Achieving results with better technology

1. Installation of a limestone crusher at the mine site Minimal raw materials haulage distance leads to savings in transport vehicle fuel, reducing dust generation caused by vehicular movement and controlling Greenhouse Gas (GHG) emissions.
2. Limestone crusher located in pit The placement of the crusher below the ground and inside the pit avoids the requirement and construction of a ramp. Consequently, it nullifies the need for vehicles to climb steep inclines, which otherwise results in higher fuel consumption and higher wear and tear of the vehicles.
3. Secondary crusher for limestone Crushing is a significantly more energy-efficient process than grinding. A secondary crusher further reduces the size of the limestone reaching the grinding mill and helps us reduce the overall specific energy consumption.
4. Online Prompt Gamma Neutron Activation Analysis Analyzer (PGNAA) Installed on the limestone transport conveyor belt, this instrument gives complete elemental analysis of the limestone moving on the conveyor. In combination with the PILE EXPERT software, it ensures that the pile is prepared with an optimum blend of minerals and aligned with the quality requirement of the desired output. With the help of this system, all grades of minerals, including overburden, are used in our processes, thus enabling us to run ‘zero reject’ operations.
5. Blend expert software This software continuously monitors and automatically calibrates the chemistry of the raw materials that are being processed, to ensure that the target chemistry of the output is maintained. In turn, it helps in precise and consistent preparation of the raw mix, which translates to efficient use of all natural materials and energy while maintaining the desired quality of the product.
6. Computational Fluid Dynamics (CFD) analysis The CFD analysis using high-tech simulations helps us study the dynamic behaviour of various process equipment such as cyclones, separators, ducts and so on. Using the CFD software, we identify opportunities to optimise our operating parameters, such as specific electric energy consumption.
7. Automated laboratory Our online robot-operated laboratory enables a 100% automated quality control process, including the collection of samples to analysis to final calibrations to be made to the systems. Through this, we realise both consistent product quality and optimum resource utilisation.
8. Variable Frequency Drives (VFDs) for process fans VFDs are installed for all process fans and pumps. The controlling dampers are removed wherever possible, thereby achieving minimum head losses in fans and pump operation. By this arrangement, significant reduction in specific electric consumption is achieved, along with reduced GHG emissions.
9. Process expert control Leveraging Industry 4.0 concepts such as Artificial Intelligence (AI) and Machine Learning (ML), our systems are continuously learning to identify areas of improvement and optimise our operations with minimal human intervention.
10. Waste Heat Recovery System (WHRS) power plant We have installed and are successfully operating an 8.8 MW waste heat recovery power plant at Mattampally, which is generating about 30% of the total energy requirement of our plant. This ushers in three primary benefits – better waste gas utilisation, lower energy cost and reduced environmental footprint in terms of emissions and pollution.