1

RELIANCE CEMENT COMPANY

PVT.LTD.

REPORT ON THE VOCATIONAL TRAINING

CONDUCTED AT RCCPL FOR B.E. [ 3rd

YEAR

MECH] STUDENTS OF VTU KARNATAKA

JANUARY 08th

-21st 2014

NAME : UK PRANAV KUMAR Roll NO: (4MW11ME060)

COLLEGE: Sri Madhwa Vadiraja Institute Of Technology

&Management, Bantakal, UDUPI - KARNATAKA.

2

ACKNOWLEDGEMENT

We are grateful to Mr. Santosh Tejwani (Senior VP and Project head) and Mr. Dilip Mohanty (head HR)(additional VP)for providing us to do the internship at RCCPL.

We heartily thank Mr. Bhaskar Bhattacharya (head of Mech Dept)(additional VP), Mr. Bhaluram Sharma(assistant VP), Mr Dharmendra Singh (GM Mech), Mr Haresh Dodhiya (DGM Process) for scheduling my program in a systematic manner.

We heartily thank Mr. Hemant Srivastava (HR) for his kind cooperation and making necessary arrangements for the training.

We are grateful to Mr. Devi Das Dinkar(Safety Dept) and Mr Ashwini Karwariya (environmental head), for his kind cooperation and guiding us during the training period.

We are grateful to Mr. Mukesh Dixit (process) for helping us in various aspects of Mech engineering and in guiding us to see the Plant and study the design of the same.

We are grateful to the Staff, Engineers, Operation Technician for their support and guidance during the training process.

Sign Sign

Dharmendra Singh Balurama Sharma

(GM Mech) (AVP Process)

3

OBJECTIVES

To understand and experience the technical aspects and working procedure of the company. To know more about the industries and production taking place in it. To experience the working environment in the company.

To gain experience in selecting the optimal way in handling situation and to learn the accepted safety practices involved in the industry.

To help us get accustomed to an organization, its business operations and administrative functions.

4

Company profile

Reliance Cement Company Private Limited (RCCPL) is a Reliance Group company and an

affiliate of Reliance Infrastructure Limited, set up in 2007, Reliance Cement Private Limited

aims to be a leader in the domain of cement manufacturing and be a part of the Indian

Infrastructure development story.

The Group’s foray into cement is a natural extension of its interests in power and

infrastructure business that would give it a competitive advantage in the cement sector.

Reliance Cement aspires to be a NextGen Cement Company, and be counted amongst the

top five cement companies in India. All proposed manufacturing facilities of Reliance

Cement will be state of art in terms of technology and scale, and will leverage best practices

in logistics and distribution.

The first two projects from the house of RCCPL are located at Madhya Pradesh and

Maharastra with a combined capacity of 10 MTPA. The Madhya Pradesh project has an

integrated unit at Maihar, a blending unit at Gondavali and a grinding unit at Raebareilly in

UP. The Maihar unit is on a fast track and slated to be commissioned in 2014.

Reliance Cement is committed towards sustainability without any compromise. Principles of

sustainable development are integral to the companies business strategy and are reflected

in its vision statement.

5

CONTENTS

TITLE PAGE

PRODUCT DESCRIPTION 6

WHY RELIANCE CEMENT? 7

INTRODUCTION 8

TRAINING AND SAFETY 10

SUMMARY ON ANALYSIS OF PRODUCTION AND

MANUFACTURING PROCESS

12

ECO FRIENDLY INNITIATIVES UNDERTAKEN BY

RCCPL

32

6

Product description

Portland Pozzolana Cement(PPC)

Reliance Cement is a new age Portland Pozzolana cement (fly ash-based) that confirms to

IS:1489(part 1) and is manufactured in state of the art plants. The plants used cutting egde

technology and equipment to consistently produce high quality cement that will help

transform your blueprints into concrete reailty.

Ordinary Portland Cement(OPC)

The cement produced by intergrinding of OPC clinker manufactured in rotart cement kiln

along with gypsum is called Ordinary Portland Cement (OPC). Depending upon th strength

requirement, OPC is further classified into OPC-33 grade, OPC-43 grade and OPC-53 grade.

7

Why Reliance Cement?

Reliance being a multinational company has stepped up along with its other wings in the

manufacture of cement and aims to achieve quality and standards in the same.

The tag line says “naya zamana naya cement” though it is new to this sector it wants to

create a benchmark and prove that reliance can rein even in this sector and to prove this it

has already started its project in Madhya Pradesh and Maharashtra.

