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Binani sets up captive plants

World Cement,

In order to attain self reliance on power, Binani Cement has set up three units of captive plants with a total of 70 MW power generation, capable of meeting 100% of its power requirement. The company is the first in India to successfully utilise high carbon flyash generated from its old captive power plant in an environmentally sound way by feeding it into the kiln system via clinker cooler through an indigenously designed system. As a result the company will be able to save approximately Rs.165 lakhs per annum.

In addition the company has installed a Multi Movable Cross Bar clinker cooler in its new cement plant at Binanigram, the first of its kind in India. Binani has also installed air-cooled condensers in both of the new captive power plants. The system is a revolutionary cooling technology that is meant to reduce the fresh water requirement for cooling by about 90% when compared with traditional water-cooled condensers. An air-cooled condenser is also being installed to replace the traditional water-cooled condenser in the company’s old thermal power plant.

In order to maintain emission levels of <25 mg/Nm3 from the kiln gases, the company has installed a reverse air baghouse with PTFE glass membrane filtering media incorporating pulse jet cleaning technology for both kilns. Through its efficient management system, Binani Cement has successfully managed to reduce specific power consumption by almost 20% and thermal energy consumption from 737 to 680 kcal/kg of clinker, contributing savings of approximately Rs.783 lakhs during the last three years. Other measures include the use of AFs, replacing cooling water pumps with energy efficient pumps and installing energy saving refractories in the kiln.

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