| | Source: http://shivacement.com/future_plan.php Growth
plans for next five years has been finalized envisaging 15 times growth
of the present capacity in two phases. SCL already entered an MOU with
Govt. of Orissa to this effect. This will facilitate statutory
approvals, additional land, mines, water & power. Additional land
and environment clearance has been already obtained for Phase-1
expansion upto 1.0 Mn.TPA. Phase-2 expansion above 2.0 Mn.TPA shall be
taken up after completion of Phase-1 with a time gap of one year. |
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Looking into rising cost of power, SCL is envisaging
to add captive power plant in future clubbed with coal benefication
facilities. |
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Fly ash from the power plant shall be captively
consumed for manufacturing PPC cement. However, this has been deferred
looking into present constraint of coal supply and to keep focus on core
activity (cement production) at present. |
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| Strategy |
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Present capacity of SCL plant is only 0.132 Mn.TPA. Thereafter, it obtained all statutory approvals, acquired land and now Phase-1 expansion is ready to take off. |
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In today's competitive scenario, volume expansion has to be
essentially clubbed with cost efficiency. Hence, the latest &
modern technology for cement grinding has been selected with aim and
target of entering into the league of "most cost efficient plant" in the country. |
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| Technology |
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The conventional technology for cement grinding is inter
mix grinding (clinker & slag/fly ash) in a Ball mill. Most of the
existing plants (more than 90%) in the country are operating with such
conventional technology. |
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Grinding index of slag is higher than clinker. Hence,
with inter mix grinding, the slag particle remains relatively coarser.
Hydraulic property of slag improves with finer grinding. Clinker is to
be ground at relatively lesser fineness, but with particle size control
in the narrow range. Such different characteristic of clinker &
slag necessitates separate grinding of clinker & slag with different
fineness and particle size to give most optimum results and minimizing
clinker cons. We have therefore, opted for separate grinding of clinker
and slag. |
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Ball mill is power guzzler. It has also
limitation of slag grinding alone due to high moisture content in the
slag and harder to grind. We have therefore selected Vertical Roller
Mill (VRM) in lieu of conventional Ball mill; which is highly energy
efficient. VRM is ideal for moist slag grinding and best suited for
particle size control. |
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With selection of latest technology, the clinker consumption
will reduce by 15-18% from present level. Power saving on cement
grinding alone will be more than 20%. |
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In a composite cement plant, major portion of power, fuel
& Limestone consumption is upto clinkerisation stage. Hence, by
reduction of clinker consumption, the over all cost on per MT of cement
shall be substantially reduced. This has been already established in
few recent plants using this technology. |
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In Phase-1 expansion, the existing Kiln shall also be
modernized to improve it's power & fuel efficiency. In Phase-2, a
new Kiln with most modern technology in combination of VRM for grinding
raw material and coal will be opted. | | | | |
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