Connect with us

Concrete

Strategic Capacity Enhancement

Published

on

Shares

Amarkant Pandey, Deputy General Manager (Process), Prism Johnson (Cement Division), Satna, presents a case study on capacity enhancement of clinker production in an existing kiln.

This case study outlines the strategic initiatives taken to enhance production capacity of Prism Johnson (Unit-2) from 8000 TPD to 9100 TPD. This would help the company to expand its market share, develop new products and fortify our position in the cement industry.
With a consistent increase in regional demand and a positive market outlook, it was imperative for Prism Johnson’s Unit-2 to augment its production capacity from 8000 TPD to 9100 TPD in FY 2020-21. This enhancement aligned with our commitment to provide high-quality cement products while maintaining operational efficiency.

Cement capacity and production
The production capacity of Prism Johnson’s Unit-2 in FY-21 was at 8000 TPD. The plant was operating close to full capacity, with production data indicating steady growth trajectory, and it was evident that the current capacity was reaching its limits, thereby necessitating the need for expansion.
New capacity: The project entailed increasing the production capacity from 8000 TPD to 9100 TPD, thereby accommodating the rising market demand.
Timeline: The project was anticipated to span across 60 days.
Technology and process improvements: To optimise efficiency, the capacity enhancement project incorporates state-of-the-art technologies and process improvements. These advancements aim to reduce energy consumption, enhance product quality and ensure sustainable production practices.
The following technical upgradations has been implemented in order to support the upgraded production:

  1. 1. Kiln feed transport bucket elevators 352.BE250 and BE340 were upgraded (to 723 tph) to increase kiln tonnage.
  2. 2. Preheater ID Fans (2) were retrofitted to suit 9100 TPD.
  3. 3. Kiln feed rotary valves, ID Fan motors and VFDs have been changed.
  4. 4. Cooler was upgraded from SF 5×6 to SF-CB 5×7 (177 to 206 m2 grate area).
  5. 5. Clinker crusher was changed from hammer to heavy duty roller breaker HRB MF-418.
  6. 6. Expansion of kiln riser duct and connection of TAD to calciner.
  7. The areas where major upgradations took place are highlighted in these figures:
    Risk assessment: Potential risks, including construction delays, regulatory approvals and associated delays, and market fluctuations, have been identified. A comprehensive risk mitigation strategy is in place to address and minimise these challenges.
    Performance evaluation: Kiln started operating in January 2023 following the upgrade. We encountered several problems with M/s FLS’s cooler hydraulics. In January and February of 2023, a new hydraulic system was installed to replace the entire one. Kiln has produced 9100 TPD of clinker since April 2023. The plant performance before and after upgrading is tabulated below.
    The chart indicates that an increase in clinker production resulted in a specific heat consumption reduction of around 5 Kcal/kg of clinker.
    Presently, kiln volumetric loading is about 7.0, which is significantly higher than what is specified in the design. Additionally, with enhanced clinker production, we are meeting all quality targets (C3S, litre weight, free lime, etc.) for the clinker.

Challenges
Crushed limestone size: Limestone size was in the higher side (+100mm to 5 per cent) and the gap between blow bar tip and lower grinding path was adjusted at 50mm previous the same was 70mm
Pile homogeneity: The homogeneity of the pile was the biggest challenge due to huge variation in the mine’s limestone quality (6 different sources of mines). We increased the stacker speed from 11m/s to 13m/s to get better homogeneity. Also, CBA was installed to control variation in input materials from mines and standard deviation of pile was reduced from 80 to 20.
Raw mills output: To fulfil raw meal requirements with increased kiln production, various modifications were done in the raw mill like replacement of old nozzle rings with new design nozzles etc.
Kiln burner replacement: Old duo flex burner replaced with Pyrojet burner to reduce frequent snowman formation, increase utilisation of high sulphur petcoke and enhance flame quality.

Conclusion
The capacity enhancement by modification from 8000 TPD to 9100 TPD is a strategic move for Prism Johnson. It positions the company to meet market demands efficiently, contribute to regional development, and ensure the long-term sustainability and competitiveness of our operations.

