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Strategic Capacity Enhancement

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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

NDMC Rolls Out Intensive Sanitation Drive Across Lutyens Delhi

Municipal body intensifies cleaning and monitoring across the capital

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The New Delhi Municipal Council has launched an intensive sanitation drive across Lutyens’ Delhi, aiming to raise cleanliness standards in the capital’s central precincts. The programme will combine enhanced manual sweeping with mechanised cleaning and systematic waste removal to cover parks, heritage precincts and prominent thoroughfares. Authorities described the initiative as a sustained effort to improve public hygiene and reduce environmental hazards while maintaining the area’s civic image.

Operational teams have been instructed to prioritise drain clearing and litter hotspots, with special attention to markets and transit nodes that attract heavy footfall. Coordination with city utilities and waste processing units will be stepped up to ensure timely collection and disposal, and supervisory rounds will monitor adherence to cleaning schedules. Officials also intend to use data-driven planning to deploy resources efficiently and to identify recurring problem areas.

The council plans to engage resident welfare associations and business stakeholders to foster community participation in maintaining cleanliness and to support behavioural change campaigns. Public communication will be amplified through notices and outreach to encourage responsible waste handling and to inform residents about collection timings and segregation norms. Enforcement measures for littering and unauthorised dumping will be reinforced as part of a broader strategy to deter violations and sustain cleanliness gains.

The move reflects a focus on urban sanitation that officials link to public health priorities and to the city administration’s commitment to maintaining civic amenities. Monitoring mechanisms will include regular reporting and inspections to review outcomes and to recalibrate operations where necessary, according to municipal sources. The council emphasised that continued community cooperation will be essential for the drive to deliver lasting improvements in the appearance and hygiene of the capital’s core areas.

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Concrete

UltraTech Appoints Jayant Dua As MD-Designate For 2027

Executive named to succeed current managing director in 2027

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UltraTech Cement has appointed Jayant Dua as managing director (MD) designate who will take charge in 2027, the company announced. The appointment signals a planned leadership transition at one of the country’s largest cement manufacturers. The board has set a clear timeline for the handover and has framed the move as part of a structured succession plan.

Jayant Dua will be referred to as MD after assuming the role and will be responsible for overseeing operations, strategy and growth initiatives across the company’s network. The company said the designation follows established governance norms and aims to ensure continuity in executive leadership. The appointment is expected to allow a phased transfer of responsibilities ahead of the formal changeover.

The decision is intended to provide strategic stability as UltraTech Cement navigates domestic infrastructure demand and evolving market dynamics. Management will continue to focus on operational efficiency, capacity utilisation and cost management while aligning investments with long term objectives. The board will monitor the transition and provide further information on leadership responsibilities closer to the effective date.

Investors and market observers will have time to assess the implications of the announcement before the change is effected, and analysts will review the company’s outlook in the context of the succession. The company indicated that it will communicate any additional executive appointments or organisational changes as they are finalised. Shareholders were advised to refer to formal filings and company releases for definitive details on governance or remuneration.

The leadership change will be managed with attention to stakeholder interests and operational continuity, and the company reiterated its commitment to delivery on ongoing projects and customer obligations. Senior management will engage with employees and partners to ensure a smooth handover while maintaining focus on safety and compliance. Further updates will be provided through official investor communications in due course.

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Concrete

Merlin Prime Spaces Acquires 13,185 Sq M Land Parcel In Pune

Rs 273 crore purchase broadens the developer’s Pune presence

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Merlin Prime Spaces (MPS) has acquired a 13,185 sq m land parcel in Pune for Rs 273 crore, marking a notable expansion of its footprint in the city.

The transaction value converts to Rs 2,730 mn or Rs 2.73 bn.

The parcel is located in a strategic area of Pune and the firm described the acquisition as aligned with its growth objectives.

The deal follows recent activity in the region and will be watched by investors and developers.

MPS said the acquisition will support its planned development pipeline and enable delivery of commercial and residential space to meet local demand.

The company expects the site to provide flexibility in product design and phased development to respond to market conditions.

The move reflects an emphasis on land ownership in key suburban markets.

The emphasis on land acquisition reflects a strategy to secure inventory ahead of demand cycles.

The purchase follows a period of sustained investor interest in Pune real estate, driven by expanding office ecosystems and residential demand from professionals.

MPS will integrate the new holding into its existing portfolio and plans to engage with local authorities and stakeholders to progress approvals and infrastructure readiness.

No financial partners were disclosed in the announcement.

The firm indicated that timelines will depend on approvals and prevailing market conditions.

Analysts note that strategic land acquisitions at scale can help developers manage costs and timelines while preserving optionality for future projects.

MPS will now hold an enlarged land bank in the region as it pursues growth, and the acquisition underlines continued corporate appetite for measured expansion in second tier cities.

The company intends to move forward with detailed planning in the coming months.

Stakeholders will assess how the site is positioned relative to existing infrastructure and connectivity.

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