In the Maihar project at Madhya Pradesh it has already created a record by completing the

whole project in just 22months which is a great milestone.

The RCCPL at Maihar has the biggest stockpile capacity of 50kilo piles to 70kilo piles,

whereas in the ordinary cement plant it is about 30kilo piles. The quality and characteristics

of this cement is fantastic when compared to the other brand cement.

Reliance cement company private limited uses highly modern equipments and technology

to manufacture the cement. The whole manufacturing process takes place in a very large

scale here at Maihar. The capacity of the plant is more than 10000 tons per day. Reliance

cement has high early strength property of 3 days, it has high lateral strength of 28 days,

high workability, high slump test of about 180. These all factors make reliance cement a far

better option than any other cement in the market available today.

8

INTRODUCTION

A cement is a binder, a substance that sets and hardens independently, and can bind other

materials together. The word “cement” traces to the romans who used the term opus

caementicium to describe masonry resembling modern concrete that was made from

crushed rock with burnt lime as binder. The volcanic ash and pulverised brick additives that

were added to the burnt lime to obtain a hydraulic binder were later reffered to as

cementum, cimentum, cament and cement.

The most important use of cement are as an ingredient in the production of mortar in

masonry, and of concrete, a combination of cement and aggregate to form a strong building

material.

What is cement?

Cement is a fine powder which sets after a few hours when mixed with water, and then

hardens in a few days into a solid, strong material. Cement is mainly used to bind fine sand

and coarse aggregates together in concrete. Cement is a hydraulic binder that is it hardens

when water is added. There are 27 types of common cement which can be grouped into 5

general categories and 3 strength classes: ordinary, high and very high. In addition, some

special cements exists like sulphate resisting cement, low weight cement and calcium

alluminate cement. The quarry is a starting point in a cement plant and are usually located

closely either to hotspots in the market or to areas to sufficient quantities of raw materials.

The aim is to keep transportation costs low. The basic constituents of cement (limestone

and clay ) are taken from quarries in this areas.

Basically cement is produced in two steps:

First, clinker is produced from raw materials. In the second step cement is produced from

cement clinker. The first step can be a dry, wet, semi-dry or semi-wet process according to

the state of the raw material.

Making clinker: the raw materials are delivered in bulk, crushed and homogenised into a

mixture which is fed into a rotary kiln. This is an enormous rotating pipe of 60-90m long and

upto 6m in diameter. The huge kiln is heated about 1500 degree Celsius inside it. The kiln is

slightly inclined to allow the material to slowly reach the other end, where it is quickly

cooled to 200 to 300 degree centigrade. The four basic oxides in the correct proportions

make cement clinker; calcium oxide(65%); silicon oxide(20%); alumina oxide(10%); iron

oxide(5%). This elements mixed homogenously will combine when heated by the flame at a

temperature of approximately 450 degree centigrade. New compounds are formed;

9

silicates, aluminates and ferrites of calcium. The final product of this phase is called “clinker”

these solid grains nodules are then stored in huge silos.

The second phase is handled in a cement grinding mill, which may be located in different

place to the clinker plant. Gypsum and possibly additional cementitious (such as blast

furnace slag, coal fly-ash, natural pozzolanas) are added to the clinker. All constituents are

grinded leading to a fine and homogenous powder. The cement is then stored in silos before

being packed and dispatched in bulk or bagged loading.

10

TRAINING AND SAFETY

Striving “towards zero accidents” can be a challenge for any organization. Organizations need to stay up-to-date with legislation and remain compliant, as breaches can lead to fines and prosecutions. A poor health and safety record can quickly damage an organization’s reputation with both customers and investors. High absenteeism is often an issue for organizations and difficult to manage without a clear process in place. RCCPL is planning OSHAS 18001 standard certificates for health and safety management. So it has to fulfill certain sets of minimum requirements for occupational health and safety management best practices. Some of the measures taken by the company are as follows:

It provides a system to identify OH&S hazards and minimize health and safety risks.

It makes sure that all elements for effective health management and safety are clearly defined.

It provides the techniques to identify potential causes of accidents within the workplace.

It improves employee awareness of risks through trainings and classroom demonstrations.

It is committed to complying with applicable legal requirements.

11

It communicates about relevant information on legal and other requirements to employees and interested parties and shows that health and safety is a priority.

It makes appropriate measure to protect the staffs.

It reassures stakeholders a best practice system is in place.

It continuously improves the health and safety performance.

It implements various policies and procedures to tackle absenteeism.

It places clear procedures for everyone to understand and follow.