ABOUT THE AUTHOR
Amarkant Pandey, Deputy General Manager (Process), Prism Johnson (Cement Division),
Satna, holds an engineering degree in mechanical with specialisation in heat and power from Institution of Engineers (India). He has an in-depth understanding of cement manufacturing processes, including raw material preparation, clinker production and cement grinding. His responsibilities include process optimisation, quality control, production planning, etc.


Concrete

The RAHSTA to Innovation

Published

on

By

Shares



As part of the 10th India Construction Festival, the RAHSTA Awards recognised outstanding contributions to the road construction industry.

On October 10, 2024, the RAHSTA Awards were held at the Jio Convention Centre in Mumbai, forming a significant part of the 10th India Construction Festival. This esteemed event serves as a pivotal platform for recognising and honouring outstanding contributions in the road construction industry, particularly those that prioritise sustainability, innovation and excellence.
RAHSTA, an acronym for ‘Roads and Highways Sustainable Technologies & Advancement’, has become synonymous with the promotion of advancements in road construction equipment and technologies. Organised by the FIRST Construction Council, the awards seek to highlight the importance of sustainable practices in infrastructure development and celebrate those organisations that lead the way in this critical area.
At the event, Pratap Padode, Founder, FIRST Construction Council, underscored the importance of skilling the workforce in the construction sector. He pointed out that construction is India’s second-largest employer, with the potential to reach 100 million jobs by 2030. However, he emphasised that a significant portion of this workforce remains unskilled, with 80 per cent of the 70 million workers lacking adequate training.
“To bridge this skill gap, we must incorporate practical orientation in engineering and management courses,” Padode urged. He highlighted the Indian Government’s initiative to onboard 1 crore interns through CSR funding over five years, encouraging construction companies to participate actively
in this programme. By doing so, he said, the industry could not only enhance skill development but also position itself for future growth and sustainability.

The RAHSTA Awards recognised seven outstanding contributions to the road construction sector, celebrating innovations that drive sustainability and efficiency:

  • Award for Highest Standards of Excellence in Road Engineering & Construction: Patel Infrastructure
  • Award for Excellence in Bridge Engineering: L&T Construction, DIAL Phase 3A Project
  • Best Road Financier Award: HDFC Bank
  • Award for Best Use of Waste Material Recycling in Road Construction: Tata Steel
  • Best Digital Technology Award in Road Building: Cube Highways and Transport Assets Advisors
  • Award for Excellence in Project Management: Haryana Rural Road Infrastructure Development Agency
  • Innovation Award in Project Execution:
  • CC Precast Solutions
    Indeed, the RAHSTA Awards 2024 were more than just a ceremony; they represented a vital call to action for the road construction sector in India. By highlighting the importance of sustainability and technological advancement, the awards inspired industry stakeholders to strive for excellence
    and innovation.
    As the event concluded, it left attendees with a renewed sense of purpose and a collective vision for a more sustainable and efficient future in infrastructure development. The RAHSTA Awards stand as a testament to the possibilities that lie ahead when industry leaders come together to embrace change and foster growth.

Continue Reading

Concrete

Equipment India Awards 2024!

Published

on

By

Shares



The titans of the construction equipment industry were honoured at the 12th BKT Equipment India Awards 2024.

