The flagship Nandyal plant is designed to produce Clinker ~ 2.2 million ton per annum (mtpa) and Portland Slag Cement ~ 4.80 mtpa. It has state-of-the-art technology sourced from global vendors.
The plant is notably environment friendly and also one of the most energy-efficient cement plants in India. By using blast furnace slag as raw material, the plant has dramatically reduced its consumption of limestone, a natural resource.
- First cement plant in India with Combi-Comflex technology
- First plant with multiple systems to control air and dust pollution
- Unique automatic packing and truck loading system that cuts down on air pollution
- Consumes half the amount of limestone required by conventional cement plants
- Reduces pollution and wastage by utilising slag as a raw material
- A net water-surplus unit
- Green processes that have earned several prestigious awards
Has 1,200 tonnes-per-hour (tph) capacity and is used to crush limestone sourced from captive mines. The plant has installed enough bag filters to confine the dust emission levels below 10 mg/Nm³.
Used to convert limestone to a very fine powder, which is stored in a 20,000 MT capacity raw-meal silo. The raw-meal grinding facility uses the latest Combi-Comflex technology that reduces power consumption substantially. The bag house is designed to ensure that emission levels from the stack remain below 10 mg/Nm³. We are the first company in the Indian cement industry to deploy this technology.
Comprises unloading, storage and feeding systems. This has nuisance bag filters and process bag filters to keep emission levels below 10 mg/Nm³ across the coal mill circuit, from the truck-unloading stage to the end product storage areas. The coal mill stack has a continuous online monitoring system, which helps maintain emission levels at around 6-7 mg/Nm³.
Preheater and kiln
Used to fire and heat up coal. The plant has installed a pyro-clone firing system to control the emissions of nitrogen gases (NOx).
The Nandyal plant uses LD slag, which is not used by conventional cement plants. This reduces the consumption of limestone and also lowers carbon emission levels by around 55 percent.
In the cement industry, packing plant personnel are heavily exposed to dust during the loading operations. We have installed the latest automatic packing and trucking loading technology, ie the FLS Ventomatic system, to safeguard the health of our people. The system prevents overexposure to dust and other harmful pollutants.
The Nandyal plant makes Portland Slag Cement (PSC), which is a mix of slag and LD slag and ordinary cement materials. PSC is an eco-friendly cement that is ideally suited for construction in coastal areas. Widely used in other developed nations, PSC is gradually gaining a foothold in the Indian construction industry.