NANDYAL WORKS

It’s a state-of-the-art technology cement production unit at Bilakalaguduru village near Kurnool District, Andhra Pradesh. The core objective of the plant is to utilise all the Blast Furnace (BF) Slag generated by JSW Steel Ltd. The plant is notably environment friendly and also one of the most energy-efficient cement plants in India. By using Blast Furnace Slag as raw material, the plant has dramatically reduced its consumption of limestone, a natural resource.

Product Portfolio and Capacity

Nandyal Works manufactures Portland Slag Cement (PSC) which is mix of Blast Furnace Slag and Ordinary Portland Cement. It also produces Ground Granulated Blast Furnace Slag (GGBS) and Ordinary Portland Cement (OPC) of 43, 53 Gr. The plant has a capacity is to produce Clinker ~ 2.2 million ton per annum (mtpa) and Portland Slag Cement ~ 4.80 mtpa.

Unique Features

  • First cement plant in India with Combi-Comflex technology and multiple systems to control air and dust pollution
  • Unique automatic packing and truck loading system that cuts down on air pollution
  • Consumes half the amount of limestone required by conventional cement plants
  • Reduces pollution and wastage by utilising slag as a raw material
  • A net water-surplus unit
  • Green processes that have earned several prestigious awards

Technology and Equipments

Coal Circuit

Comprises unloading, storage, and feeding systems. This has nuisance bag filters and process bag filters to keep emission levels below 10 mg/Nm³ across the coal mill circuit, from the truck-unloading stage to the end product storage areas. The coal mill stack has a continuous online monitoring system, which helps maintain emission levels at around 6-7 mg/Nm³.

Preheater and Kiln

Used to fire and heat up coal. The plant has installed a pyro-clone firing system to control the emissions of nitrogen gases (NOx).

Impact Crusher

Has 1,200 tons-per-hour (tph) capacity and is used to crush limestone sourced from captive mines. The plant has installed enough bag filters to confine the dust emission levels below 10 mg/Nm³.

Rawmill

It is used to convert limestone to a very fine powder, which is stored in a 20,000 mt capacity raw-meal silo. The raw-meal grinding facility uses the latest Combi-Comflex technology that reduces power consumption substantially. The baghouse is designed to ensure that emission levels from the stack remain below 10 mg/Nm³. JSW is the first company in the Indian cement industry to deploy this technology.

Packing plant

In the cement industry, packing plant personnel are heavily exposed to dust during the loading operations. Nandyal plant has installed the latest automatic packing and truck loading technology, i.e. the FLS Ventomatic System to safeguard the health of workers. The system prevents overexposure to dust and other harmful pollutants.

Plant Head’s Note

“Our use of the Combi-Comflex technology has kept us ahead of the curve and helped us produce green cement. This production process uses less energy compared to conventional methods of cement making and slag from our steel plant is put into better use here. With teamwork and dedication, we are aiming to make JSW Cement the most widely used Portland slag cement across the country.”