On October 10, 2024, Mumbai played host to the much-anticipated 12th BKT Equipment India Awards 2024, an event that recognised and celebrated the outstanding achievements within the construction equipment sector. The grand ceremony took place at Jio Convention Centre and was among the highlights of the India Construction Festival, which gathered industry leaders, manufacturers and financiers from across the nation to honour innovation and excellence in this vital sector.
The inaugural addresses set a reflective tone for the evening, emphasising the importance of collaboration and information sharing within the industry. In his opening speech, Pratap Padode, Founder, First Construction Council, remarked, “At Equipment India, we have always tried to enhance the standard of the industry. During this 17th year of our existence, we still find that companies are trying to hide behind a veil as far as the disclosure of factual data is concerned.” His emphasis on transparency resonated with the audience, highlighting the critical need for the construction equipment sector to adopt best practices for data sharing, akin to those seen in the automobile industry.
For his part, Vipin Sondhi, Chairman, RAHSTA Committee, and former MD and CEO, JCB India and Ashok Leyland, also shared optimistic insights, stating, “Today, we celebrate not just the figures but the remarkable individuals behind them – the innovators, manufacturers and teams that push the boundaries of what’s possible.” He highlighted the impressive growth of equipment sales, which saw a 26 per cent increase during FY2023-24, reflecting strong market recovery and renewed confidence.
The 12th BKT Equipment India Awards not only celebrated the achievements of key players in the construction equipment sector but also served as a reminder of the collective effort required to drive the industry forward. The event reaffirmed its commitment to supporting the industry’s ongoing evolution, ensuring that India remains a significant player in the global construction equipment market. With the industry poised to grow at a CAGR of 12 per cent, reaching $25 billion by the end of the decade, the evening left attendees inspired and motivated to continue pushing boundaries in their respective fields.
A significant highlight of the evening was the presentation of the Equipment India Person of the Year 2024 award to Jaideep Shekhar, Managing Director, Terex India. Under his astute leadership, the company has achieved remarkable growth, marked by innovation and a commitment to excellence. The jury praised his strategic vision, which has not only propelled the company’s success but also contributed positively to the broader industry landscape.
Receiving the award, Shekhar expressed heartfelt gratitude, stating, “I’m deeply grateful to the jury and Equipment India for this remarkable honour. This award reflects not only my contributions but also the dedication and hard work of my team. I have been associated with the industry for more than 25 years and this award motivates me to keep pushing boundaries and to lead the growth
with integrity.”
The award presentation was made all the more special by the presence of previous winners of the Equipment India Persons of the Year, including Vipin Sondhi, former MD and CEO, JCB India (Equipment India Person of the Year 2013); Sandeep Singh, Managing Director, Tata Hitachi Construction Machinery (Equipment India Person of the Year 2015); and Dimitrov Krishnan, Managing Director, Volvo Construction Equipment India (Equipment India Person of the Year 2013).
The event also witnessed the recognition of numerous companies across various categories, showcasing the best of the best in the construction equipment sector. Indeed, as the industry gears up for future challenges, the awards stood as a testament to resilience, creativity and the unwavering spirit of collaboration. Together, the participants are set to build a brighter tomorrow for the construction equipment industry in India, fostering innovation and sustainable practices that will serve the nation for years to come.

Winners of the 12th BKT Equipment India Awards

  • Equipment India Person of the Year 2024:Jaideep Shekhar, Managing Director, Terex IndiaGreen Factory of the Year: Tata Hitachi Construction Machinery
  • Best After-Sales Service Provider: Tata Hitachi Construction Machinery
  • Concrete Pumps: Schwing Stetter India
  • Truck Cranes: Sany Heavy Industry India
  • Asphalt Plants: Ammann India
  • Asphalt Finishers: Ammann India
  • Batching Plants: Schwing Stetter India
  • Crawler Cranes: Sany Heavy Industry India
  • Piling Rigs: Sany Heavy Industry India
  • Rigid Dump Trucks: Caterpillar India
  • Motor Graders: Caterpillar India
  • Mini Excavators: Tata Hitachi Construction Machinery
  • Crawler Excavators: Tata Hitachi Construction Machinery
  • Mobile Cranes: Action Construction Equipment
  • Crawler Dozers: BEML
  • Skid-Steer Loaders: Doosan Bobcat India
  • Wheel Loaders: LiuGong India
  • Self-Loading Concrete Mixers: AJAX Engineering
  • Tower Cranes: Action Construction Equipment
  • Compaction Equipment: Case Construction
  • Mobile Cranes: Action Construction Equipment

“I congratulate ASAPP Info Global on the outstanding success of the conference and award shows! It was a privilege to be part of such an insightful session with industry leaders.”
– Sanjay Koul, President- India and South East Asia and Managing Director, Timken India

Continue Reading

Concrete

22nd CONSTRUCTION WORLD Global Awards Excellence Revisited!

Published

on

By

Shares



At the 22nd CONSTRUCTION WORLD Global Awards, over 50 awards in 21categories were presented to industry stalwarts.

The 22nd CONSTRUCTION WORLD Global Awards, was held on October 9 and 10, 2024, at the Jio World Convention Centre, Mumbai, and hosted by infrastructure think-tank FIRST Construction Council in partnership with CONSTRUCTION WORLD (CW) and Equipment India (EI) magazines. Incidentally, the spectacular RAHSTA Expo was India’s first indoor trade fair for construction equipment technology.

