mechanical symptoms.
Why Ordinary Portland Cement?
OPC 53 Grade
This is an Ordinary Portland Cement which has slightest 28 days nature of 530 Kg/CM2 (53 MPa) and is expected to meet all the particulars indicated in BIS IS: 12269 (1987). Produced using predominant quality clinker & gypsum, Penna OPC 53 Grade gives great support to structures; a consequence of its optimal particle size transport, transcendent hardened structure and balanced stage association.
OPC 43 Grade
This is an Ordinary Portland Cement which has minimum 28 days nature of 430 Kg/CM2 (43 MPa) and meets all the particulars determined in BIS IS: 8112 (1989). Unless an endeavor obliges fantastic bond, the usage of 43 Grade OPC is generally recommended all things considered basic improvement work. It is in like manner broadly used as a piece of the generation of precast things, for instance, pieces, pipes and tiles.
Right when typical Portland bond is mixed with water its substance compound constituents encounter a movement of manufactured reactions that cause it to set. These substance reactions all incorporate the development of water to the fundamental compound blends. This compound reaction with water is called "hydration". Each one of these reactions happens at a substitute time and with differing rates. Development of all these reactions gives the data about how Ordinary Portland cement hardens and builds quality. Those blends and their part in setting of solid are as under:
1. Tricalcium silicate (C3S): Hydrates and sets rapidly and is for the most part responsible for starting set and early quality. Typical Portland securities with higher rates of C3S will show higher early quality.
2. Dicalcium silicate (C2S): Hydrates and sets slowly and is for the most part responsible for quality additions recent week.
3. Tricalcium aluminate (C3A): Hydrates and sets the speediest. It liberates a ton of warmth rapidly and adds to some degree to right on time quality. Gypsum is added to Ordinary Portland concrete to retard C3A hydration. Without gypsum, C3A hydration would bring about typical Portland concrete to set rapidly in the wake of including water.
4. Tetracalcium aluminoferrite (C4AF): Hydrates rapidly however contributes alongside no to quality. Most normal Portland bond shading effects are a direct result of C4AF.
High caliber of bond makes it suitable for:
- Making high audit concrete with honest to goodness mix layout.
- Early structure work departure in view of high early quality headway achieves speedier advancement.
- Optimally higher fineness gives better cohesiveness, upgraded workability happening denser concrete and dominating surface culmination.
- Economical utilization of cement due to high caliber through fitting strong mix arrangement
- All kind of plain and R.C.C., semi and particular improvement work, in the same path as expansions, conduits, slip structure work, pre-stressed channel/shafts and more.
- Also suitable for all sort of specific strong repair work like gunniting et cetera.
There are loads of biological impacts of Cement on our inclination. One of the noteworthy issues is spread of CO2 from the Cement business. It is watched that world yearly 1.6 billion tons era of bond covers 7% of carbon dioxide's yearly creation. It may cause various respiratory issues like asthma, bronchitis, and nasal sicknesses.
The solid collecting industry is work focused and uses far reaching scale and possibly dangerous gathering systems. The business experiences mishap rates th1+
at are high differentiated and some other collecting business undertakings. There are different dangers inalienable to the bond creation process. It is commitment of the assembly to complete the laws as delineated in EPA (Environmental Protection Agency) principle to guarantee the environment.