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. Kiln feed transport bucket elevators 352.BE250 and BE340 were upgraded (to 723 tph) to increase kiln tonnage.
2. Preheater ID Fans (2) were retrofitted to suit 9100 TPD.
3. Kiln feed rotary valves, ID Fan motors and VFDs have been changed.
4. Cooler was upgraded from SF 5×6 to SF-CB 5×7 (177 to 206 m2 grate area).
5. Clinker crusher was changed from hammer to heavy duty roller breaker HRB MF-418.
6. Expansion of kiln riser duct and connection of TAD to calciner.
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.
Cement stocks surged over 5% on Monday, driven by Jefferies’ positive outlook on demand recovery, supported by increased government capital expenditure and favourable price trends.
JK Cement led the rally with a 5.3% jump, while UltraTech Cement rose 3.82%, making it the top performer on the Nifty 50. Dalmia Bharat and Grasim Industries gained over 3% each, with Shree Cement and Ambuja Cement adding 2.77% and 1.32%, respectively.
“Cement stocks have been consolidating without significant upward movement for over a year,” noted Vikas Jain, head of research at Reliance Securities. “The Jefferies report with positive price feedback prompted a revaluation of these stocks today.”
According to Jefferies, cement prices were stable in November, with earlier declines bottoming out. The industry is now targeting price hikes of Rs 10-15 per bag in December.
The brokerage highlighted moderate demand growth in October and November, with recovery expected to strengthen in the fourth quarter, supported by a revival in government infrastructure spending.
Analysts are optimistic about a stronger recovery in the latter half of FY25, driven by anticipated increases in government investments in infrastructure projects.
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The Ministry of Steel has proposed a 25% safeguard duty on certain steel imports to address concerns raised by domestic producers. The proposal emerged during a meeting between Union Steel Minister H.D. Kumaraswamy and Commerce and Industry Minister Piyush Goyal in New Delhi, attended by senior officials and executives from leading steel companies like SAIL, Tata Steel, JSW Steel, and AMNS India.
Following the meeting, Goyal highlighted on X the importance of steel and metallurgical coke industries in India’s development, emphasising discussions on boosting production, improving quality, and enhancing global competitiveness. Kumaraswamy echoed the sentiment, pledging collaboration between ministries to create a business-friendly environment for domestic steelmakers.
The safeguard duty proposal aims to counter the impact of rising low-cost steel imports, particularly from free trade agreement (FTA) nations. Steel Secretary Sandeep Poundrik noted that 62% of steel imports currently enter at zero duty under FTAs, with imports rising to 5.51 million tonnes (MT) during April-September 2024-25, compared to 3.66 MT in the same period last year. Imports from China surged significantly, reaching 1.85 MT, up from 1.02 MT a year ago.
Industry experts, including think tank GTRI, have raised concerns about FTAs, highlighting cases where foreign producers partner with Indian firms to re-import steel at concessional rates. GTRI founder Ajay Srivastava also pointed to challenges like port delays and regulatory hurdles, which strain over 10,000 steel user units in India.
The government’s proposal reflects its commitment to supporting the domestic steel industry while addressing trade imbalances and promoting a self-reliant manufacturing sector.
The Indian government has introduced anti-dumping duties on anodized aluminium frames for solar panels and modules imported from China, a move hailed by the Aluminium Association of India (AAI) as a significant step toward fostering a self-reliant aluminium sector.
The duties, effective for five years, aim to counter the influx of low-cost imports that have hindered domestic manufacturing. According to the Ministry of Finance, Chinese dumping has limited India’s ability to develop local production capabilities.
Ahead of Budget 2025, the aluminium industry has urged the government to introduce stronger trade protections. Key demands include raising import duties on primary and downstream aluminium products from 7.5% to 10% and imposing a uniform 7.5% duty on aluminium scrap to curb the influx of low-quality imports.
India’s heavy reliance on aluminium imports, which now account for 54% of the country’s demand, has resulted in an annual foreign exchange outflow of Rupees 562.91 billion. Scrap imports, doubling over the last decade, have surged to 1,825 KT in FY25, primarily sourced from China, the Middle East, the US, and the UK.
The AAI noted that while advanced economies like the US and China impose strict tariffs and restrictions to protect their aluminium industries, India has become the largest importer of aluminium scrap globally. This trend undermines local producers, who are urging robust measures to enhance the domestic aluminium ecosystem.
With India’s aluminium demand projected to reach 10 million tonnes by 2030, industry leaders emphasize the need for stronger policies to support local production and drive investments in capacity expansion. The anti-dumping duties on solar panel components, they say, are a vital first step in building a sustainable and competitive aluminium sector.