Maihar Cement is a division of Century Textiles and Industries Ltd, a flagship company of BK Birla Group. Group. The company is well diversified diversified having interest interest in cement, textiles, rayon, chemicals, pulp and paper.
Maihar Cement is situated at Sarlanagar (Maihar) Dist. Satna in the State of Madhya Pradesh with an installed installed capacity capacity of 3.80 Million TPA. TPA.
Maihar is 45 45
Kms South - East of Satna on Howrah - Mumbai Central Railway Main Line. Maihar Maihar is well well known known for Shard Sharda a Devi Devi Temple emple and Maihar Maihar Gharan Gharana a Music Music whose proponent was renowned Musician Padma Vibhushan Baba Allaudin Khan.
Devi Sharda (Maihar) Apart from Maihar Cement, company has two more cement plants namely Century Cement at Baikunth, Dist. Raipur in the State of Chhattisgarh with an installed capacity of 1.80 1.80 Million TPA TPA and Manikgarh Cement at Gadchandur, Dist. Dist. Chandr Chandrapu apur, r, Mahara Maharasht shtra ra with with an ins instal talled led capaci capacity ty of 1.50 1.50 Milli Million on TPA. TPA.
The combined combined Capacity Capacity of all cement plants plants taken taken altogether altogether is 7.80
Million TPA. TPA. More emphasis emphasis is given for production of blended cement which which constitutes about 95% of the total cement produced by the company.
Plants of Century Textiles & Industries Limited:
Century Cement - Chhattisgarh Maihar Cement – Madhya Pradesh
Manikgarh Cement – Maharashtra
Units
Figures in Million TPA 2008-09
Century Cement
2.1
Maihar Cement
3.8
Manikgarh Cement
1.9
Total
7.8
The capacity enhancement to 7.80 Million TPA is under implementation by carrying out modification, up gradation and debottlenecking of existing plant & machinery and equipments, which is likely to be completed by Oct-Dec
2007 Quarter Quarter.. All cement cement plants plants are equipped equipped with captive power plants, which not only ensure an uninterrupted power supply, but also help company substantially on power cost, as the own generated power is quite economical as compared to grid power.
The company sells its cement under its premium brand name - BIRLA GOLD.
Maihar Cement has its own Captive Mines with rich limestone reserves at Bhadanpur Bhadanpur just 7 Kms from the plant. Mines' Mines' working is fully mechanize mechanized d and and an over overla land nd belt belt conv convey eyor or of 7 kms kms pass passin ing g thro throug ugh h hill hilly y terr terrai ain n tran transp spor orts ts lime limest ston one e from from mine mines s to plan plant. t.
The The aest aesthe heti tic c view view of the the
surrounding area has been maintained by afforestation of the mining area and also by creating water reservoir in the excavated area.
A Panoramic view of Mines
To meet the need of the hour and in order to reduce the cost of production, so as to be comp compet etit itiv ive, e, Maih Maihar ar Ceme Cement nt has has inst instal alle led d its its own own Capt Captiv ive e
Ther Therma mall Power ower Plant Plant and the total total ins instal talled led capaci capacity ty is 35 MW which which is helpful in uninterrupted running of the plants on sustainable basis.
Power Plant View
Strategic location of the plant, connected with NH-7 puts Maihar Cement in a very advantageous position so far as logistics is concerned. concerned. The Plant is well connected by Road Road with all the major marketing centers. centers. Being situated on Mumbai - Howrah (via Allahabad) main Railway Line, it is also well connected with all the States in East & North East.
Rail Lines
Maih Maihar ar Ceme Cement nt is pione pioneer er in prod produc ucin ing g Blen Blende ded d Ceme Cement nt i.e. i.e. Portl ortlan and d Pozzolana Pozzolana Cement. The motivation for the production production of blended cement has been been prim primar aril ily y environment.
with the the
aim aim
of pre preserv serviing lim limesto estone ne rese eserves ves
and and
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Low Heat of hydration resulting in resistance to cracking.
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Resistance to corrosive water and chemical attacks and thereby longer life to steel/iron steel/iron structure underneath.
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High degree of impermeability and workability for the concrete mix.
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Higher ultimate strength at longer duration d uration
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Higher degree of fineness, resulting in -
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Comp Comple lete te chem chemic ical al react eactio ion n
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Easy workabil bility
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Incr Increa ease sed d pl plast asticity city
Reduced Reduced Alkali Alkali aggregate aggregate reaction reaction as also free free lime expansion and thereby resistance to cracking.
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Lower drying shrinkage and low leaching value.
PPC can be used for any type of construction which earlier had been the forte of OPC. Howeve Howeverr due to it's it's specia speciall attrib attribute utes, s, it's it's use is rathe ratherr imper imperati ative ve for the follow following ing construction works.