Benchmarked to global standards
At the inaugural session, Sanjay Bhatia, Upa-Lokayukta, Government of Maharashtra, along with Vipin Sondhi, Chairman, RAHSTA Expo Committee, and Pratap Padode, Founder, FIRST Construction Council, inaugurated the RAHSTA Expo. Expressing delight at the huge display of construction technology, Bhatia said, “The expo has put the construction industry on an international standard. India is experiencing nation-building at a robust pace and I am truly impressed with the work now being done by our youth with their startups, many of whom are showcasing their innovation here.”

Special bytes
At the 22nd CONSTRUCTION WORLD Global Awards, over 50 awards in 21 categories were presented to over 50 companies.
“I am thrilled to accept this award on behalf of Century Ply,” said Anup Mangaserri, Chief Executive Officer – Laminates, Century Plyboards India.
“It’s an honour to be recognised and I extend my heartfelt thanks.”
“Tata Consulting Engineers has made significant strides in nation-building projects in India and
high-impact engineering efforts abroad,” said BR Parthasarathy, Senior Vice President and Head – Infrastructure Cluster, Tata Consulting Engineers (TCE), sharing his pride in receiving the ENR Award. “This recognition underscores our global capabilities and we are honoured to be part of this journey.”
For his part, Sarat Chandak, CEO, H&R Johnson, said, “We are truly delighted to receive this award as the most admired brand in the construction world. This recognition reflects the dedication and hard work of the brand over its six-year journey in India. Thank you for acknowledging our efforts.”
And Sandeep Desai, Executive Director, and Ananta Rayaprolu, Director, Afcons Infrastructure, noted, “This is a proud moment for the entire Afcons team to have this particular trophy and prestigious award. Afcons has always been at the forefront of extreme engineering, and we are really happy for this acknowledgment, which motivates us to continue pushing the boundaries of innovation.”
Joining the chorus of gratitude, Manish Kumar, Executive Vice President, ITD Cementation, stated, “It is an incredible honour to receive this award and to be here for this event, which is very well organised. Being recognised among the best of our peers in the industry is truly a privilege. I accept this on behalf of my team and company and we are deeply grateful for this recognition.”
Many winners addressed the efforts that led to their recognition. “We are extremely proud and thankful that our founder has received the CW Person of the Year (Private Sector) award,” said Hardik Agrawal, Director, Dineshchandra Agrawal (DRAIPL). “This recognition reflects the relentless efforts of the entire Dinesh Chandra Group. We are deeply motivated by this honour and we thank the CONSTRUCTION WORLD Global Awards for this acknowledgment.” And Lalit Chhabra, Managing Director, PINI India, added, “It is a tremendous honour to receive this award. We are delighted that our global efforts have been recognised. This is a testament to what we have done in the past and our hard work. We look forward to improving our ranking in the years to come.”
Sharing his excitement, Ryoya Watanabe,
Senior Manager – BD & Marketing Division, Nippon Koei India, said, “We are headquartered in Tokyo and I am excited and honoured to accept this prestigious award. Thank you very much for this recognition.”
Meanwhile, Saji Samuel, Executive Vice President (Long Products), JSW Steel, brought the conversation around to India’s bright future. “I feel elated with this award because this is going to propel India into a five trillion-dollar economy as quickly as possible,” he remarked. “I wish CONSTRUCTION WORLD all the very best and hope many new companies will participate in this event going forward. I feel very proud to hold this trophy in my hand on behalf of my company.”
This collection of leaders from different sectors was a showcase of the diversity and excellence celebrated by these prestigious awards, marking significant milestones in their respective industries.
As Rajiv Poddar, Managing Director, BKT, observed, “India Construction Festival 2024 has once again proven to be an invaluable platform for the construction equipment industry. The convergence of innovative ideas and collaborative efforts showcased here reflects our collective commitment to growth and excellence. Congratulations to ASAPP Info Global for orchestrating such a successful event and to all the award winners – your achievements are a testament to the bright future of our industry.”

An event to remember Another highlight of the event was the launch of Pratap Padode’s book, Tarmac to Towers – India’s Infrastructure Story.
Indeed, in keeping with tradition, the annual CWGA Awards ceremony was a memorable celebration of architectural achievements and a platform for dialogue on critical issues affecting the construction industry.

 

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds