PROJECT ENGINEERING,

MANAGEMENT AND IMPLEMENTATION

EXECUTED 33 GREENFIELD, PROJECT ENGINEERING AND MANAGEMENT ASSIGNMENTS

1.75 mio tons per annum Split Located

Portland Slag Cement (PSC) Project

The Tata Group is the largest industrial conglomerate and a pioneer in the area of steel production in India. Starting in 1911, the company branched into multiple industrial sectors. In 1990, they decided to diversify into cement production and used slag, which is a waste by-product of the steel manufacturing process. Holtec was engaged as the prime consultant.

The split located plants were commissioned in 1993. The clinkerisation plant at Sonadih, Madhya Pradesh, with an installed capacity of 1.0 mio tons per annum, grinds 0.3 mio tons per annum of OPC. The grinding plant at Jojobera, Bihar is fully fed by Sonadih and produces 1.45 mio tons per annum of

Portland Slag Cement (PSC).

In 1999, after a strategic decision by the Tata’s to disinvest in the cement sector, Lafarge India acquired both the plants.

Owner

Lafarge India Limited

Consultant

Holtec Consulting Private Limited, India

Supply of Main Machinery

Fuller Loesche USA and KCP Chennai

KHD Germany and Cimmco Birla

Scope of Consulting Services

• Strategic Location Services and Techno-economic Feasibility Study

• Raw Material Identification

• Basic Engineering, Procurement, Detailed Engineering & Inspection

• Geo-technical Investigation

• Project Implementation & Management

• Supervision of Construction, Erection, Trial Runs and Commissioning

Key Project Data

At Sonadih

Crusher, Impact type 650 tph

Raw Mill, VRM 280 tph

Blending Silo, CF type 18000 t

Kiln with 5 stage PH/PC 3300 tpd

Coal Mill, VRM 40 tph

Cement Mill with Roll Press 60 tph

Packer, Double Discharge 180 tph

At Jojobera

Roller Press, 4 Nos 70 tph

(2 each for Slag & clinker)

Cement Ball Mill 140 tph

Packers, Double Discharge 3 x 180 tph

Salient Features

• Use of slag, a waste by-product of steel production process

• Split located clinkerisation and PSC grinding, 500 km apart

• Use of Roller Presses for grinding slag and clinker for the first time in India

• On line material analyser for optimum use of raw materials

• Separate grinding of slag and clinker, as also the use of Pedal Mixer for PSC production

• Railway siding at Nipania, 21 Km from the clinkersation plant, used for clinker despatches

Achievements

• Achieved 100-130% kiln production on a sustained basis

• Power consumption less than 90 Kwh/t of cement for OPC

• Totally dust free environment

• No major modifications in 7 years of plant operations

• SATISFIED CUSTOMER

HOLTEC CONSULTING PRIVATE LIMITED