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Hydraulic Structures
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Mass Concreting Works
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Marine Structures
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Masonry Mortars and Plastering
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Under aggressive Conditions
The The basic basic raw mater material ial in the produc productio tion n of cement cement is Limesto Limestone. ne. The Limestone ore as obtained from the Mines is fed to the Raw Mills after first crushing it to acceptable size. Certain additives such as Laterite, Bauxite,
High High Grade Grade Lime Limest ston one( e(Sw Swee eete tene ner) r) etc. etc. are are also also intr introd oduc uced ed alon alongw gwit ith h Limestone into the Raw Mills as applicable. In the Raw Mills, the above inputs are reduced reduced to a particul particular ar fineness. fineness.
The output output of the Raw Raw Mills, Mills, called called
'Raw Meal' is then burnt in the Kiln and then cooled to produce Clinker. Clinker. The fuel used for burning of limestone is powdered coal produced from the coal Mill. The Clinker is thereupon fed into Cement Mill & pulverized along with Gypsum to yield the basic cement. cement. A certain proportion proportion of Clinker in the production of cement is replaced by Fly ash to produce PPC.
Process in Nutshell Scenic View of Our Uniqueness: 1.
Limestone excavated from Mines is transported through Dumpers and fed to crushers wherein it is reduced from above 850 mm to 80 mm size.
2.
Environmental Environmental friendly Conveyor belts transport the limestone from the Crusher to the Plant Site over a distance of 7 kms.
3.
Scientifically designed Stackers provide for stacking of the limestones received from the mines in circular / longitudinal stock piles. Use of Reclaimers Reclaimers ensures consistency in quality.
4.
State of the the Art Vertical Roller Roller Mill Mill grinds Limestone Limestone feed to powdered powdered form called Raw Meal.
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Most advanced Coal Mill pulverizes the coal to be injected into Kiln for burning of Raw Meal.
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Rotary Rotary Kiln provides for Clinkerisation where in Raw Meal fed from VRM is first burnt to melting (1400 C) & then cooled to 100 - 120 C by means of coolers immediately outside the Kiln to produce Clinker. Clinker.
7.
Close Circuit Cement Mill ensures high quality grinding of clinker, clinker, gypsum and Pozzolana to yield best possible uniformity of the cement particles.
8.
Centralized Control Room monitoring the manufacturing process through computers.
Cons Consis iste tenc ncy y and and accu accura racy cy in the the pack packin ing g of bags bags by elec electr tron onic ic packing machines: Packing Plant is equipped with computer controlled electronic packers, which ensure that cement bags are packed and sealed to 50 kg of cement each accurately. accurately. Manual check is also carried out at random to monitor computer accuracy and introduce correction as applicable.
Loading of bags in the wagon/trucks is carried out automatically by means of wagon / truck loading machines, equipped with Electronic Loading Counters which accurately keep count of the Number of bags ba gs being loaded.
Effi Effici cien entt logi logist stic ic & tran transp spor orta tati tion on netw networ ork k ensu ensurres prom prompt pt deli delive very ry of materials to the customers.
Right from inception, great emphasis has been laid at Maihar Cement on mainta maintaini ining ng ecolo ecologic gical al balanc balance e and envir environm onmen ental tal prese preserva rvatio tion n so as to prov provid ide e
gree green, n,
heal health thy y
and and
poll pollut utio ion n
free free
envi enviro ronm nmen ent. t.
Cont Contin inuo uous us
monitoring of various Pollution Control equipments are done round the clock to main mainta tain in emis emissi sion on leve levels ls much much belo below w the the norm norms s sp spec ecif ifie ied d by Stat State e Pollution Pollution Control Board.
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Installation of highly efficient Pollution Control Equipments viz., ESPs, Bag Houses Houses and Pu Pulse lse Jet Dust Dust Collec Collector tors s at ever every y dust dust genera generatin ting g point in the Plant.
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Regular monitoring of all stacks and ambient air quality.
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Prope Properr treat treatmen mentt of domest domestic ic afflue affluent nt genera generated ted from from resid resident ential ial colony colony in Oxidat Oxidation ion Ponds and use of trea treated ted water water for planta plantatio tion n purposes.
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Massive efforts for plantation of various species of trees for ecological up-gradation.
View of Greenaries in Plant Area
To control fugitive emission, following additional steps have been taken: Covering of Conveyor belts transporting various process materials •
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All raw materials are stored in covered gantry.
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Water sprinklers have been provided on the roads to check fugitive emission generated due to movement of vehicles
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Concretization Concretization of roads and floors inside the Plant The Fly Ash generated from Thermal Power Plant is used as an additive for manufacture of PPC.
The Plant Plant maintains maintains perfect perfect harmony harmony with environm environment ent through through effective effective pollution control measures measures in respect respect of air, water, water, land and noise level. All efforts are made to curb pollution at grass root level.
We at Maihar Cement are fully conscious of the environmental impacts of our activitie activities. s. We also realize realize the need for minimizin minimizing g the impacts, impacts, towards towards preservation of environment in keeping with the image of BK Birla Group of companies as a socially responsible organization.