It shows its commitment to employees by keeping them safe.

It has a well-equipped health care centre for emergencies.

It trains its employees to tackle various hazardous situations through class room teachings and instructions.

Safety equipment being used at RCCPL

Hazards and accidents are inevitable in organization and workplaces. Couple of unfortunate incidents also took place in RCCPL Maihar plant leading to the loss of lives. Incident and accident rates are minimum. Occupational Health and Safety risks are better controlled. Overall costs of accidents are least .Insurance premiums are least. Improved levels of compliance to health and safety legislation. Reduced likelihood of fines and prosecutions, which in turn lead to less HSE or local regulator visits and lower insurance premium providing financial benefit. Improved reputation and stakeholder satisfaction. Greater involvement and commitment from employees and the management team, resulting in improved health and safety culture.

12

SUMMARY ON ANALYSIS OF PRODUCTION AND

MANUFACTURING TECHNOLOGY

Reliance Cement Company is a cement manufacturing plant. Here the main product being

manufactured is Portland pozzolana cement (PPC) and Ordinary Portland cement (OPC) with

PPC being the major product.

The initial production step in the Portland cement manufacturing is raw materials

acquisition. Calcium, element of highest concentration in Portland cement is obtained from

limestone known as natural cement rock

MINING

Limestone exists in the form of layers in the soil. The concentration of limestone differs with

depth and the land characteristics. Drills are made in the land to certain depth and the

percentage of limestone in different depth is obtained. Then limestone is obtained from

underground mines through open phase quarries and blasting using gelatine explosives and

detonating them. These results in cracks in the mines which are later quarried and

transported. The limestone which are being quarried are transported using trucks to the

crusher where this big boulders of limestone are crushed to small parts around 80mm to

100mm size. This crushed material is transported to the stock pile using overland belt

conveyers (OLBC) or dumpers by road.

In RCCPL the limestone source is around 7Km from the factory and are transported using

OLBC presently they are being transported using dumpers by road due to construction of

OLBC.

STOCKPILE

Generally called as the material handling system. The stockpile is very close to the factory.

The OLBC brings the materials and dumps it using stackers which are large machines

designed to uniformly distribute the materials in piles and are stored for the usage. The

stockpile has railway access from which wagon filled with raw materials arrive. There is a

control room from where they control the process. The wagon unloading section contains a

side arm charger which holds moves the wagon near the tipper. The clamp beam will clamp

the wagon. The counterweight of the tippler whose function is to balance, rotate and trip

the wagon and to unload the material from it. The materials will be dumped 15m below the

ground level to a pit (LL1BC1) and sent to the main indoor service station(MISS) and

connects to a belt conveyer which sends this materials to the stacker for stocking.

13

Wagon tippler

stacker

14

Reclaimer

The material which comes from the indoor service station comes through the belt conveyers

and forms a pile through the stacker. Here in reliance the capacity of the pile is one of the

largest in India and is about 50-70 thousand tons pile. Whenever the material is required for

production the reclaimer takes in the fixed amount of material by moving its harrow and

homogenously mixes the material and through bucket conveyers it conveys it to the belt

conveyers. Here the main belt being 311BC1. Then the belt splits and distributes according

to the raw material and conveys limestone, bauxite, coal, iron ore, silica. These raw

materials then reach the raw mill for further process and mixing.

Belt conveying system

The raw material requires to be transported from one place to another to undergo different

process and this cannot be done by manually transporting and loading of raw materials. So

there are belt conveyers from each section connecting to other sections. The belt conveyers

used in raw mill are M24 grade belt and to join the ends of the belt they use TC310+

hardener in a 45 degree angle cut for better quality joint. The counterweights are added to

the belts for increasing the tension in the belt and to prevent it from sagging.

The belt conveyers are supported by carrying idlers in normal places and by impact idler in

places where the feed is being dumped. The safety precautions taken in belt conveyers are

pull chord (which turns off the moving belt when pulled) and belt switch (which shuts down

the moving belt when it gets out of track or sways out of path) which ensures the safety and

reliability of the operators as well as the raw material being conveyed in the belt conveyers.

15

Pull chord Belt switch

Belt conveyer with raw material

16

RAW MILL

The belt conveyer brings the raw material to the raw mill and dumps the limestone and

bauxite-ironore mixture to different hoppers arranged accordingly. These hoppers are

attached with hydraulic load cell which determines the load on the hopper. The capacity of

each hopper being 200 tons. The hoppers then distributes the raw material to the apron

feeder and way feeder which are used to feed the limestone and mixture of bauxite and

ironore respectively.

