Integrating eco-friendly practices into its production processes
The company has recently commissioned its Clinkerization Unit at Shiva Cement Limited, a subsidiary of JSW Cement Limited, at Village Telighana, P.O. Biringatoli, Kutra, Sundargarh District in Odisha.
Shiva Cement Works is installed with Clinker Production Capacity of 1.4 MTPA (4,000 TPD) and has recently started commercial production of clinker since January’23. Equipped with all the latest technologies and most energy efficient systems, the Shiva plant having a capacity of 1.4 MTPA, will take the total clinkering capacity of JSW Cement to 4.5 MTPA. The plant is designed to achieve capacity with lowest possible Specific Power and Fuel Consumption and thus can be considered as one of the most sustainable manufacturing unit of JSW Cements.
Waste Heat Recovery System
The plant has deployed Waste Heat Recovery System that converts waste heat derived during the production process into energy. WHRS with a capacity of 8.9 MW, to capture and utilize excess heat from preheater and clinker cooler gases from kilns and other processes which will reduce its power consumption. Generated power from WHRS shall be evacuated at 11KV and synchronized with grid power in kiln-cooler sub-station. Through this system, the plant will be meeting ~70% of total power demand. This will help JSW cement meet its commitment to reach net zero by 2050 by reducing its scope 2 emissions. Also the major equipment drives are installed with Variable frequency drives (VFD’s) for smooth operation & improve energy efficiency.
Another initiative at Shiva Cement Works, that is instrumental towards the company’s decarbonisation journey, is its co-processing facility. Co-processing system, still under commissioning, is designed for feeding of solid RDF and usage of various alternative fuels and materials with 30% of Thermal Substitution Rate (TSR) to reduce consumption of fossil fuels such as coal and conserve natural resources. This will not only reduce our scope 1 CO2 emissions but will also be contributing to waste management and environmental conservation efforts.
Shiva Cement is installed with Robotic Lab to increase operation health and safety of the employees. The facility will help to control cement quality with cost effective production, continuous plant operation & maintaining proper documentation and avoid inconsistent in sample collection. Robotic lab supports and helps in Monitoring and stabilizing critical process parameters, continuous measurements of process parameters demonstrating the process stability, such as temperature, O2 content, pressure and flowrate in order to produce best in quality clinker. Equipment’s such as XRD and XRF shall be able to perform self-diagnostics with real time status display to identify possible sources of error.
The dust laden gases shall be dedusted in bag house having dust emission of ≤ 10 mg/Nm3. Nuisance Bag Filters have been considered at every material transfer points and shall keep the dust emission below ≤ 15 mg/Nm3to minimize the fugitive dust emissions during operation of the plant. Modern technology burners, dosing systems (fuel and kiln feed), emissions monitoring and kiln control systems have been considered to minimize gaseous emissions from combustion processes (e.g. NOx, CO, SO2).