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Prevention Prevention of pollution p ollution incidental to Plant operations
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Adopting clean technology and eco-friendly processes in the Plant
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Compliance with all applicable legal and statutory requirements requirements
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Conservation of natural resources
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Reduction Reduction in waste generation.
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Awareness Awareness amongst employees and business associates.
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Contin Continual ual impro improvem vement ent in envir environm onment ental al perfor performan mance ce by effect effectiv ive e implementation
Every year tree plantation is undertaken in a planned manner on a massive scale. As a result the barren land acquired by the Company looks like green land today with different varieties of trees, gardens, lawns, fountains, flora and fauna. The plant presents presents a wonderful wonderful balance balance between concrete concrete and ecology with smokeless chimneys and lush greenery all around. Number of Trees surviving as on date is 1058840.
Cement Industry is highly energy intensive and leads to generation of CO2 duri during ng clin clink keris erisat atio ion n proc proces ess s due due to calc calcin inat atio ions ns of lime limest ston one e and and combustion combustion of fossil fossil fuel inside the Kiln. CO2 is a Green Green House Gas (GHG) (GHG) which leads to depletion of ozone layer above earth's atmosphere causing health health hazard hazard for all living living beings. beings. Maihar Cement Cement is actively actively engaged engaged in reduction of GHG emissions and has undertaken CDM projects. The project activities consist of an increase in % addition of fly ash in Portland Pozzolana Cement (PPC) as well as an increase in the proportion of PPC in the over all prod produc uctt mix. mix. This This lead leads s to reduc educti tion on in us usag age e of clin clink ker in ceme cement nt production which in turn contributes to reduction in GHG emissions.
At Maih Maihar ar Ceme Cement nt,, prop propor orti tion on of Blen Blende ded d Ceme Cement nt has has been been grad gradua uall lly y enha enhanc nced ed over over the the last last few few year years s and and toda today y tota totall ceme cement nt prod produc ucti tion on compri comprises ses of Blende Blended d Cement Cement only only. The proje project ct activi activity ty contri contribut butes es to sustai sus tainab nable le develo developme pment nt at Region egional, al, Nation National al and Global Global levels levels in the following ways. •
Reduction Reduction of GHG emissions - by way of reduction reduction in clinker clinker usage in cement production as explained above;
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Indu Indust stri rial al Waste aste Util Utiliz izat atio ion n - Fly Fly
Ash As h
Hand Handli ling ng and and
disp dispos osal al not not
only involves extra cost for Thermal Power Plant (TPP) but also leads to land and air pollution as well as water contamination at fly ash ponds / land fills. Hence the project project indirectly indirectly helps TPP in cost reduction reduction and pollut pollution ion abatem abatement ent..
It also also leads leads to reduc reductio tion n in specif specific ic energy energy
consum consumpti ption on for cement cement manufa manufactu cture re and positi positivel vely y contri contribut butes es to conservation of coal which is a valuable renewable natural resource. resource. Reduced usage of clinker in cement manufacture also means reduction in mining / extraction of limestone and its associated fugitive dust emission, loss loss of bio-div bio-diver ersit sity y etc. etc. There Therefor fore e the CDM proje project ct relat related ed activi activity ty has excellent environmental benefits in terms of reduction of carbon emissions, conse conserv rvat atio ion n of natu natura rall resou esourc rces es lik like lime limest ston one e and and coal coal,, decr decrea ease sed d environmental environmental degradation and enhanced waste utilization.
All All out out effo effort rts s are are made made at ever every y leve levell to achi achiev eve e the the high highes estt leve levell of effici efficienc ency y in manag managing ing and conser conservin ving g energ energy y resou resourc rces. es. This This includ includes es invol nvolve vem ment of bot both fina financ ncia iall and and hum human resour sourc ces coupl ouple ed wit with technological upgradation. Following measures have been taken at Maihar Cement for conservation of electrical and thermal energy: energy: •
Upgradation of Kilns by installation of LP cyclones and upgradation of pre-heater section and CIS MFR system on Clinker Grate Cooler;
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Close circuiting of Raw Mills and Cement Mills by installation of High efficiency Classifiers;
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Installation of pre-grinder in conjunction with close circuit Cement Mills for capacity upgradation and reduction of specific power consumption;
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Replacement of pneumatic conveying system of Raw meal and cement by Mechanical handling system
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Incorporation of VVVF drives;
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Repla eplace ceme ment nt of low low effi effici cien ency cy fan fan impe impell ller ers s by high high effi effici cien ency cy Impellers;
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Optimization of Raw Mills and Cement Mills by upgradation of internals and grinding media charge;
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Dry Fly Ash storage and handling system has been installed at Cement Mill.
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Installation of high efficiency dynamic separators for Coal Mills in place of static Grit separators for power saving and better residue control
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Process Process automation with DCS and Fuzzy Fuzzy logic control