Apron Feeder

17

The feeders contain rod gates to adjust the quantity of material flowing through the

feeders. These contain pan conveyers which are used to convey the raw materials to the

belt conveyers and scrapers to scrap the unwanted material sticking the belt after dumping.

In every place where material is being dumped in belt there are bag filters are present. The

bag filters have a separate passage for the flow of its particles. The bag filters are used to

separate the fine dust particles from the materials and air.The filtered particles are again

sent to the belt conveyers and the air is sent out.

In the belt conveyers raw materials are passed through the magnetic separators on the way

to to the grinding mill near the preheater.

Magnetic seperators

The materials transport associated with dry raw milling system can be accomplished by a

variety of mechanisms, including screw conveyers, belt conveyers, drag conveyers, bucket

elevetors, airslide conveyers and pneumatic conveying system.

18

GRINDING MILL

The grinding mill consist of two roll mills which contains heavy cylinders in the form of

rollers which are rolled against each other and crush the material through hydraulic action.

One of the roller is driven by main motor and the other by auxiliary motor the power of

each being 1250KW and 50KW respectively. The power is transmitted using the knuckle

joint coupling from motor to the roller. There are cooling systems attached to these gear

drives transmitting power to the rollers. The auxiliary roller being stationary helps the

materials for grinding when passed between the rollers.

The material that arrives to the grinding mill through belt conveyers are stored on hoppers

and are passed to the v separators. The coarse material which are present on the v

separator are passed to the rollers for grinding and then through the bucket elevators it

goes to the dynamic separators .It then passes to the twin cyclone and then proceeds to the

blending silo. Blowers are used for transporting the materials here. The fine materials which

are present in the v separators are sent to the bag filters and then directly sent to the twin

cyclone which then proceeds accordingly.

Schematic diagram of grinding mill

19

Grinding mill rollers at RCCPL(side view)

Coupling and gear from the power shaft to the grinding roller

20

DRIER

Raw materials received by a plant contain a small amount of water. Limestone contains 2 to

5% of water and clay about 5 to 10%. The dry process needs to evaporate water when

grinding and the drier may be a rapid dryer or impact dryer with disintegrated or crushing

function instead of the rotary dryer.

For drying exhaust gas from the kiln and preheater is used, but sometimes a hot gas

generator is installed when water content in raw material increases.

The dry raw mix is pneumatically blended and stored in specially constructed silos until it is

fed to the pyro-processing system.

BLENDING SILO

Blending Silo Air slide at blending silo

Basically blending silo is a cylindrical storage structure having a conical shape cross section

inside it. Its completely made of RCC. Here the material that arrives at the top gets

uniformly distributed because of the conical structure and accumulates in the sides of the

structure. These stored raw materials then passes through the air slide and there are 12 air

21

slides in different direction and logically operated in different direction for proper blending

and mixing of the raw material.

These then flow to the surge bin to which a bag filter is attached. The surge bin collects the

material and then passes it to the air slide which is inclined at an angle. The air slide consist

of 2 layers separated by fabric cloth and air passes in the lower layer and material is passed

in the upper layer and due to the action of air, vibration is created which moves the

materials downwards to the bucket elevators.

PREHEATER TOWER

Pre-heater tower at RCCPL

The preheater is the tallest structure in the cement manufacturing plant.it is 160m height

and has 9 floors in it. It consist of bucket elevetors, huge air ducts, cyclone chamber, bag

filter, blowers, compressors.

The materials from the blending silo arrives at the bucket elevator here there are cup

shaped buckets attached in series which carry the materials vertically upward and dump

22

them at the top and return back for the next cycle. These bucket elevetors(411BE1)

are run by motors.

Bucket elevators

Schematic diagram of the process

These bucket elevators dump the materials into the divergent gate where the materials split

into two streams and flows to the cyclone chamber. There are two air ducts which sucks the

air from the top and passes down to the bag filter. All the dust material along with air passes

in this goes for recirculation. There are 6 cyclone chambers in each stream. The main forces

acting in cyclone chamber are gravitational force, centrifugal force and uplifting force. The

material that comes inside the cyclone chamber gets mixed with air from blower and moves

23

to the previous cyclone camber because of the suction force from the air ducts. Only the

heavy material in it sediments and passes down the chamber. Inside the cyclone chamber

there is cyclonic effect is produced which rotates the material and sends back the air and

dust material to the pervious cyclone chamber. At the last cyclone chamber heat is being

added from the burning of pulverised coal, this heat has highest intensity at the last cyclone

separator and its intensity successively decreases in the previous cyclone chambers. Thus

when the material reaches the last of the cyclone chamber will be having very high

temperature ready for calcination process and will be fed to the kiln.

BAG HOUSE

The bag house has 10 bag filters whose main function is to filter the fine dust particles and

to separate it from air. Basically the bag filter contains number of wire cage in cylindrical

shape placed horizontally in the bag filter. This wire cage is covered with cloth which

absorbs the materials. When the mixture of dust and air passes this bag filter the dust

particle gets collected in the cloth material and the air filters out and passes to the air

exhaust. At the top of the bag filters there are solenoids. These produce small vibrations to

the cloth bags at logically set time. Due to this the materials attached to the cloth bag falls

off to the hopper. The capacity of the motor which runs the hopper is 1.5KW and passes the

materials back to the twin cyclone for the circulation.

24

COAL MILL

Here in Reliance, coal comes in wagons and there is a wagon trippler for that. Then stocked

coal is being reclaimed by reclaimer through belt conveyers. Then it proceeds to the coal

mill. There is need of enormous amount of heat for the processing in kiln and heat is also

required for driers and grinders. The coal mill basically dries coal of size 40 to 70mm while

milling it into powdered coal, and supplies it as kiln sintered fuel. Here the pulverising of

coal takes place and fine powdered coal which are easy for burning and have high calorific

value is sent to the kiln.(water is poured over coal in order to prevent spontaneous firing

and flying of powder in the coal storage). The coal mill gets its feed from the belt conveyer

and it stores it in hoper, it then uses pressurised pneumatic method to transfer the coal to a

grinder which grinds the coal to fine particles. The basic structure is same as the vertical

roller mill, even here bag filters are attached and fine coal is separated. The pulverised coal

is then divided into two pipes one which goes to the pre-heater heating it and the other that

goes to the kiln as the fuel. The flow of the coal in the coal mill in hoper and pneumatic

systems and pipes all can be controlled from the main control room which is monitoring all

the process in the factory.

Kiln, Coal mill and Tertiary air duct

25

Kiln or CLINKER BURNER

Kiln

This consist of a cylindrical type kiln having a length of about 40 times of the shell’s inner

diameter, which is generally known as a long economical kiln, lined with refractory material

to protect the steel shell and retain heat within the kiln, installed with an inclination of 2.5

to 4% and slowly rotated at 4 to 4.5 rpm. The raw material is slurry and fed from the upper

end of kiln while fuel is blown in from the lower end of the kiln. The temperature at the kiln

is about 1400degree Celsius. At this temperature calcinations and sintering takes place and

clinker nodule are formed these are extremely hot and molten form of this fluid flows from

the kiln.

At the raw material inlet, a chain curtain zone is installed extending to 20 to 25% of the

overall length to help dry the slurry. The hot clinker, which has been sintered in the kiln, is

sent to the cooler and cooled down.

The hot gas from the kiln is often used as a source of heat for pre-heater and for drying raw

material in raw mill and grinding.

26

COOLER

Cooler ESP system of RCCPL

Clinker cooling in the cement industry has the following task to perform: cooling the clinker

produced in the kiln to the lowest possible temperature, perheating the secondary and

tertiary air required for combustion process to the highest possible temperature, cooling

the clinker at such a rate which are suitable to give the required properties of the clinker.

From the kiln the molten nodule flows to the cooling tower where the cooling of the molten

material occurs and cools at around 200 to 400 degree. These are achieved by fans attached

to the cooler. There are 12 fans connected to the cooler of 450KW each. Here the molten

materials cool down considerably and then there is electro static precipitator on top of the

cooler which separates the particulate matter such as nitrogen oxide, sulphur dioxide,

carbon monoxide, carbon dioxide which are the primary emissions in the manufacture of

portland cement. The shape of the passage is designed for maximum efficiency of the

process.

The separator line in calciner of preheater receives the hot gases from the cooler via tertiary

air duct. Due to heavy dust loading at the cooler gates tertiary air duct is used and is

regulated by means of pneumatic gates. The dust is very hot around 900 deg C.

After the cooling process the material is poured into deep pan conveyer belts which

transports the material into the clinker silo. Deep pan conveyers are used here because the

temperature of the material is very high. This is a chain drive and is driven by a motor at a

rate of 160 KW and has efficiency of 95%. There are pull chords for safety and maintaince.

This is inclined upwards and carries the material to the top of the clinker silo.

27

CLINKER SILO

Clinker silo and rejection

The clinker silo is the biggest silo in the cement mfg plant and it is a 60m dia structure and is

covered by dome shaped structure supported by the truss. The height of the structure

being 22m, it has a a rejection silo adjacent to it. The material which is rejected passed to

the rejection silo for storage. The clinker silo has many openings in the bottom of its surface

for the passage of the clinker to the cement mill through the deep pan conveyer.

28

CEMENT MILL

(from right to left) Pan conveyers connection clinker silo, cement mill and cement house

The cooled clinker is mixed with small amount of gypsum upto 5%, which will help regulate

the setting time when the cement is mixed with other materials and becomes concrete. This

mill contains machines similar to the raw mill where gypsum is added in this case. There are

apron feeders and way feeders which supply material to the belt conveyers and the

magnetic seperators are attached at their end.

CEMENT HOUSE

Schematic diagram of Cement House

29

This is a place where the final process for preparation of cement takes place. In this mill

addition of flyash takes place to the grinded materials takes place. The flyash comes from

the flyash silo through the belt conveyers. The main process in this cement house is grinding

and fine powdering of the materials. There is a vertical type grinder in this station. Here

again there are primary and secondary grinders. The primary grinder leave the clinker,

ground to the fineness of sand, and the secondary grinder leave the clinker ground to the

finesse of flour, which is the final product ready for marketing. There are again bag filters

present in this station as fine dust particles are persent and are filtered and processed and

passed for the storage silo

Vertical grinding machine at Cement House Storage Silo

STORAGE SILO

The structure of storage silo is very similar to the blending silo, and has a conical cross-

section for proper mixing and stores the finished product. There are three storage silo

containing Portland Pozzolona cement and Ordinary Portland cement. Even these contain

bag filters and air slides in it and operates in similar way as the blending silo. These have

high storage capacity and can readily store finished products which are ready for packing.

30

PACKING PLANT

Packing plant at RCCPL (under construction)

Here the pacing of the finished product takes place and makes it ready for marketing. The

cement is passed through packing machines where it accurately weights the cement bags

upto 50Kg and packs it in a paper bags and seals them which passes directly to the wagon

loading sector.

WAGON LOADING

Here there is provision for the loading of the bulk loading as well as the normal loading of

the finished cement packs to the wagon making it ready for marketing. It consists of a

platform and rail tracks for the wagon to arrive and the loading to take place. The loading is

done according to the work order and released accordingly.

31

CENTRAL CONTROL ROOM

Central Control Room is the major station from where all the machines operation in the

whole plant is controlled and operated. This is a sector having the whole visualisation of

each machine and monitors all the process taking place in the cement plant.

Operators of this section must be very well qualified and experienced as they handle the

whole factory from one place. For eg: Operators can find out about the load in the belt

conveyers by measuring the power consumed by the motor and by knowing this the

operator can turn on or off the feed.

The whole process in the factory is maintained by controlling the air flow (draft) and feed in

the machines. Proper care and monitoring must be taken in the control room for the

efficient running of the plant.

Here there is constant quality testing on each batch and other tests conducted to meet the

standards and specifications of the cement being manufactured

32

ECO FRIENDLY INITIATIVES

UNDERTAKEN BY RCCPL

The modern cement plant at Maihar has 2 stage 6 cyclone separators in each stage.

Whereas in the other cement mgf plant normally has 3-4 cyclone separators. This

minimises the heat consumed in the kiln as they are pre-heated very well, thus

reducing the fuel consumption and being more eco friendly.

There are 4 bag house and number of bag filters installed at many points in the plant

to minimise and reuse the dust produced in the process and keep the environment

safe.

As per the mandatory government guideline RCCPL has reserved 33% of the area for

green belt and planning to develop the green belt soon. This consumes the CO2

emitted in the factory.

Water treatment plants are being installed for treatment of the domestic water

generated in the factory and this will be recycled and reused for maintaining the

green belt.

The factory is planning to achieve the international standards ISO 1401-2004 and to

implement the same.

There are water harvesting technology being used in the structures and places

nearby.

Promotion of ponding in nearby village area and the Reliance group has promoted

and installed more than 2000 solar lamps and also installed bio-gas plants in the

surrounding area thereby keeping the whole surrounding ecofriendly and sustaining

the growth of the plant.

There are also monitoring and surveillance done at the area to maintain the ambient

surrounding, to have a better environment and to stay green. These are the green

initiatives planned by the Reliance Group in the Maihar Project.